Heavy duty air filter assembly

Abstract: A heavy duty air filter assembly has a housing (10,12) with a removable end cover (14) enclosing a generally cylindrical pleated paper filter element (16) sealing of the element at around the delivery port (20) one end of the housing being provided for by an annular groove (26) the radially opposed annular walls (57,59) of which sealingly engage a resiliently deformable annular projection (54) which is carried by the respective end cap (52) of the filter element (16).

Description: This invention relates to heavy duty air filter assemblies especially but not exclusively for use in vehicles fitted with internal combustion engines. Almost all internal combustion engines in land vehicles are fitted with an intake air filter assembly. In a large modern commercial vehicle fitted with an internal combustion engine it is usual to provide an externally mounted air filter assembly. Typically such an assembly may comprise a generally cylindrical housing having a fixed base at the lower end of the cylinder and a removable cover at the upper end. A generally cylindrical or frusto-conical replaceable filter element is retained within the housing, usually coaxially therewith such that a flow path is provided for air entering through a port in the cylindrical wall to the region between the cylindrical wall and the filter, inwardly via the walls of the filter and outwardly via a central delivery port of the base. In known arrangements sealing between the filter element and the base is achieved by an annular end seal maintained by compressive force between the removable cover and the base. Alternatively in order to avoid the need for substantial compressive force between the cover and the base, it has been proposed to provide for a radial seal between the filter element and an annular cylindrical surface carried by the base portion. Such an arrangement may provide the added advantage of some tolerance of axial movement allowing for easier sealing of the removable cover and for some differential thermal expansion and contraction between the housing and the filter element. However, although advantageous, the above mentioned radial seal between the filter element and a cylindrical surface carried by the base portion does impose a requirement for substantial radial compressive forces to maintain the seal integrity and in order to impart such forces the filter element still needs to be constructed relatively rigidly to permit pressing into position from the open end of the housing without causing twisting or buckling of the filter pleats. This will usually dictate the provision of a centre tube which is integral with the ends of the filter element. By way of example, GB-A-880812 shows a filter assembly, in Figure 12, in which a soft flexible gasket is secured directly to the paper filter element itself and engaged in a parallel sided groove. This is maintained by compressive force between the removable cover and the base of the housing. A somewhat improved concept is disclosed in FR-A-2063849 in which the filter assembly comprises a housing, a base and side walls forming said housing, a removable cover to said housing, a relatively rigid annular filter element mounted in said housing, an air inlet to said housing externally of said filter element, a delivery port internally of said filter element, said filter assembly further comprising an annular inner side wall and an annular outer side wall disposed radially outwardly and concentric with said inner side wall, said inner and outer side walls being substantially parallel, to form a substantially parallel sided annular groove on said housing, said filter element comprising an annular paper filter element, an internal mesh liner within said paper element, and moulded end caps connected to said paper filter element and to said mesh liner at each end of said filter element, one of said moulded end caps being an annular end cap and further comprising an outwardly extending integral projection. The object of the present invention is to provide an improved filter assembly which avoids the need to impose such high twisting or buckling forces during the putting together or servicing of the assembly. The filter assembly according to the present invention is characterised in that said paper filter element is an elongate filter element, in that the inner side wall extends through said base and forms said delivery port, and in that said projection is radially resiliently deformable, said projection having substantially parallel radially inner and outer walls engaging the inner and outer walls surfaces of said groove respectively. The filter element may be a conventional cylindrical or frusto-conical annular filter element, preferably with an internal metal mesh liner. The structure of the present invention is very advantageous insofar as a complete seal is provided between the annular projection and the groove and if there is any radial expansion or contraction, e.g. due to thermal stresses, the outer side wall of the groove will expand and contract and will maintain the inner wall surface of the projection against the inner side wall of the groove thereby ensuring good sealing. Depending on the material from which the filter is made, the annular projection preferably has an axial length of between 2½% and 5% of the axial length of the filter element and preferably between 3% and 4%. Such a size will enable the sealing to be maintained even though the housing may expand and contract significantly due to thermal changes. GB-A-885767 disclosed a filter element for use in a filter assembly, including a housing with a removable cover, said filter element being a relatively rigid elongate annular paper filter element, an internal supporting casing to said filter element, a moulded end cap at each axial end of the filter element, moulded to said paper filter element and to said support casing, one of said end caps being an annular end cap, an axially extending annular projection formed integrally with said one annular end cap. The filter element according to the present invention is characterised in that said supporting casing is a mesh liner, in that said projection is a radially resilient projection having substantially parallel inner and outer wall surfaces, adapted to engage in an annular groove in an end wall of the filter housing, said projection having an axial length between 2½% and 5% of the axial length of said filter element. In order that the present invention may more readily be understood, the following description is given, merely by way of example, reference being made to the accompanying drawing in which:- Figure 1 is a side elevation, partly in section, of one embodiment of filter according to the invention; and Figure 2 is a section taken along the line II-II of Figure 1. A generally cylindrical moulded thermoplastic, e.g. polypropylene filter housing 10 has an integrally moulded lower base 12 and a removable moulded cover 14 of a similar material between which is mounted a generally cylindrical, annular, pleated paper filter element 16. A tangential air inlet port 18 is connected to the lower part of the housing 10 and the base 12 has a central downwardly extending air delivery port 20 which continues upwardly above the base 12 into the interior of the housing to form an inner annular wall 22. It will be noted that the base 12 is stepped so as to provide, between the inner wall 22 and an outer wall 24 forming the step, an annular groove 26. This groove includes a number (one or more and as illustrated four) axially extending venting grooves 28 extending from the base of the groove 26 to the main base 12 of the housing 10. Further axially extending grooves 30 may be formed on the outer surface of the upper portion of the inner annular wall 22, to the top 32 of which may be mounted cross-ribs 34 which are chamfered at 36. The cover 14 is provided with an annular flange 38 which engages a complementary flange 40 just below the top of the housing, with an optional O-ring 42 being inserted therebetween. The cover 14 is held in position by means of simple clips 44, thereby forming a sealed enclosure, the annular inlet region 46 of which communicates with the inlet port 18, this being separated from the delivery port 20 by the filter element 16. This filter element is a mainly conventional pleated paper element, but in the present example the upper ends of the pleats are sealingly embedded in an end cap 48, typically formed of polyurethane, having an annular bead 49, which is engageable in an annular recess 50 of the cover. The cover may be separate from or effectively integral with this annular end plate 48 in which case the cover would be replaceable with the filter element when required. The lower end of the filter element 16 is similarly embedded in an annular moulded end cap 52 formed of a relatively soft polyurethane having an integral radially resiliently deformable projection 54 which is dimensioned completely to fill the annular groove 26. The annular projection 54 has a substantially parallel radially inner and outer wall surfaces 56,58 and an end surface 60. There is in fact a very slight taper towards the end surface 60 of the inner and outer surfaces 56,58 to facilitate moulding. The inner surface 56 is just radially inwardly of the conventional mesh liner element 62 constraining the inner surface of the annular paper filter material 64. This mesh liner may be formed of metal or plastic. Assembly is relatively straight forward. When the filter element 16 is introduced, either already connected to the cover 14, or before the cover 14 is put in place, the annular projection 54 is guided by the chamfer 36 on the cross-ribs 34 (if provided) and by the ridges formed between the axial grooves 30 so that it engages into the annular groove 26, which has substantially parallel inner and outer walls 57,59 engaged by said wall surface 56,58 respectively. Again the walls 57,59 are slightly tapered downwardly. Clearly because the annular projection 54 substantially fills the groove 26 there will be a need to displace air within this groove during this insertion step and it is for this reason that the axial venting grooves 28 are provided. While other forms of venting are contemplated, e.g. on the inner annular wall 22 and to the exterior through the bottom, the illustrated structure of the grooves 28 on the inner surface of the outer wall 24 are preferred. This arrangement allows the air to escape readily and does not allow the ingress of any dirt. When the clips 44 are engaged on the flanges 38,40, the projection 54 will be firmly pressed into the groove 26 thereby providing a good seal. If there is any thermal or other expansion and contraction, then the outer wall 24 forming the groove 26 will expand and contract with the inner wall 22 and thus will maintain a good air tight seal between the lower part of the filter element 16 and the housing 10. Because the grid element 62 is not outwardly displaced significantly from the inner surface 56 (as is conventional) a thorough and full usage of the sealing element is achieved and problems of expansion and contraction are overcome. It is important that the annular projection 54 should have a significant axial length to ensure that there is no chance of disengagement from the groove 26. Quite clearly these filter elements are subject to very different climatic conditions and there will be quite a measure of expansion and contraction of the housing. With this in mind, the axial extent of the inner surface 56 of the projection 54 should be between 2½% and 5% of the axial length of the filter element and preferably between 3% and 4%. The provision of the chamfer 36 and the axial grooves 30 (if provided) associated with the inner wall 22 and the axial grooves 28 associated with the outer wall 24 of the groove 26 not only facilitates insertion of the filter element, but also facilitates removal by avoiding sticking. In an alternative assembly, the filter element 16 may be constructed to have an end cap and projecting part similar to that at the bottom, at both ends, the cover being moulded to provide an annular groove of similar dimensions to the groove 26. In yet another alternative, the upper end of the filter element may be formed with an end closure which simply rests in a locating and abutting formation moulded within the cover. In this and the previous alternative, the end cover does not normally need to be replaced with a filter element on servicing the assembly. In a still further construction, at least the filter element end cap at the lower (outlet) end may be provided with an annular groove presenting radially opposing annular sealing faces which cooperate with a resiliently deformable projection carried by the respective internal end surface of the housing. However, the structure as illustrated is greatly preferred because it would be relatively expensive to provide such a resiliently deformable projection on the housing and possibly also the cover. In a yet a further construction, the respective end caps of the filter element and the base of the housing may carry annular grooves which receive opposite ends of a replaceable moulded annular resilient flexible seal.

Claims: A filter assembly comprising a housing (10), a base (12) and side walls forming said housing, a removable cover (14) to said housing, a relatively rigid annular filter element (16) mounted in said housing, an air inlet (18) to said housing externally of said filter element, a delivery port (20) internally of said filter element, said filter assembly further comprising an annular inner side wall (22) and an annular outer side wall (24) disposed radially outwardly and concentric with said inner side wall, said inner and outer side walls (22,24) being substantially parallel, to form a substantially parallel sided annular groove (26) on said housing, said filter element comprising an annular paper filter element (64), an internal mesh liner (62) within said paper element, and moulded end caps (48,52) connected to said paper filter element and to said mesh liner at each end of said filter element, one of said moulded end caps (52) being an annular end cap and further comprising an outwardly extending integral projection (54), characterised in that said paper filter element (16) is an elongate filter element, in that the inner side wall (22) extends through said base and forms said delivery port (20), and in that said projection (54) is radially resiliently deformable, said projection having substantially parallel radially inner and outer walls (56,58) engaging the inner and outer walls surfaces (57,59) of said groove (26) respectively. A filter assembly as claimed in claim 1, characterised in that annular projection has an axial length of between 2½% and 5% of the total axial length of the filter element. A filter assembly as claimed in claim 1 or 2, characterised in that said inner wall (22) further comprises cross-ribs (34) mounted thereon, and chamfers (36) on said cross-ribs effective to guide said annular projection into said annular groove. A filter assembly as claimed in claim 1, 2 or 3, characterised in that one annular end cap (52) extends within said mesh liner to an extent whereby said mesh liner is disposed not significantly outwardly of the inner surface of said annular projection. A filter element (16) for use in a filter assembly, including a housing (10) with a removable cover (14), said filter element (16) being a relatively rigid elongate annular paper filter element (64), an internal supporting casing (62) to said filter element, a moulded end cap (48,52) at each axial end of the filter element, moulded to said paper filter element and to said support casing, one of said end caps (52) being an annular end cap, an axially extending annular projection (54) formed integrally with said one annular end cap, characterised in that said supporting casing is a mesh liner (62), in that said projection is a radially resilient projection having substantially parallel inner and outer wall surfaces (56,58), adapted to engage in an annular groove in an end wall of the filter housing (10), said projection having an axial length between 2½% and 5% of the axial length of said filter element. A filter element according to claim 5, characterised in that said one annular end cap (52) extends within said mesh liner (62) to an extent whereby said mesh liner is disposed not significantly radially outwardly of the inner surface (56) of the annular projection (54). A filter element as claimed in claim 5 or 6, characterised in that said inner wall wall surface (56) of the annular projection (54) forms an axial extension of the inner diameter of the annular end cap (52).

Inventors: GLADSTONE ROBERT, GLADSTONE, ROBERT
Applicants: COOPERS FILTERS LTD, COOPERS FILTERS LIMITED
Application year: 1995
Main classification: F02M35
IPC codes: F02M35, B01D46