Abstract:
An air cleaner assembly, a main filter element, and a method for servicing an air cleaner assembly are provided according to the present invention. The air cleaner assembly includes an air cleaner housing and a main filter element. The air cleaner housing can include a safety liner or support having a closed end cap that supports the main filter element, and helps reduce the tendency of the main filter element to rotate during use of the air cleaner assembly.

Description:
[0001]    This application is being filed on 8 Oct. 2007, as a PCT International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Paul R. Coulonvaux and Johnny Craessaerts, both citizens of Belgium, applicants for the designation of the US only, and claims priority to U.S. Provisional Patent Application Ser. No. 60/849,096, filed Oct. 6, 2006, and U.S. Provisional Patent Application Ser. No. 60/963,068, filed Aug. 1, 2007. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present disclosure concerns air cleaners with removable and replaceable (i.e., serviceable) filter cartridges. Methods of servicing are also provided. 
       BACKGROUND 
       [0003]    Air filtering is used in a variety of arrangements. A typical application is as an air cleaner for intake air to internal combustion engines. After a period of use, filter media within the cleaner requires servicing, either through cleaning or complete replacement. Typically, for an air cleaner used within internal combustion engines such as on a vehicle, filter media is contained in a removable or replaceable (for example, serviceable) component, element or cartridge. Examples are shown in U.S. Pat. Nos. 4,211,543; 4,135,899; 3,672,130; 5,445,241; 5,700,304; 6,051,042; 6,039,778; 5,547,480; 5,755,842; and 5,800,581; and PCT Publication WO 89/01818 and WO 06/026241; the complete disclosures of all these references being incorporated herein by reference. 
         [0004]    Improvements in filter arrangements relating to assembly and use, are desirable. 
       SUMMARY 
       [0005]    An air cleaner assembly, a main filter element, and a method for servicing an air cleaner assembly are provided according to the present invention. The air cleaner assembly includes an air cleaner housing and a main filter element. The air cleaner housing includes a safety liner having a closed end cap that supports the main filter element. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a side, perspective view of a main cleaner assembly according to the present disclosure. 
           [0007]      FIG. 2  is a cutaway, exploded, perspective view of components of the assembly of  FIG. 1 . 
           [0008]      FIG. 2   a  is a cutaway, side, sectional view showing an alternative arrangement for attaching the safety liner to the air cleaner housing. 
           [0009]      FIG. 3  is a perspective view showing attachment of the safety liner to the housing of the assembly of  FIG. 1 . 
           [0010]      FIG. 4  is a perspective view showing attachment of the safety liner to the housing of the assembly of  FIG. 1 . 
           [0011]      FIG. 5  is a cutaway, perspective view of components of the assembly of  FIG. 1 . 
           [0012]      FIG. 6  is a cutaway, perspective view of components of the assembly of  FIG. 1  showing attachment of a safety media. 
           [0013]      FIG. 7  is a cutaway, perspective view of components of the assembly of  FIG. 1  showing attachment of a safety media. 
           [0014]      FIG. 8  is a partial, sectional view of the assembly of  FIG. 7 . 
           [0015]      FIG. 9  is a cutaway, perspective view of the assembly of  FIG. 7  showing attachment of the main filter element. 
           [0016]      FIG. 10  is a cutaway, perspective view of the assembly of  FIG. 7  showing attachment of the main filter element. 
           [0017]      FIG. 11  is a cutaway, perspective view of the assembly of  FIG. 1 . 
           [0018]      FIG. 12  is a partial, sectional view of the assembly of  FIG. 11  without the access cover. 
           [0019]      FIG. 13  is a side, perspective view of an alternative air cleaner assembly according to the present disclosure. 
           [0020]      FIG. 14  is a cutaway, exploded, perspective view of components of the assembly of  FIG. 13 . 
           [0021]      FIG. 15  is a cutaway, perspective view of a portion of the assembly of  FIG. 13 . 
           [0022]      FIG. 16  is a partial, sectional view of the assembly of  FIG. 15 . 
           [0023]      FIG. 17  is a cutaway, perspective view showing attachment of the safety filter media. 
           [0024]      FIG. 18  is a cutaway, perspective view showing attachment of the safety filter media. 
           [0025]      FIG. 19  is a partial, sectional view of the assembly of  FIG. 18 . 
           [0026]      FIG. 20  is a cutaway, perspective view showing attachment of the main filter element. 
           [0027]      FIG. 21  is a cutaway, perspective view showing attachment of the main filter element. 
           [0028]      FIG. 22  is a partial, sectional view of the assembly of  FIG. 13  without the access cover. 
           [0029]      FIG. 23  is a end view showing the slot on the closed end of the main filter element of  FIG. 22 . 
           [0030]      FIG. 24  is a partial, exploded view of the assembly of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Now referring to  FIGS. 1 and 11 , an air cleaner assembly is shown at reference number  10 . The air cleaner assembly  10  includes an air cleaner housing  12 , a main filter element  14 , and a safety filter element  16 . The air cleaner assembly  10  can be applied in the filtering or cleaning of a variety of gases. The air cleaner assembly  10  is suited for cleaning air for use in an internal combustion engine, such as the engine of a vehicle such as a truck, bus, tractor, or construction equipment; or for a generator. 
         [0032]    The air cleaner housing  12  includes an air inlet  18  and an air outlet  20 . In  FIG. 11 , the air cleaner assembly  10  has been cutaway to show the internal components and, as a result, the air inlet  18  is not shown in  FIG. 11 . Nevertheless, it should be understood that the air inlet  18  is present on the operable air cleaner assembly  10 . In general, dirty air or air in need of cleaning enters the air cleaner assembly  10  through the air inlet  18 , and clean air exits the air cleaner assembly  10  through the air outlet  20 . 
         [0033]    The air cleaner housing  12  includes optional mounting legs or supports  22  thereon to facilitate mounting. Alternatively, the air cleaner assembly  10  can be mounted with a separate mounting band or bracket. The air cleaner assembly  10  can be provided in a variety of orientations. An exemplary orientation has the outlet  20  extending vertically. However, many of the principles and techniques described can be applied to air cleaner assemblies mounted in other orientations. 
         [0034]    The particular air cleaner air cleaner housing  12  has a housing side wall  24  that can generally be considered as cylindrical in overall shape. The air inlet  18  can be referred to as a tangential inlet  26  that goes through the housing side wall  24 . The term “tangential” in this context is meant to indicate that a center line of the air inlet  18  is not directed toward a center access of the air cleaner assembly  10 , but rather is directed more tangentially. This causes the air entering through the tangential inlet  26  to begin movement in a swirling pattern. The swirling pattern is facilitated by the generally cylindrically shaped housing side wall  24 . Alternatively, the air inlet can be provided so that it is radial. That is, the air entering through the air inlet can enter in a radial direction toward a center of the air cleaner assembly. 
         [0035]    The air cleaner air cleaner housing  12  includes a main housing  28  and a service cover  30 . For the particular air cleaner air cleaner housing  12 , parts of the main housing  28  and the service cover  30  form the housing side wall  24 . The service cover  30  is constructed so that it is removable from the main housing  28 . Latches  32  are available for holding the service cover  30  onto the main housing  28 . The particular latches  32  shown are a type of over center latch  34 . Other types of latches can be used. The service cover  30  includes a closed end  36 . In general, the characterization of a closed end means that mass air flow does not occur through the closed end  36 . That is, the closed end  36  does not operate as an air inlet or outlet during operation of the air cleaner assembly  10 . 
         [0036]    The air outlet  20  can be characterized as a circular, axial, outlet  38 . By “axial” in this context, it is meant that a center line or axis of the outlet  20  extends parallel to a center line or axis of the air cleaner housing  12 . In the particular instance shown, the center line of the circular, axial, outlet  38  is coaxial with the center line of the air cleaner housing  12 . Of course, alternative configurations are available. For example, the air outlet can be eccentrically positioned relative to the center line of the air cleaner housing  12 . 
         [0037]    The main housing  28  has a first end  29  and a second end  31 . The air outlet  20  extends through the first end  29 , and the air inlet  18  extends between the first end  29  and the second end  31 . The service cover  30  attaches to the main housing  28  at the second end  31 . The first end  29  and the second end  31  can both be characterized as open. The first end  29  can be characterized as open because of the presence of the air outlet  20  extending therethrough. The second end  31  can be characterized as open because the service cover  30  is removable from the first end  31 . When the service cover  30  is attached to the second end  31 , the air cleaner second end  35  can be characterized as closed. The air cleaner first end  33  can be characterized as open for the same reason that the main housing first end  29  is characterized as open. 
         [0038]    Now referring to  FIGS. 2-5 , assembly of the safety liner  40  as part of the air cleaner housing  12  is shown. The safety liner  40  includes an open support structure  42 , a safety liner closed end cap  44 , and a plurality of attachment tabs  46  at a downstream end  48 . The open support structure  42  is provided to support the safety filter element  16 , and allow air to flow therethrough to the open interior  50  of the safety liner  40 . During operation of the air cleaner assembly  10 , air that flows into the open interior  50  can generally be considered clean air and flows out through the air outlet  20 . 
         [0039]    The attachment tabs  46  extend from the safety liner  40  so that they are capable of engaging openings  52  provided in the flange  53  of the air outlet  20 . The attachment tabs  46  can be provided so that they extend at about a  90 ° angle relative to the cylindrically extending direction of the safety liner  40 . The attachment tabs  46  can engage or fit within the openings  52  in the flange  53 . The flange  53  extends sufficiently far away from the outlet collar  55  to receive the attachment tabs  46 . As a result of a twisting movement of the safety liner  40 , the attachment tabs can extend beneath the flange  53 , and can snap into place within the snap fit opening  58 . As shown in  FIGS. 3 and 4 , the attachment tabs  46  include a snap fit member  60  that fits within the snap fit opening  58 . Once the snap fit member  60  engages the snap fit opening  58 , the safety liner  40  can generally be considered to be locked in place and can be considered a part of the air cleaner housing  12 . 
         [0040]    An alternative arrangement for attaching the safety liner  40 ′ to the air cleaner housing  12 ′ is shown in  FIG. 2   a . The safety liner  40 ′ includes a flange  53 ′ extending radially away from the axis of the air cleaner along a circumference of the safety liner  40 ′. The flange  53 ′ includes openings (not shown but similar to openings  52  in the flange  53 ) for receipt of the attachment tabs  46 ′ extending radially from the air cleaner housing  12 ′. The attachment tabs  46 ′ can have a structure similar to the attachment tabs  46  except that they extend radially from the radial seal member  66 ′. In addition, the attachment tabs can include snap fit members, and the snap fit members can engage snap fit openings in the flange  53 ′. 
         [0041]    Now referring to  FIGS. 2 ,  5 , and  8 , the safety liner closed end cap  44  can be characterized as having a spherical shape  45 . By a spherical shape, it is meant that the outside surface  47  is generally curved and provides an apex  49  at about the center of the safety liner closed end cap  44 . The safety liner closed end cap  44  can be provided with shapes other than a spherical shape. 
         [0042]    Now referring to  FIGS. 6-8 , the safety filter element  16  extends over the safety liner  40 . In  FIG. 6 , the safety filter element  16  is shown being applied over or removed from the safety liner  40 . The safety filter element  16  includes a safety downstream seal member  62  and a safety end cap seal member  64 . The safety downstream seal member  62  is provided for sealing between the downstream end  48  of the safety liner and a radial seal member  66  that is part of the air cleaner housing  12 . The downstream end  48  of the safety liner can include a sealing surface  51  that can be considered part of the main housing  28 . The safety downstream seal member  62  fits between the sealing surface  51  and the radial seal member  66  to provide a seal. 
         [0043]    The safety filter element  16  includes a media structure  68 . The media structure  68  is shown as a tri-layer structure including a first layer  70 , a second layer  72 , and a third layer  74 . The first layer  70  and the third layer  74  can be provided as media, and the second layer  72  can be provided as a support structure to support the safety filter element  16  so that it maintains its shape. Alternatively, the first layer  70  and the third layer  74  can be support structure, and the second layer  72  can be filtration media. Other alternatives are possible. For example, the media structure can be provided as a by-layer structure including one layer or two layers of filtration media. The media structure  68  extends within the downstream seal member  62  so that the media structure  68  extends between the downstream end  48  of the safety liner  40  and the radial seal member  66 . As a result, the media structure  68  assists in the seal between the downstream end  48  and the radial seal member  66 . 
         [0044]    The media structure  68  extends into the end cap seal member  64 . The safety end cap seal member  64  provides a sealing engagement with the safety liner closed end cap  44 . The end cap seal member  64  provides an annular seal around the end cap periphery  61 . The safety end cap seal member  64  includes a gripping surface  63  that allows one to grasp the safety end cap seal member  64  and pull the safety filter element  16  off of the safety liner  40 . 
         [0045]    Now referring to  FIGS. 9-12 , placement of the main filter element  14  within the air cleaner housing  12  is shown. The characterization of a “main filter element” refers to the element that provides a majority of the air filtering function. The safety filter element is generally intended to protect the air inlet for the combustion engine during replacement of the main filter element  14 . Accordingly, when the main filter element  14  is removed from the air cleaner housing  12 , the safety filter element  16  remains in place to provide protection to the internal workings of the, for example, combustion engine. 
         [0046]    The main filter element  14  includes a main filter element radial seal member  80 , a main filter closed end cap  82 , and filtration media  84 . An exemplary type of filtration media  84  that can be used includes pleated media  86 . The main filter element  14  can include a main filter element support  88  and a cover  90  to support and protect the filtration media  84 . The cover  90  can be provided as a mesh or screen. 
         [0047]    In  FIG. 9 , the service cover  30  has been removed from the air cleaner housing  12  and the main filter element  14  is being introduced into or removed from the housing interior  92 . As shown in  FIG. 10 , the main filter radial seal member  80  forms a radial seal with the radial seal member  66  of the air cleaner housing  12 . The radial seal member  80  can be characterized as an inward facing radial seal member because the sealing surface is provided toward the inner portion of the main filter element  14 . In addition, it should be understood that the filtration media  84  can be potted within the first open end cap  81  that can contains the radial seal member  80 , and the second closed end cap  83 . 
         [0048]    The closed end cap  82  includes an annular rim area  94 , a recess  95 , and a central bump  96 . The annular rim area  94  generally covers the filtration media  84  that extends annularly or cylindrically within the housing interior  92 . The filtration media  84  can be embedded within the main filter closed end cap  82  at the annular rim area  94 . The central bump  96  can be provided having a sufficiently spherical shape or other shape so that when the main filter element  14  is fully inserted within the housing interior  92 , the central bump  96  contacts or is supported by the safety liner closed end cap  44 . In a preferred arrangement, the central bump  96  does not contact the safety closed end cap  44  at the apex  49 , but does contact the safety closed end cap  44  or is supported by the safety closed end cap  44  along an annular area  97  between the apex  49  and the end cap periphery  61 . In general, the closer the annular area  97  is to the end cap periphery  61 , the larger the potential contact area. Increased contact area can assist with the stability of the main filter element  14  within the housing  12 . In order to provide this contact, the closed end cap  82  includes a recess  95  between the annular rim area  94  and the central bump  96 . The recess  95  can extend annularly between the annular rim area  94  and the central bump  96 . 
         [0049]    The service cover  30  can be attached to the main housing  28  and latched in place. The service cover  30  can include a service cover annular rim area  102 , a service cover central bump  104 , and a service cover recess  106 . In general, the service cover annular rim area  102 , the service cover central bump  104 , and the service cover recess  106  can be provided so that they generally correspond with the closed end cap annular rim area  94 , the closed end cap central bump  96 , and the closed end cap recess  95 . The service cover can help hold the main filter element  14  in place within the housing  12 . The service cover annular rim area  102  can help push the main filter element  14  in place. 
         [0050]    During operation, air enters the air cleaner assembly  10  through the air inlet  18 . Air circulates between the housing side wall  24  and the main filter element  14 , and passes through the main filter element  14  and then through the safety filter element  16 , into the open interior  50 , and out of the air cleaner assembly via the air outlet  20 . 
         [0051]    Now referring to  FIGS. 13-22 , an alternative embodiment of an air cleaner assembly is shown at reference number  150 . The air cleaner assembly  150  can include a housing  152 , a main filter element  154 , and a safety liner  180 . The air cleaner assembly  150  provides for the filtering or cleaning of a variety of gases such as air for internal combustion engines. 
         [0052]    The housing  152  includes an air inlet  158  and an air outlet  160 . The air inlet  158  can be characterized as a tangential air inlet  162 . The air outlet  160  can be characterized as an axial air outlet  163 . The housing  152  additionally can include an optional drop tube  164  and can include optional mounting legs  166 . The drop tube  164  can include an ejector valve  168 . The housing  152  includes a main housing  170  and a service cover  174  that attaches to the main housing  170 . The drop tube  164  and the ejector valve  168  can be provided as part of the service cover  174  or if desired, can be provided as part of the main housing  170 . 
         [0053]    The air cleaner assembly  150 , as well as the housing  152 , can be characterized as having a first end  165  and a second end  167 . In general, the air outlet  160  can be characterized as extending through a housing end  169  at the first end  165 . In addition, the air inlet  158  can be characterized as being provided between the first end  165  and the second  167 , but can also be characterized as adjacent to the first end  165  in the embodiment shown in  FIG. 13 . The service cover  174 , in the embodiment shown, can be characterized as attaching at the housing second end  167 . 
         [0054]    The housing  152  includes a main housing  170 . The main housing  170  can be characterized as having a relatively cylindrical housing side wall  172 . The air cleaner housing  152  includes a service cover  174  that attaches to the main housing  170 . The service cover  174  can attach to the main housing  170  by latches  176 . 
         [0055]    Now referring to  FIGS. 14-16 , attachment of the safety liner  180  to the collar  182  is shown. The safety liner  180  includes bayonets  184 , and the collar  182  includes bayonet receivers  186 . The bayonets  184  slide within the bayonet receivers  186  to fit. The bayonet receivers include first side walls  188  and second side walls  190 . The first side walls  188  and the second side walls  190  hold the bayonets  184  in place. In addition, the bayonet receivers  186  can be molded in place. By way of example, the safety liner can include about 4 to about 8 bayonets and the collar can include about 4 to about 8 bayonet receivers to receive the bayonets. 
         [0056]    The safety liner  180  additionally includes a support structure  192  for supporting the safety filter element  156 . In addition, the safety liner  180  includes a closed end cap  194 . The closed end cap  194  includes a central cone extension  196 , and a shoulder area  198  extending about the central cone extension  196  and between the central zone extension  196  and the closed end cap periphery  200 . The closed end cap periphery  200  generally refers to the annular edge region at the periphery of the closed end cap  194 . 
         [0057]    The collar  182  includes an arm  201 , a collar extension  202 , a safety seal member  204  extending from collar extension  202 , and a radial seal member  206  extending from the collar extension  202 . A gasket or o-ring  208  can be provided to seal the collar  182  to the downstream end cap  169  of the housing  152 . The collar  182  can be snap fit onto the housing end  169 . The snap fit assembly is generally shown in  FIGS. 14 and 16 . 
         [0058]    Now referring to  FIGS. 17-19 , placement of the safety filter element  156  on the support structure  192  is shown. The safety filter element  156  includes a safety seal member  212 , a safety end cap seal member  214 , and a safety media structure  216 . The safety media structure  216  can be provided similar to the safety media structure  68 . The safety media structure  216  can be provided having a layer of filtration media  218  and a layer of support structure  220 . The layer of filtration media  218  can, if desired, be pleated media. 
         [0059]    The safety seal member  212  includes a lower seal member  222  and an upper seal member  224 . The safety seal member  212  engages the safety seal member  204  to provide a seal so that the lower seal member  222  and the upper seal member  224  provide compressive force on the safety seal member  204 . The safety seal member  204  can be referred to as the housing safety seal member because it is part of the housing. The safety seal member  212  can be referred as a pinch radial seal because the lower seal member  220  and the upper seal member  224  compress the safety seal member  204 . The safety seal member  212  can be made of polyurethane material. 
         [0060]    The safety end cap seal member  214  includes a first extension arm  221  that engages the closed end cap  194  at a base  226  of the central cone extension  196 . The base  226  can be provided as part of the shoulder  198 . The base  226  helps seal, center, support, and guide the safety filter element  156  on the support structure, and avoid risk of collapsing. The safety end cap seal  214  includes a second extension arm  223  that extends axially along a length of the safety media structure  216 . The second extension arm  223  extends beyond the first extension arm  221  axially toward the apex  228  of the central cone extension  196 . The safety end cap seal member  214  can be provided as a polyurethane material. In addition, the structure of the safety end cap seal member  214  can provide a desirable guide for the safety media structure  216  during the molding process. 
         [0061]    Now referring to  FIGS. 20-24 , insertion of the main filter element  154  into the housing interior  230  is shown. The main filter element  154  includes a first open end cap  239 , a second closed end cap  242 , and a main filtration media  244  extending from the first open end cap  239  to the second closed end cap  242 . The first open end cap  239  includes a radial seal member  240  and an axial seal member  241 . The radial seal member  240  includes a radial seal surface  246  that engages the radial seal member  206  to create an annular, radial seal. The radial seal member  240  can be characterized as an outwardly directed radial seal because the direction of the seal is outward and toward the radial seal member  206 . The radial seal member  206  can be referred to as the housing radial seal member  206 , and the radial seal member  240  can be referred to as the main filter element radial seal member  240 . The axially seal member  241  is provided extending axially from the first open end cap  239 . The axially seal member  241  can be characterized as a molded-in-place lip type axially seal  243 . That is, the lip type axially seal can be provided so that it flexes when the main filter element is introduced into the housing. This allows the main filter element to absorb and tolerate the length of the main filter element while avoiding friction that can cause where between the main filter element and the service cover. The axially seal member  241  can be provided extending axially from the first open end cap  239  between the radial seal member  240  and the outer, peripheral  243  of the first open end cap  239 . Furthermore, the main filtration media  240  can be potted within the first end cap  239  and within the second closed end cap  242 . The first end cap  239  and the second end cap  242  can be made from polyurethane material. 
         [0062]    The end cap  242  can be characterized as a closed end cap  250 . The end cap  242  includes an annular rim area  252 , a central bump  254 , and a recess  256  between the annular rim area  252  and the central bump  254 . The annular rim area  252  and the central bump  254  can be considered extending axially away from the first end  165 . Similarly, the recess  256  can be characterized as an area extending axially toward the first end  165 . In general, the annular rim area  252  contains the filtration media and extends cylindrically or conically. The central bump  254  is constructed to receive the central cone extension  196  when the main filter element  154  is fully inserted within the housing interior  230 . The recess  256  is constructed to engage the first extension arm  221  and provide contact between the recess  256  and the first extension arm  221 . This contact that can extend annularly or circumferentially can help hold the safety filter element  156  in place. 
         [0063]    The annular rim area  252  includes an annular rim periphery  258  and can include a series of exterior slots  260 . The service cover  174  can be constructed to engage the slots  260  via bumps  280  on the service cover  174  to help hold the main filter element  154  in place to avoid rotation and vibration that might cause it to wear out. 
         [0064]    The service cover  174  can be provided having an inner surface  282  that generally conforms to the closed end cap  250 . In general, the inner surface  282  can include a projection  284  that fits within the recess  256 , and can include a reverse cone  286  that receives the central bump  254 . Furthermore, the inner surface  282  can include an annular rim  288  that surrounds the main filter element  154 . The service cover  174  can be made of a plastic material and can be designed to guide, support, and push the safety element in place and participate to maintain the seal between the safety filter element  156  and the safety liner  180 .