Patent Publication Number: US-11660560-B2

Title: Filter with interlocking housing interface

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     The present application is a continuation of U.S. patent application Ser. No. 16/097,773, filed Oct. 30, 2018, now U.S. Pat. No. 11,141,687, which is a national stage of PCT Application No. PCT/US2017/030386, filed May 1, 2017, which claims the benefit of priority to U.S. Provisional Patent Application No. 62/330,310, filed May 2, 2016. The contents of all of these applications are hereby incorporated by reference in their entirety and for all purposes. 
    
    
     TECHNICAL FIELD 
     The present application relates to filter elements for use with filtration systems. 
     BACKGROUND 
     Internal combustion engines generally combust a mixture of fuel (e.g., gasoline, diesel, natural gas, etc.) and air. Prior to entering the engine, intake air is typically passed through a filter element to remove contaminants (e.g., particulates, dust, water, etc.) from the intake air prior to delivery to the engine. The filter element requires periodic replacement as the filter media of the filter element captures and removes particulate from the intake air passing through the filter media. Accordingly, the filter element is typically removably received in the housing such that when the filter element is installed, a seal is formed between the filter element and the housing preventing bypass of the intake air around the filter element. The use of a non-authorized filter element in a filtration system may lead to a poor seal or no seal thereby allowing intake air to bypass the filter element, which can damage the internal combustion engine. 
     SUMMARY 
     Various example embodiments relate to filter elements. One such filter element includes first filter media and second filter media. The filter element further includes a frame member coupled to the first filter media and the second filter media. The frame member secures the first filter media and the second filter media (such as into a V-shape). The filter element includes a seal member is attached to and extends from the frame member. The seal member includes a U-shaped channel structured to receive a ridge of a housing when the filter element is installed in the housing. The seal member is structured to form a seal between the filter element and the housing when the filter element is installed in the housing. 
     In an embodiment, a filter element includes first filter media, second filter media, a frame, and a seal member. The frame is coupled to the first filter media and the second filter media, the frame securing the first filter media and the second filter media. The seal member is attached to and extends from the frame. The seal member includes a U-shaped channel structured to receive a ridge of a housing when the filter element is installed in the housing. The seal member is structured to form a seal between the filter element and the housing when the filter element is installed in the housing. 
     In another embodiment, a filtration system includes a housing and a filter element. The housing includes a keyway. The filter element is positioned within the housing. The filter element includes first filter media, second filter media, and a frame. The frame is coupled to the first filter media and the second filter media. The frame secures the first filter media and the second filter media. The keyway interfaces with the filter element to facilitate positioning of the filter element within the housing. 
     In still another embodiment, a filter element includes first filter media, second filter media, and a frame. The frame is coupled to the first filter media and the second filter media. The frame secures the first filter media and the second filter media. The frame includes a first frame member, a second frame member, a first side wall, and a second side wall. The first frame member is coupled to a first end of the first filter media and a first end of the second filter media. The second frame member is coupled to a second end of the first filter media, opposite the first end of the first filter media, and a second end of the second filter media, opposite the first end of the second filter media. The first side wall is positioned along a first side of the first filter media and a first side of the second filter media. The first side wall is coupled to the first frame member and the second frame member. The second side wall is positioned along a second side of the first filter media, opposite the first side of the first filter media, and a second side of the second filter media, opposite the first side of the second filter media. 
     These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG.  1    shows a perspective view of a filtration system according to an example embodiment. 
         FIG.  2    shows a cross-sectional view of the filtration system of  FIG.  1   . 
         FIG.  3    shows another cross-sectional view of the filtration system of  FIG.  1   . 
         FIG.  4    shows an exploded view of the filtration system of  FIG.  1   . 
         FIG.  5    shows a perspective view of the filter element of the filtration system of  FIG.  1   . 
         FIGS.  6 ,  7 ,  8 ,  9 ,  10 ,  11 , and  12    each show a different close-up view of the filter element of the filtration system of  FIG.  1   . 
         FIG.  13    shows a cross-sectional view of the filter element installed in the housing of the filtration system of  FIG.  1   . 
         FIG.  14    shows another cross-sectional view of the filter element installed in the housing of the filtration system of  FIG.  1   . 
         FIGS.  15  and  16    each show a cross-sectional view of a filtration system having the air flow direction reversed compared to the filtration system of  FIG.  1   . 
         FIG.  17    shows an exploded view of the filter element of the filtration system of  FIG.  1   . 
         FIG.  18    shows a cross-sectional view of the filter element of the filtration system of  FIG.  1   . 
         FIG.  19    shows a top view of a first frame of the filter element of the filtration system of  FIG.  1   . 
         FIG.  20    shows a top view of a second frame of the filter element of the filtration system of  FIG.  1   . 
         FIG.  21    shows a perspective view of the second frame of  FIG.  20   . 
         FIG.  22    shows an exploded view of the filter element of the filtration system of  FIG.  1    during manufacturing. 
         FIG.  23    shows another exploded view of the filter element of the filtration system of  FIG.  1    during manufacturing. 
         FIG.  24    shows a perspective view of the filter element of the filtration system of  FIG.  1    during manufacturing. 
         FIG.  25    shows an exploded view of the filter element of the filtration system of  FIG.  1    during manufacturing. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the figures generally, a filtration system having a filter element removably received in a housing is shown. In some arrangements, the filter element includes two panel filters coupled to a frame that secure the panel filters in a V-shape such that a cross-section of the filter element has a V-shape. In other arrangements, the filter element includes filter media arranged in an alternate shape, such as a rectangular panel, a cylindrical shape, or the like. The filter media comprising the filter element may be pleated or non-pleated. The filter element includes a seal having an alignment channel. The housing includes an alignment rib that is received in the alignment channel of the filter element when the filter element is installed in the housing. A cover is removably secured to the housing. When the cover is secured to the housing and the filter element is installed in the housing, the cover compresses the seal member against the housing forming an axial seal between the housing and the filter element. In some arrangements, the seal member does not form a radial seal against the housing. In other arrangements, the seal member forms only a radial seal or a combination of a radial and axial seal. 
     Referring to  FIG.  1   , a perspective view of a filtration system  100  is shown according to an example embodiment. Referring to  FIG.  2    and  FIG.  3   , cross-sectional views of the filtration system  100  are shown. Referring to  FIG.  4   , an exploded view of the filtration system  100  is shown. The filtration system  100  includes a housing  102  and a cover  104 . The cover  104  is removably coupled to the housing  102 . The cover  104  may be removably coupled to the housing  102  through fasteners (e.g., screws), clamps, snap fit connections, or a combination thereof. The cover includes an air inlet  106  structured to provide air to be filtered to the filtration system  100 . The housing  102  includes an air outlet  108  structured to provide filtered air to a component, such as an internal combustion engine. As shown best in  FIGS.  2  through  4   , a filter element  110  is removably received within the housing  102  and the cover  104 . The filter element  110  has a V-shaped cross section (as shown in  FIG.  2   ). 
     Referring to  FIGS.  5 - 12   , various views of the filter element  110  of the filtration system  100  are shown. The filter element  110  includes first filter media  112  and second filter media  114 . In some arrangements, the first filter media  112  and the second filter media  114  are panel filters that form the filter element  110 . The first filter media  112  and the second filter media  114  may be the same type of filter media or different filter media. In some arrangements, the first filter media  112  and the second filter media  114  are pleated filter blocks as described in U.S. Pat. No. 6,375,700, entitled “DIRECT FLOW FILTER,” which is herein incorporated by reference in its entirety and for all purposes. In some arrangements, the pleat tips of the first and second filter media  112  and  114  are blocked on one end and open on the other end. In other arrangements, the pleat tips are blocked on both ends. 
     The filter element  110  includes a frame comprising a first frame member  116  and a second frame member  118 . The first frame member  116  and the second frame member  118  secure the first filter media  112  and the second filter media  114  into a V-shape (e.g., as shown in  FIG.  2   ). The first frame member  116  and the second frame member  118  provide durability and structure to the filter element  110  and serve as manufacturing fixtures during manufacturing of the filter element  110 . The first frame member  116  and the second frame member  118  protect the first and second filter media  112  and  114  during manufacturing and during installation of the filter element  110  into the housing  102 . As shown best in  FIG.  12   , the second frame member  118  wraps around the edge of the first and second filter media  112  and  114  limiting the exposure of the first and second filter media  112  and  114  to come in contact with other objects (e.g., the housing  102  during installation of the filter element  110 ). The rigidity created by the first and second frames  116  and  118  also improve the aesthetics and durability of the filter element  110 . The rigidity helps to prevent the first filter media  112  and the second filter media  114  from collapsing during use and limits the stress on the first filter media  112  and the second filter media  114  during sealing (as described below with respect to the seal member  124 ). Further the first and second frames  116  and  118  provide a grip area for a technician installing the filter element  110  into the housing  102  or removing an installed filter element  110  from the housing  102 . 
     The first filter media  112  and the second filter media  114  may include any of pleated media, corrugated media, tetrahedral media, or variations thereof. U.S. Pat. No. 8,397,920, entitled “PLEATED FILTER ELEMENT WITH TAPERING BEND LINES,” by Moy et al., filed on Oct. 14, 2011, and issued on Mar. 19, 2013, assigned to Cummins Filtration IP Inc., which is incorporated by reference in its entirety and for all purposes, describes a tetrahedral filter media. Some configurations of tetrahedral filter media include a plurality of inlet tetrahedron flow channels and a plurality of outlet tetrahedron flow channels. The inlet tetrahedron merge in a central portion of the filter material, thereby allowing axial cross-flow of air between the inlet tetrahedron channels prior to the air passing through the filter media. Such an arrangement provides for additional dust loading on the upstream side of the media, which increases filter capacity. The tetrahedral flow channels may be stacked, layered, or coiled into various shapes and configurations. For example, the first and second filter media  112  and  114  may have, for example, thirty to eighty stacked layers of tetrahedral flow channels. These stacked layers of tetrahedral flow channels can be arranged to form various shapes. For example, layers of tetrahedral flow channels, the layers having different lengths and/or widths, can be stacked such that the stacked layers of tetrahedral flow channels substantially match the V-shape of the filter element  110  as shown and described. Specific arrangements of such tetrahedral filter media are further described in U.S. Pat. No. 8,397,920. 
     The filter element  110  includes side walls  120 . In some arrangements, the side walls  120  are comprised of urethane. Alternatively, the side walls  120  be comprised of plastisol. In such arrangements, the first filter media  112  and the second filter media  114  may be potted into or overmolded into the side walls  120 . For example, a face of a first pleat within the first filter media  112  and a face of a first plate within the second filter media  114  may be potted into one of the side walls  120 , and a face of a second pleat within the first filter media  112  and a face of a second plate within the second filter media  114  may be potted into the other of the side walls  120 . 
     In some arrangements, the side walls  120  each have a trapezoidal shape. In some arrangements, the side walls  120  include a flat surface for receiving a label (e.g., a product label or identifier). The outer perimeter thickness of the side walls  120  is controlled during manufacturing by using a closed mold, which allows for a controlled surface with which to engage during additional manufacturing operations. Additionally, the first and second frames  116  and  118  include urethane shut-off ridges  122  that prevent the urethane forming the side walls  120  from over-expanding and blow (as shown in  FIGS.  6 ,  7 , and  10   ). The tapered shape of the filter element  110  allows for improved filter alignment and serviceability. 
     The filter element  110  includes a seal member  124 . As shown in  FIG.  3   , when the filter element  110  is installed in the housing  102 , the seal member  124  is compressed by the cover  104  against the housing  102  and forms an axial seal with the housing  102 . In some arrangements, the seal member  124  is urethane. In such arrangements, the seal member  124  may be overmolded over the first frame member  116  and the side walls  120 . The axial seal prevents air entering the filtration system  100  through the inlet  106  from bypassing the filter element  110 . As shown in  FIGS.  5 ,  7 , and  8   , the seal member  124  includes a U-shaped channel  126 . The U-shaped channel  126  receives a ridge of the housing  102  (as shown in  FIG.  3   ). The interaction between the U-shaped channel  126  and the ridge helps to align the filter element  110  during installation of the filter element  110  into the housing  102 . During installation, when the cover  104  is secured to the housing  102 , a ridge  128  on the cover  104  presses into the seal member  124  to help form the axial seal. 
     In some arrangements, the seal member  124  does not include a U-shaped channel. According to some embodiments, the seal member  124  has a stepped geometry. In these embodiments, the seal member  124  may provide multiple sealing faces that interface with the cover  104 . The top and/or bottom of the seal member  124  may be stepped in this fashion such that the seal member  124  may be tailored for a target application. 
     Referring again to  FIG.  4   , the housing  102  includes a keyway  130  that receives and guides the filter element  110  during installation of the filter element into the housing  102 . The keyway allows the filter element  110  and the housing  102  to nest together. The keyway  130  is structured to function as a support surface that generally limits the amount of movement of the filter element  110  within the housing, thereby limiting the strain on the filter element  110  caused by vibration or heavy loading on the filter element  110  during operation of the filtration system  100 . The keyway  130  also prevents the filter element  110  from sagging during horizontal configurations of the filter element. In some arrangements, the keyway  130  is angled to match the angle of the V-shape of the filter element  110 . In further arrangements, the keyway  130  includes an internal rib that provides a positive stop to limit movement of the filter element  110  during installation. In some arrangements, the housing also includes a side-support keyway  132  that supports the side of the filter element  110  within the housing  102  (e.g., as shown in  FIG.  4   ). In such arrangements, the side-support keyway  132  is angled to match the V-shaped contour of the side walls  120  of the filter element  110 . The interaction of the filter element  110  with the keyway  130  and the side-support keyway  132  are shown in  FIGS.  13  and  14   . 
     During operation of the filtration system  100 , air to be filtered enters in through the inlet  106  and passes into the central area of the V-shape formed between the first filter media  112  and the second filter media  114  through the supports of the first frame member  116 . The air then passes through the first filter media  112  and the second filter media  114 , where the first filter media  112  and the second filter media  114  removes and captures contaminants in the air (e.g., dust, dirt, moisture, etc.). The filtered air then exits the housing  102  through the outlet  108 . Accordingly, the air flows in a general air flow direction designated by arrow  134  of  FIG.  1   . When the filter element  110  is replaced, the V-shaped pocket formed between the first filter media  112 , the second filter media  114 , and the two side walls  120  contains all of the captured contaminants thereby resulting in a clean filter cartridge service. In an alternative arrangement, the filtration system  100  is structured to have airflow move in the opposite direction. Such an arrangement is shown in  FIGS.  15  and  16   . In such an arrangement, the cover  104  may be fitted with an outlet hood  136 . In either arrangement, the cover  104  can be formed to receive and/or distribute the air directly from the open area between the first filter media  112  and the second filter media  114  thereby improving the flow characteristics of the system. 
       FIGS.  17  through  25    show additional views of the filtration system  100  and its components. As shown specifically in  FIG.  17   , the second frame member  118  may receive a single urethane seal. In this way, a de-molding operation may not be required when assembling filter element  110 . The single urethane seal may contact both the first filter media  112  and the second filter media  114 . 
     It should be noted that any use of the term “example” herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). 
     References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other example embodiments, and that such variations are intended to be encompassed by the present disclosure. 
     The terms “coupled” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. 
     It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Additionally, features from particular embodiments may be combined with features from other embodiments as would be understood by one of ordinary skill in the art. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various example embodiments without departing from the scope of the present invention.