Source: http://www.google.com/patents/US20090266041?ie=ISO-8859-1
Timestamp: 2014-09-16 06:06:58
Document Index: 383657728

Matched Legal Cases: ['art 35', 'art 35', 'art 35', 'art 35', 'art 35', 'art 35', 'art 35', 'art 56', 'art 35', 'art 35', 'art 110', 'art 110', 'art 35', 'art 110', 'art 110', 'art 185', 'art 184', 'art 801']

Patent US20090266041 - Seal arrangement for filter element; Filter element assembly; and, methods - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsA filter cartridge arrangement is provided which includes a media pack comprising Z-filter media, a preform and a housing seal member. Improvements in the preform and seal member are described which include: a single beveled surface of the seal member to facilitate installation; and, an inside region...http://www.google.com/patents/US20090266041?utm_source=gb-gplus-sharePatent US20090266041 - Seal arrangement for filter element; Filter element assembly; and, methodsAdvanced Patent SearchPublication numberUS20090266041 A1Publication typeApplicationApplication numberUS 12/321,130Publication dateOct 29, 2009Filing dateJan 14, 2009Priority dateDec 22, 2003Publication number12321130, 321130, US 2009/0266041 A1, US 2009/266041 A1, US 20090266041 A1, US 20090266041A1, US 2009266041 A1, US 2009266041A1, US-A1-20090266041, US-A1-2009266041, US2009/0266041A1, US2009/266041A1, US20090266041 A1, US20090266041A1, US2009266041 A1, US2009266041A1InventorsKevin Schrage, Troy Murphy, Donald Raymond Mork, Ross Norman Anderson, Thomas G. Miller, Sheldon Anderson, John Orlin KirkwoodOriginal AssigneeDonaldson Company, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (6), Referenced by (3), Classifications (15), Legal Events (1) External Links: USPTO, USPTO Assignment, EspacenetSeal arrangement for filter element; Filter element assembly; and, methodsUS 20090266041 A1Abstract A filter cartridge arrangement is provided which includes a media pack comprising Z-filter media, a preform and a housing seal member. Improvements in the preform and seal member are described which include: a single beveled surface of the seal member to facilitate installation; and, an inside region of the seal member having a tip adjacent in inwardly directed lip of the preform, to control flash during molding. A variety of media pack configurations and features are described.
(a) a filter media pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces; the filter media pack having an outer side extending between the first and second flow faces; (b) a seal support having an extension disposed at least partially over the second flow face; the extension having an interior surface, facing inwardly generally toward the axis, and an opposite surface; (c) a seal component molded-in-place on, and around, the extension; and, (d) a projection on the seal support disposed toward the central axis from the interior surface of the extension;
(i) the projection being a portion of the seal support in contact with a mold when the seal component is molded-in-place; and,
(a) the projection, on the seal support, disposed toward the central axis from the interior surface of the extension is an annular projection. 3. The filter element of claim 2:
(a) the projection on the seal support projects in a direction different from a direction of projection of the extension. 4. The filter element of claim 1 including:
(a) an annular extension joined to the extension at a bend and extending between the extension and the second flow face; and (b) the projection on the seal support, disposed toward the central axis from the interior surface of the extension, is configured and positioned to inhibit mold material from rising along a surface portion of the seal support, when the projection is in contact with a mold as the molded-in-place seal component is formed. 5. The filter element of claim 4 wherein:
(a) the seal support comprises a portion of a preform having a portion extending around a side of the filter media pack. 6. The filter element of claim 4 wherein:
(a) the annular extension, joined to the extension at a bend, includes a portion thereon extending around a side the filter media pack. 7. The filter element of claim 1 wherein:
(a) the seal component includes a portion positioned on an outer surface of the extension and has a seal surface configured to form an outwardly directed radial seal with an air cleaner housing; and (b) the seal component includes a portion extending over an end of the extension, and a portion of the seal component is positioned along the interior surface of the extension, wherein the portion of the seal component positioned along the interior surface of the extension is inhibited from having radially inner flash by the projection on the seal support, disposed toward the central axis from the interior surface of the extension, when the projection is in contact with a mold, and while the molded-in-place seal component is formed. 8. The filter element of claim 1 wherein:
(a) the projection on the seal support disposed toward the central axis defines a smaller inner perimeter than an inner perimeter of the seal component. 9. The filter element of claim 1 wherein:
(b) the media pack comprises a fluted sheet of media attached to a second sheet of media and wound about the axis. 10. The filter element of claim 9 wherein:
(a) the seal support comprises a portion of a preform including a media face crosspiece arrangement extending over the second flow face. 11. The filter element of claim 1 wherein:
(a) the filter media pack has a generally circular outer perimeter. 12. The filter element of claim 1 wherein:
(a) filter media pack has an oval outside perimeter shape. 13. The filter element of claim 1 including:
14. The filter element of claim 13 wherein:
(a) the end piece is separate from the seal component. 15. The filter element of claim 11 wherein:
(a) the seal component comprises a radial seal region and is positioned on the extension, the radial region comprises a single beveled, outer axial surface including a straight section at least 4 mm long extending at an angle, HE, of 30� to 60�, inclusive, relative to a plane perpendicular to a direction between the media pack first and second flow faces, the beveled outer surface being positioned in extension between a portion of the radial seal region and the outer tip of the seal member. 16. A filter element comprising:
(a) a filter media pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces; the filter media pack having an outer side extending between the first and second flow faces; (b) a seal support having an extension disposed at least partially over the second end face; the extension having: an interior surface facing the axis; and, an opposite surface; (c) a seal component molded-in-place on, and around, the extension;
(i) the projection being a portion of the seal support in contact with a mold, when the seal component is molded-in-place; and
(a) the projection is provided by a lip projecting from the seal support. 18. The filter element of claim 17 wherein:
(a) the projection disposed toward the central axis from the interior surface projects in a direction different from a direction of projection of the extension of the seal support. 19. The filter element of claim 17 including:
(i) the projection on the seal support, disposed toward the central axis from the interior surface of the extension, being positioned to inhibit mold material from rising along a surface of the annular extension when the projection is in contact with a mold as the molded-in-place seal component is formed.
(a) the seal support comprises a portion of a preform having a portion extending around a side of the filter media pack. 21. The filter element of claim 16 wherein:
(a) the projection on the seal support disposed toward the central axis defines a smaller inner perimeter than an inner perimeter of the seal component. 22. The filter element of claim 16 wherein:
(b) the media pack comprises a fluted sheet of media attached to a second sheet of media and wound about the axis. 23. The filter element of claim 16 wherein:
(a) the seal support comprises a portion of a preform including a media face crosspiece arrangement extending over the second flow face. 24. A filter element comprising:
(a) a filter media pack having first and second flow faces and defining an axis extending through the first and second flow faces; the filter media pack having an outer side extending between the first and second flow faces; (b) a seal support having an extension disposed at least partially over the second flow face; the extension having: an interior surface facing toward the axis, and, an opposite surface; (c) a seal component molded-in-place on, and around, the extension;
25. The filter element of claim 24 wherein:
(a) the projection projects in a direction different than a direction of projection of the extension. 26. The filter element of claim 25 including:
(i) the projection on the seal support, disposed toward the central axis from the interior surface of the extension, being positioned to inhibit mold material from rising along an interior surface of the annular extension when the projection is in contact with a mold, when the molded-in-place seal component is formed; the projection also separating material of the seal component, along the interior surface, from the annular extension.
(a) the seal support comprises a portion of a preform having a portion extending around a side of the filter media pack. 28. The filter element of claim 26 wherein:
(a) the seal component is positioned on an outer surface of the extension and has a seal surface configured to form an outwardly directed radial seal with an air cleaner housing; and (b) the seal component includes a portion extending over an end of the extension and a portion of the seal component is positioned along the interior surface of the extension, wherein the portion of the seal component positioned along the interior surface of the extension is inhibited from having radially inner flash by the projection on the seal support disposed toward the central axis from the interior surface of the extension, when the projection is in contact with a mold, as the molded-in-place seal component is formed. 29. The filter element of claim 28 wherein:
(b) the media pack comprises a fluted sheet of media attached to a second sheet of media and wound about the axis. 30. The filter element of claim 29 wherein:
(a) the seal support comprises a portion of a preform including a media face crosspiece arrangement extending over the second flow face. 31. The filter element of claim 24 wherein:
(a) the projection on the seal support disposed toward the central axis defines a smaller inner perimeter than an inner perimeter of the seal component. 32. A filter element comprising:
a filter pack, a seal member, and a seal support frame operatively connecting the seal member to the filter pack, the seal member being formed separately from the seal support frame; the filter pack having first and second oppositely facing flow faces, and defining a longitudinal axis passing through the first and second flow faces; and the seal support frame including a canted annular extension thereof, for supporting the seal member, the canted annular extension projecting from one of the first and second flow faces of the filter pack at an oblique angle to the longitudinal axis, and having a first end and a distal end thereof; the seal support frame further including an inwardly canted intermediate annular segment extending between the first end of the canted annular extension and the one of the first and second flow faces of the filter pack, to thereby form a V-shaped, outwardly opening, annular groove at the juncture of the canted annular extension and the inwardly canted intermediate annular segment. 33. The filter element of claim 32, wherein the filter pack includes a fluted filter media having a plurality of flutes of porous filter material.
34. The filter element of claim 32, wherein the first end of the canted annular extension is disposed nearer than the distal end thereof to the longitudinal axis, such that the canted annular extension is canted outward from the longitudinal axis.
35. The filter element of claim 34, wherein the seal member is molded onto the canted annular extension using a mold, and the canted annular extension defines an inner surface thereof having a raised annular rib extending therefrom for contacting and sealing against the mold, to thereby limit the extent of the seal member along the inner surface of the canted annular extension.
36. The filter element of claim 32, wherein a portion of the seal member extends into the V-shaped annular groove.
37. A filter element, comprising:
a filter pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces, the filter pack having an outer filter pack surface extending transversely between the first and flow faces; a seal support frame including an annular extension disposed at least partially over the second flow face, the seal support frame having an inner surface facing inwardly generally toward the axis and an outer surface facing generally outwardly away from the axis; an annular seal member molded along the annular extension; and an annular mold contact formed along the inner surface of the seal support frame, the annular mold contact disposed inwardly of the annular seal member along the inner surface relative to the axis. 38. The filter element of claim 37, wherein the annular mold contact is provided by an annular rib projecting from the seal support frame.
39. The filter element of claim 38, wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension.
40. The filter element of claim 37, wherein the seal support further includes a canted annular segment joined to the annular extension at a bend, the canted annular segment extending generally between the annular extension and the second flow face, the annular mold contact preventing mold material from rising along the inner surface along the canted annular segment.
41. The filter element of claim 40, further comprising an annular sidewall joined to the canted annular segment, the annular sidewall extending around the outer filter pack surface.
42. The filter element of claim 37, wherein the seal member is molded over the outer surface of the seal support frame to provide an annular outer seal surface adapted for forming a radial seal, and wherein the seal member is also molded over an end of the annular extension and along the inner surface to provide an annular inner seal surface, the annular inner surface being disposed outwardly of the mold contact relative to the axis.
43. The filter element of claim 37, wherein the annular mold contact defines a smaller inner perimeter than an inner perimeter of the annular seal member.
44. The filter element of claim 37, wherein the filter pack is a fluted media having a plurality of flutes including a first set of flutes that are closed proximate to the first flow face and a second set of flutes that are closed proximate to the second flow face, the fluted media pack having a fluted sheet joined to a face sheet which are wound about the axis into an annular shape.
46. A filter element, comprising:
a filter pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces, the filter pack having an outer filter pack surface extending transversely between the first and flow faces; a seal support frame including an annular extension disposed at least partially over the second flow face, the seal support frame having an inner annular surface facing inwardly generally toward the axis and an outer annular surface facing generally outwardly away from the axis; an annular seal member molded around the annular extension along the inner annular surface and the outer annular surface; and an annular mold contact formed along the inner surface of the seal support frame, the annular mold contact preventing flow of mold material along the inner surface such that the annular seal member extends a greater distance toward the first flow face over the outer annular surface as compared to the inner annular surface. 47. The filter element of claim 46, wherein the annular mold contact is provided by an annular rib projecting from the seal support frame.
48. The filter element of claim 47, wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension.
49. The filter element of claim 48, wherein the seal support further includes a canted annular segment joined to the annular extension at a bend, the canted annular segment extending generally between the annular extension and the second flow face, the annular mold contact preventing mold material from rising along the inner surface along the canted annular segment.
50. The filter element of claim 46, further comprising an annular sidewall joined to the canted annular segment, the annular sidewall extending around the outer filter pack surface.
51. The filter element of claim 46, wherein the annular mold contact defines a smaller inner perimeter than an inner perimeter of the annular seal member.
52. The filter element of claim 46, wherein the filter pack is a fluted media having a plurality of flutes including a first set of flutes that are closed proximate the first flow face and a second set of flutes that are closed proximate the second flow face, the fluted media pack having a fluted sheet joined to a face sheet which are wound about the axis into an annular shape.
53. The filter element of claim 52, wherein said seal support frame integrally includes a flow face screen extending over the second face.
54. A filter element, comprising:
a filter pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces, the filter pack having an outer filter pack surface extending transversely between the first and flow faces; a seal support frame including an annular extension disposed at least partially over the second flow face, the seal support frame having an inner surface facing inwardly generally toward the axis and an outer surface facing generally outwardly away from the axis; an annular seal member molded along the annular extension at least partially over the inner surface; and annular rib projecting from the seal support frame along the inner surface, the annular rib being disposed between the seal material along the inner surface and the second flow face. 55. The filter element of claim 54, wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension.
56. The filter element of claim 55, wherein the seal support further includes a canted annular segment joined to the annular extension at a bend, the canted annular segment extending generally between the annular extension and the second flow face, the annular rib separating mold material along the inner surface from the canted annular segment.
57. The filter element of claim 56, further comprising an annular sidewall joined to the canted annular segment, the annular sidewall extending around the outer filter pack surface.
58. The filter element of claim 56, wherein the seal member is molded over the outer surface of the seal support frame to provide an annular outer seal surface adapted for forming a radial seal, and wherein the seal member is also molded over an end of the annular extension and along the inner surface to provide an annular inner seal surface, the annular inner surface being disposed outwardly of the annular rib relative to the axis.
59. The filter element of claim 58, wherein the filter pack is a fluted media having a plurality of flutes including a first set of flutes that are closed proximate to the first flow face and a second set of flutes that are closed proximate to the second flow face, the fluted media pack having a fluted sheet joined to a face sheet which are wound about the axis into an annular shape.
60. The filter element of claim 59, wherein said seal support frame integrally includes a flow face screen extending over the second face.
61. The filter element of claim 54, wherein the annular rib defines a smaller inner perimeter than an inner perimeter of the annular seal member.
CROSS-REFERENCE TO RELATED APPLICATION The present application is a continuation-in-part application of U.S. application Ser. No. 12/215,725, filed Jun. 30, 2008 which is a continuation of U.S. application Ser. No. 11/019,883, filed Dec. 21, 2004 which issued as U.S. Pat. No. 7,396,376 on Jul. 8, 2008 with a claim of priority to U.S. Application 60/532,783 filed Dec. 22, 2003. A claim of priority to U.S. application Ser. Nos. 12/215,725, 11/019,883, and 60/532,783 is made to the extent appropriate. The complete disclosures of U.S. application Ser. Nos. 12/215,725, 11/019,883, and 60/532,783 are incorporated herein by reference.
The present application is a continuation of U.S. application Ser. No. 12/084,730, filed May 7, 2008 which is a National Stage Application of International Application PCT 2006/043836 filed on Nov. 8, 2006 with a claim of priority to U.S. Application 60/735,650 filed on Nov. 9, 2005. A claim of priority to U.S. application Ser. Nos. 12/084,730 and 60/735,650 is made to the extent appropriate. The complete disclosures of U.S. application Ser. Nos. 12/084,730 and 60/735,650 are incorporated herein by reference.
FIELD OF THE INVENTION The present invention relates to air cleaners with removable and replaceable, i.e., serviceable, filter element components. Although other applications are possible, the invention described is particularly useful in air cleaners for use in filtering intake air for engines (used for example in: vehicles, construction, agricultural and mining equipment; and, generator systems). The invention specifically concerns seal arrangements provided on serviceable filter elements, for such air cleaners. The invention also concerns methods of assembly and use.
The techniques described herein are for variations in the seal arrangements of the types described in U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005, PCT Publication WO 05/63361, published Jul. 14, 2005, U.S. Pat. No. 6,190,432 and European Patent EP 1 159 052, each of which is incorporated herein by reference.
SUMMARY According to the present disclosure a filter element is provided, for use in air filtering. Typically, the filter element comprises a media pack including opposite inlet and outlet ends (or faces). The media pack typically defines: a set of inlet flutes open at the inlet end of the media pack to passage of air to be filtered therein, the inlet flutes typically being closed at a location within a distance of 10% of the total length of the inlet flutes from the outlet end of the media pack; and, a set of outlet flutes closed to passage of air to be filtered therein at a distance within 10% of the total length of the inlet flutes from the inlet end of the media pack and open the passage of filtered air therefrom at the outlet end of the media pack. The media pack is typically closed passage of air therethrough, in between the inlet and outlet ends, without filtering flow through the media pack. The element further includes: a preform positioned adjacent a first one of the inlet and outlet ends of the media pack; and, a seal arrangement mounted on the preform.
In certain preferred applications, the media pack is a coiled z-filter media arrangement; and, the seal arrangement comprises foamed polyurethane. The media pack can have a variety of shapes and configurations. Two examples depicted are: an oval perimeter shape (periphery), for example having a racetrack perimeter or cross-sectional shape; and, a cylindrical shape having a circular perimeter (periphery) or cross-sectional shape. A variety of alternate shapes, are possible.
The techniques described herein were developed to provide improvements in such arrangements as those described in U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005 and PCT Publication WO 05/63361, published Jul. 14, 2005, U.S. Pat. No. 6,190,432 and European Patent EP 1 159 052, incorporated herein by reference. The improvements described herein can be applied in other applications, as well.
BRIEF DESCRIPTION OF THE DRAWINGS I. Selected Figures from US 2005/0166561 and PCT WO 05/63361 FIGS. 1-25 FIG. 1 is a side elevational view of a filter element according to an example from U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005 and PCT Publication WO 05/63361, published Jul. 14, 2005.
FIG. 7 is a side elevational view of a filter element according to a second example from U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005 and PCT Publication WO 05/63361, published Jul. 14, 2005.
FIG. 19 is a fragmentary, schematic, perspective view of z-filter media useable in arrangements according to U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005 and PCT Publication WO 05/63361, published Jul. 14, 2005.
FIG. 22 is a schematic view of a process for manufacturing media according to U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005 and PCT Publication WO 05/63361, published Jul. 14, 2005.
FIG. 23 is a schematic cross-sectional view and optional end dart for media flutes useable in arrangements according to US 2005/0166561 and PCT WO 05/63361.
FIG. 24 is a schematic perspective view of a media material useable in the filter elements of FIG. 1 and FIG. 7.
FIG. 25 is a schematic view of a system using an air cleaner having a filter cartridge component according to U.S. Publication US 2005/0166561 A1, published Aug. 4, 2005 and PCT Publication WO 05/63361, published Jul. 14, 2005.
II. Selected Figures from U.S. Pat. No. 6,190,432 and EP 1 159 052 FIGS. 26-27 FIG. 26 is a perspective view of a filter cartridge in accord with the description of U.S. Pat. No. 6,190,432 and European Patent EP 1 159 052.
FIG. 27 is an enlarged fragmentary cross-sectional view of a seal portion of the cartridge of FIG. 26.
III. Figures Depicting Selected Improved Arrangements FIGS. 28-40 A. Example Chamfered or Beveled Seals, FIGS. 28-31 FIG. 28 is a top plan view of a molded seal member portion useable in an arrangement in accord with selected ones to the previously described filter arrangements.
FIG. 29 is a cross-sectional view taken along line 29-29, FIG. 28.
FIG. 30 is an enlarged fragmentary view of a portion of FIG. 29.
FIG. 31 is a cross-sectional view analogous to FIG. 29, of an alternate variation in the depleted seal member.
B. Modifications Involving a Preform Central Projection to Facilitate Molding of the Seal Member, FIGS. 32-40 FIG. 32 is a schematic side elevational view of a filter cartridge including a seal with a modified preform in accord with principles described herein and depleting an optional end piece thereon.
FIG. 33 is a schematic cross-sectional view of media pack and seal portions of the cartridge depicted in FIG. 32; the cross-section of FIG. 33 being taken along a long axis.
FIG. 34 is a second schematic cross-sectional view of the cartridge depicted in FIG. 32; the cross-section of FIG. 34 being taken along a short axis.
FIG. 35 is an enlarged fragmentary cross-sectional view of a portion of FIG. 34.
FIG. 36 is a top plan view of a preform component usable in the filter cartridge of FIGS. 32-35.
FIG. 37 is a cross-sectional view taken along line 37-37, FIG. 36.
FIG. 38 is a cross-sectional view taken along line 38-38, FIG. 36.
FIG. 39 is a cross-sectional view taken along line 39-39, FIG. 36, and depicted inverted as it would when placed in a mold for a molding step forming a seal.
FIG. 40 is a cross-sectional view of an overmolded seal member that would be formed on the preform of FIG. 37 to form the cartridge FIG. 32.
DETAILED DESCRIPTION I. General Information The present disclosure relates to filter elements useable in air cleaner assemblies. In general, the preferred filter elements of concern herein are those in which: (a) the media of the elements comprises a first fluted (typically folded or corrugated) sheet of media attached to a second sheet of media (typically a flat media or nearly flat media) to form a single facer; and (b) in which the single facer combination is either wound or stacked, to create a media arrangement comprising a plurality of inlet flutes open at an inlet end or face of the filter media and closed at or near (typically within 10% of the total length of the inlet flutes of) the outlet and/or face of the media; and, a plurality of outlet flow flutes sealed closed at or near the inlet and/or face of the media (i.e., typically within 10% of the total length of the outlet flutes of the inlet and/or face), and open at the outlet end or face of the media. Typically the media pack is also closed to flow therethrough, entering the inlet face and exiting the outlet face, of air which has not been filtered by passage through the media of the media pack.
Such media arrangements are well known and are described for example in U.S. 2005/0160561 A1 published Aug. 4, 2005; PCT WO 05/63361 published Jul. 14, 2005; U.S. Pat. No. 6,190,432 and EP 1 159052; the complete disclosures of these four U.S. patents being incorporated herein by reference. Herein, such media will sometimes be referred to as z-filter media; and, media packs formed from such media as z-filter media packs.
Many variations of such media can be used, with the principles according to the present disclosure. For example, the end seals of the flutes (flute seals) can be provided in a variety of ways, including through utilization of sealant beads; darting, folding or other arrangements for distorting the shape of the flute at the end and/or closing and sealing the flute ends; and through combinations thereof. Not all flutes need to be sealed closed in the same way. The particular approach to flute sealing is generally a matter of choice, not specifically related to the general principles described herein (except as indicated) in connection with provision of seals between the serviceable filter element and a housing or housing component, in use.
In general, z-filter media pack arrangements as described, are used in serviceable filter elements, i.e., filter elements that are removable and replaceable with respect to an air cleaner in which they are used. Generally, such z-filter media packs are provided with sealing arrangements for engagement with portions of air cleaner parts such as a housing, in use. Herein, such seals are referred to as �air cleaner seals� or �housing seals,� or by variants thereof. A variety of such air cleaner seals are known. One type, involving an outside or outwardly directed radial seal, is described in U.S. Pat. No. 6,350,291 at Ref. #250, FIG. 5.
II. The Arrangements of US Publication 2005/0166561 A1 (published Aug. 4, 2005 and PCT Publication WO 05/63361 (published Jul. 14, 2005) The techniques described herein are applicable in conjunction with the principles described in US 2005/0166561 and PCT WO 05/63361, each of which is incorporated by reference. Therefore, before the improvement techniques of the present application improvement are described, general principles of US 2005/0166561 and WO 05/63361 are described.
A. An Example Element, FIGS. 1-6.
The reference numeral 1, FIG. 1, generally depicts a serviceable filter element (air filter cartridge) according to the disclosures of US 2005/0166561 and WO 05/63361. The filter element 1 depicted, comprises a z-filter media pack 2 having an air cleaner seal arrangement (housing seal arrangement) 3 positioned thereon.
Again, herein, the term �air cleaner seal arrangement�, �housing seal arrangement� and variants thereof is generally meant to reference a seal arrangement 3 provided on a serviceable filter element or cartridge 1 in such a manner that, when the filter element 1 is installed in an air cleaner for use, the seal arrangement 3 provides for an air seal with appropriate componentry or portions of air cleaner, typically an air cleaner housing. The term �serviceable element� in this context, is meant to refer to a filter element 1 which is removable and replaceable with respect to other portions of an air cleaner.
The particular air cleaner seal arrangement 3 depicted comprises an outside radial seal member. By the term �outside radial seal member� in this context, it is meant that the surface 6 which forms a seal with an air cleaner component, in use, is directed radially outwardly, rather than radially inwardly with respect to the portion of the serviceable filter element 1 on which it is mounted.
FIG. 2 is a top plan view of filter element arrangement 1. Referring to FIG. 2, the z-filter media 2 and seal arrangement 3 are provided with an oval outside perimeter shape, in this instance corresponding to two similar, opposite, curved ends 20, 21 spaced apart by two opposite, generally sides, 22, 23. Herein this specific oval configuration will generally be referred to as a �racetrack� shape with sides 22, 23 being generally straight. Racetrack shaped z-filter media pack elements are described in the prior art, for example, in U.S. Pat. No. 6,350,291 at FIG. 10. It will be seen that many of the principles of the present disclosure can be applied in elements having media packs with alternate peripheral shapes, for example circular, as described herein below. Another variation in the oval shape would one in which the opposite sides are not straight, but are curved somewhat, with less curvature than the ends. Another shape which is possible, is a shape which has two pairs of opposite, generally straight, sides which may or may not have a slight curvature to them, with four substantially curved corners. An example of this type of element is described in U.S. provisional application 60/457,255, in FIG. 22, the complete disclosure of which is incorporated herein by reference.
The various shapes identified in the previous paragraph, indicate that the principles discussed herein can be applied to a wide variety of coiled shapes, not just the ones shown in the figures.
Referring to FIG. 1, the filter element 1 includes an optional end piece or skid skirt 30 thereon, at an opposite end of the media 2 from the seal arrangement 3. The optional end piece or skid skirt 30 can be used to provide engagement between element 1, and structure in a housing, during use, to facilitate installation. Examples of such end pieces are shown and described, in PCT Publication number WO 03/095068, published Nov. 20, 2003, at FIGS. 4 and 8, the complete disclosure of PCT publication WO 03/095068 being incorporated herein by reference. The optional end piece 30 is discussed further below, in association with description of FIGS. 17 and 18.
Referring to FIG. 2, seal arrangement 3 comprises: a rigid preform part or insert 35; and, a molded seal component 36. By the term �preform part� and variants thereof, as used in this context herein, it is meant that part 35 is formed prior to formation of the molded seal component 36 to form the seal arrangement 3. Indeed, in a typical manufacturing process for filter element 1, as described below: media pack 2 would be preformed; part 35 would be preformed; and, the two parts (2, 35) would be placed together in a mold, for formation of the molded seal component 36. Herein, the particular molded seal component 36 depicted is sometimes referred to as an �overmold,� or by variants thereof.
The media pack 2, FIG. 3, is a coiled media pack. In general the media pack 2 comprises a corrugated media sheet secured to a flat or nearly flat sheet to form a strip or single facer, which is itself coiled in the configuration shown. Thus, the media pack 2 comprises a single strip of the corrugated sheet/flat or non-corrugated sheet, or single facer, coiled and configured as shown. In FIG. 2, although the media pack is shown schematically, the outer three coils are indicated. Referring to FIG. 1, the outside tail end of the outer most coil is shown at 37. For the embodiment shown, tail end 37 is sealed and secured in position, by a hot melt sealant strip 38, although alternatives are possible.
Referring again to FIG. 3, it is noted that there is no center board, center gap, center piece or center seal schematically shown in the media pack 2. The media pack 2 is simply shown schematically with respect to this point. Center boards can be used, for example as described in U.S. Pat. No. 6,348,084, incorporated herein by reference. Interdigitated center strips can be used, for example as described in U.S. Provisional Application Ser. No. 60/467,521, filed May 2, 2003. Center seals can also be used, for example as described in U.S. Provisional Application Ser. No. 60/467,521, filed May 2, 2003. No specific choice from among these, and variants, is meant to be indicated with respect to FIG. 3.
Referring to FIG. 3, the preform part 35 depicted includes three sections generally comprising: housing seal support section 40; media engagement periphery or skirt 41; and, media face cross-piece arrangement 43.
Attention is directed now to FIG. 4. FIG. 4 is a fragmentary enlarged view of a portion of FIG. 3. In FIG. 4 it can be seen that no portion of preform 35 extends around the outer periphery or side 2 a of the media pack 2. This will be preferred, for arrangements according to the present disclosure, although alternates are possible. For the particular arrangement depicted in FIG. 3, media engagement portion 41 includes an edge 45 which is brought into engagement with flow face 16 of the z-filter media pack 2 and which does not project to, or beyond, an outer perimeter edge 16 a of flow face 16. The particular preform 35 depicted includes a small ridge 45 a, FIG. 6 which projects slightly into media pack 2. Preferably ridge 45 a is no greater than 1 mm and comes to a fine point, to help contain flow of rising urethane, during formation of the seal component 36, and desirably from extending across flow face 16.
Referring still to FIG. 4, molded seal component 36 is positioned with a portion 48 overlapping and sealing a joint 49 where preform part 35 engages flow surface 16 of the media pack 2. In particular, the depleted molded seal component 36 includes a portion 51 which extends beyond the joint 49 in a direction away from flow face 16 (toward opposite flow face 15, FIG. 3) a distance of at least 5 mm, preferably at least 8 mm, and typically a distance within the range of about 9 mm to 18 mm, inclusive.
In general, portions 48 and 51 of the molded seal component 36, provide then, for a sealing between the media pack 2 and the preform part 35 at this location, and also for sealing around and against media pack 2, adjacent face 16, to inhibit undesired, contaminated, air flow at this region.
Referring to FIG. 1, and in particular to hot melt seal strip 38, typically the strip 38 is continuous and terminates, underneath region 51 of overmold 36, at a location spaced at least 4 mm from face 16, FIG. 4. Typically an extension of 6-12 mm of strip 38 will be positioned underneath overmold 36. The termination of strip 38 at least 4 mm from surface 16 ensures that over a distance of at least 4 mm, the seal material of overmold 36 is sealed directly to the media pack 2 adjacent end face 16. This will help avoid leak between the overmold 36 and the media pack 2 at this location.
From review of FIG. 3, it can be seen that portion 40 of preform part 35 is positioned to back up housing seal 56 and stepped portion 56 a of molded seal arrangement 36. Thus, preform part 35, in part, serves a function of providing for rigid backup to the strength of the seal when air cleaner seal portion 54 is compressed in the thickness (typically at least 10% in thickness at the portion of most compression) upon installation in an air cleaner, with compression being of surface 56 toward portion 40. Typically, the distance of compression is within the range of 1.5-2.8 mm, at the thickest part 56 b of seal 56, usually about 1.9-2.5 mm.
The recess of surface 40 across face 16, from outer periphery 2 a of the media pack 2, provides that the filter element 1 can be installed in air cleaners that are originally configured, for example, to receive elements such as element 450, FIG. 15 of U.S. Pat. No. 6,350,291, incorporated herein by reference. Of course alternate configurations are possible.
Media engagement portion 41 is configured to extend radially outwardly, in extension between portion 40 and edge 57. Media engagement portion 41 is configured as a radially outwardly directed skirt, from region 40. This outward extension means that ends of outlet flutes in the z-filter media pack 2, at region 60, FIG. 3, are not closed to passage of air therefrom, during filtering operation. If region 41 was not positioned as a flared, diagonal, skirt, but rather section 40 extended to point 61, flutes in region 60 would be blocked by extension 41, for air flow therefrom. This would lead to increased restriction, and less efficient use of the media. Typically angle X, FIG. 6, is within the range of 20�-70�, to accommodate the desired skirt. The angle X is the angle between the inside surface of skirt 41 and the media face 16.
It is noted that for the preferred element 1 depicted in FIG. 4, no portion of the molded seal component 36 is positioned along interior surface 40 a of section 40. Further, typically no portion of molded seal component 36 is provided along inner surface 41 a of region 41, except possibly for some bleed or flash immediately adjacent edge 45. This latter, when deliverable, prevents undesired levels of flash across surface 16.
A variety of cross piece configurations are useable. In FIG. 2, the particular cross piece arrangement 43 depicted, comprises: a grid of parallel extensions 43 a between opposite sides 22, 23; interconnected by diagonal framework 43 b. In FIG. 5, a perspective view is provided, showing preformed part 35. It can be seen that the preform part 35 can be formed as a single integral unit, for example through injection molding or other molding processes. It was typically formed from a polymer such as a (33% for example) glass filled nylon material.
Referring to FIG. 4, it is noted that where cross-brace 43 engages skirt 41, the angle of the skirt 41 relative to the face 16 may be interrupted somewhat. However, in general, at other locations the skirt 41 will typically have the preferred angle X as characterized above.
The techniques described in US Publication 2005/0166561 and PCT WO 05/63361 could be applied in a wide variety of element configurations and sizes. The following dimensions were provided in examples only, and to help understand the wide application of the described techniques. The overmold 36, in its thickest location, could be about 10-12 mm thick, for example about 11.5 mm. The longest cross-sectional dimension of the racetrack shaped media pack could be about 300-320 mm, for example about 308 mm. The shortest cross-sectional dimension of the racetrack shaped element could about 115-125 mm, for example about 121 mm. The length of the straight sides could be about 175-195 mm, for example about 188 mm.
Before formation of arrangements such as described above is discussed application of the same principles in an alternate configuration will be discussed in connection with FIGS. 7-10.
B. The Arrangement of FIGS. 7-10 Attention is first directed to FIG. 7. FIG. 7 is a side elevational view of a filter element or cartridge 101. The filter element or cartridge 101 comprises a z-filter media pack 102 and seal arrangement 103. The element 101 further includes optional end piece 104 at an end 102 b of media pack 102 opposite from an end 102 a in which seal arrangement 103 is located.
In general, and referring to FIG. 7, surface 106 of seal arrangement 103, is configured to provide a housing seal, as an outwardly directed radial seal, with a housing or air cleaner component in use (of course alternatives are possible). Surface 106 may be configured, in cross-section, analogously to surface 56, FIG. 4.
Attention is now directed to FIG. 8, in which element 101 is depicted in top plan view. From the view of FIG. 7, it can be seen that element 101 has a generally circular outer perimeter 108 defined by both the outer circumference of the seal arrangement 103 and media pack 102. In FIG. 8, grid work 109 is viewable, extending across flow face 105; in this instance face 105 preferably being an outlet flow face.
Attention is now directed to FIG. 9, which shows a cross-sectional view through element 101. From FIG. 9, it can be seen that the seal arrangement 103 comprises a preformed part 110 and an overmold or molded seal component 111. The preform part 110 and molded seal component 111 may generally be analogous to the preform part 35 and molded seal component 36 of the embodiment shown in FIGS. 1-5, except made with a round outer perimeter.
Specifically, element 101 includes a core 113, around which the media pack 102 is wound. Core 113 can be provided in snap fit engagement with a portion 114 of preform part 110. A variety of engagement arrangements can be used, including the one, for example, described at FIG. 5 in U.S. Pat. No. 6,517,598, incorporated herein by reference. Core 113 is shown in schematic. It would typically be provided with a plug therein. The plug could be integral with a remainder of core 113 or is added thereto.
In FIG. 10, an enlarged fragmentary view of a portion of FIG. 9 is shown. The preform part 110 includes a housing seal support 116; and, a media pack engagement portion 117, configured as a radially outwardly directed skirt 118; and media face cross piece arrangement 109 (FIG. 8). (At region 114 the inside outward skirt 118 is shown filled because the cross-section is taken through cross piece grid work 109, FIG. 8). For element 101, these components generally provide the same basic operation as the analogous components for element 1, FIG. 1.
C. Process for Assembly of Elements (Air Filter Cartridges) According to FIGS. 1-10.
In general, elements (air filter cartridges) corresponding to element or cartridge 1, FIG. 1, and element or cartridge 101, FIG. 6, are formed the processes involving the following:
1. Preforming the media pack component (2, 102); 2. Preforming the preformed part (35, 110) of the seal arrangement; 3. Positioning the preform part (35, 110) and media pack component (2, 102) appropriately with respect to one another in a mold. 4. Molding (in the examples shown by overmolding) seal material to form the appropriate molded seal component of the arrangement. 5. Demolding. 6. Optionally placing the skid (30, 104) on an end of the element opposite the seal. In this context, the term �overmolding� and variants thereof are meant to refer to molding a molded seal component 36, 111 in position: (a) with a portion of the molded seal component 36 over the outside of joint between the preformed part (35, 110) of the seal arrangement and the media pack (2, 102); and, (b) with a portion of the same seal component 36, 111 (i.e. preferably a portion integral with a remainder of the overmold) positioned to form an air cleaner seal. Typical and preferred processes will use, for the formation of the molded seal component, a foaming polyurethane, as described below. Herein, a molded seal component 36 which has been made by overmolding as defined, will sometimes be referred to as an overmold. The portions of the overmold seal, are preferably integral with one another; the overmold 36, 111 being preferably molded from a single pool of polymer.
Typically, the thickness of the molded seal component, in the region of the seal surface, is configured so that compression of the thickness of the thickest portion of the molded seal component in this region, will be at least 10%, and typically at least 15%, when the element (1, 101) is installed in an air cleaner for use. This can be accomplished with configurations as shown, using materials as described below.
Attention is first directed to FIG. 11. In FIG. 11, reference numeral 180 identifies a mold arrangement useable to form the overmold seal arrangement of FIGS. 1-10. Mold arrangement 180 is shown in fragmentary, cross-section. The portions indicated will provide an understanding of how the overmold seal arrangement can be formed. The remainder of the mold will be configured either round or obround, etc., depending on the particular instance of application.
Finally, part 185 includes inner wall 215 and upper flange 218. The flange 218 extends over portion 205 of center part 184. Inner wall 215 includes a surface 216 which will define selected portions of the seal member, during the molding process, as discussed below in connection with FIG. 15. Section 217 will cap the mold, and engage media, during a molding operation as described.
1. At region 240, the most outwardly projecting portion of the molded seal member 235 (number that above) is formed. Portion 240 then, will form the outer most portion of the outwardly directed radial seal member, i.e., the part that compresses most in use as an air cleaner seal; 2. Surface 241 is a portion of mold undercut, which is used to form a portion of region 240. 3. At region 245, rise of the material 235 around the outside surface 232 of the media pack 231 is capped or stopped by mold piece 185, in particular by region 216 of mold piece 185. At location 247, some of the resin of overmold 235 has risen into the media pack between an outer most layer 248 of the media pack 231 and the layer underneath. This rise will tend to close off any otherwise open flutes at this location. In general, this will render the outer most layer of the media pack (for example layer 46 a, FIG. 4) such that while it can be used for filtering material, air must pass into the next inner layer, before it can exit the media pack. What this means or ensures is that even if the outer most wrap of media pack is damaged during handling or installation, leakage will not result. Thus, in a typical arrangement made in this manner, a third set of flutes, closed at both ends, is present in the media pack. This third set is present, preferably, only in the outermost wrap. These flutes would otherwise be outlet flutes, and will sometimes be referred to by such terms.
Demolding can be accomplished by forcing the element out of the mold 180, in a powered process. Equipment to cause the forcing can engage the cross-pieces on the preform 230. Generally the overmold 235 will compress sufficiently, to be pushed past undercuts in the mold. It is anticipated that typically, with materials and configurations described herein, demolding can be accomplished with a force of 110 lbs. or less, typically about 100 lbs. (The demolding force would typically be applied directly to the gridwork of the preform 35, 110).
Typically with such arrangements, the polyurethane formulation chosen provides for a high foam, very soft, molded end cap. In general, the principal issue is to utilize a formulation that provides for an end cap that is such that a robust seal will result under conditions which will allow for hand assembly and disassembly. This generally means that the seal range which has material is a relatively low density, and exhibits appropriate and desirable compression load deflection and compression set.
Typically the formula chosen will be such as to provide end caps having an as molded density of no greater than 28 lbs./cubic foot, usually no more than 22 lbs./cubic foot, often no greater than 18 lbs/cubic feet and preferably within the range of 12 to 17 lbs/cubic foot.
One example usable material includes the following polyurethane, processed to an end product having an �as molded� density of 14-22 pounds per cubic foot. The polyurethane comprises a material made with I36070R resin and I305OU isocyanate, which are sold exclusively to the assignee Donaldson by BASF Corporation, Wyandotte, Mich. 48192.
1. Z-Filter Media Configurations, Generally.
In general, the corrugated sheet 403, FIG. 19, is of a type generally characterized herein as having a regular, curved, wave pattern of flutes or corrugations 407. The term �wave pattern� in this context, is meant to refer to a flute or corrugated pattern of alternating troughs 407 b and ridges 407 a. The term �regular� in this context is meant to refer to the fact that the pairs of troughs and ridges (407 b, 407 a) alternate with generally the same repeating corrugation (or flute) shape and size. (Also, typically in a regular configuration each trough 407 b is substantially an inverse of each ridge 407 a). The term �regular� is thus meant to indicate that the corrugation (or flute) pattern comprises troughs and ridges with each pair (comprising an adjacent trough and ridge) repeating, without substantial modification in size and shape of the corrugations along at least 70% of the length of the flutes. The term �substantial� in this context, refers to a modification resulting from a change in the process or form used to create the corrugated or fluted sheet, as opposed to minor variations from the fact that the media sheet 403 is flexible. With respect to the characterization of a repeating pattern, it is not meant that in any given filter construction, an equal number of ridges and troughs is necessarily present. The media 401 could be terminated, for example, between a pair comprising a ridge and a trough, or partially along a pair comprising a ridge and a trough. (For example, in FIG. 19 the media 401 depicted in fragmentary has eight complete ridges 407 a and seven complete troughs 407 b). Also, the opposite flute ends (ends of the troughs and ridges) may vary from one another. Such variations in ends are disregarded in these definitions, unless specifically stated. That is, variations in the ends of flutes are intended to be covered by the above definitions.
In the context of the characterization of a �curved� wave pattern of corrugations, the term �curved� is meant to refer to a corrugation pattern that is not the result of a folded or creased shape provided to the media, but rather the apex 407 a of each ridge and the bottom 407 b of each trough is formed along a radiused curve. Although alternatives are possible, a typical radius for such z-filter media would be at least 0.25 mm and typically would be not more than 3 mm. (Media that is not curved, by the above definition, can also be useable).
An additional characteristic of the particular regular, curved, wave pattern depicted in FIG. 19, for the corrugated sheet 403, is that at approximately a midpoint 430 between each trough and each adjacent ridge, along most of the length of the flutes 407, is located a transition region where the curvature inverts. For example, viewing back side or face 403 a, FIG. 19, trough 407 b is a concave region, and ridge 407 a is a convex region. Of course when viewed toward front side or face 403 b, trough 407 b of side 403 a forms a ridge; and, ridge 407 a of face 403 a, forms a trough. (In some instances, region 430 can be a straight segment, instead of a point, with curvature inverting at ends of the straight segment 430).
Referring to the present FIG. 19 and as referenced above, the media 401 has first and second opposite edges 408 and 409. When the media 401 is coiled and formed into a media pack, in general edge 409 will form an inlet end for the media pack and edge 408 an outlet end, although an opposite orientation is possible as discussed below with respect to FIG. 24.
In general, standard flute configurations from the corrugated box industry can be used to define corrugation shapes or approximate corrugation shapes for corrugated media. Comparisons above between the DCI A flute and DCI B flute, and the corrugation industry standard A and standard B flutes, indicate some convenient variations. A variety of other flute sizes and shapes can also be used with arrangements described herein.
2. Manufacture of Coiled Media Configurations Using Fluted Media, Generally.
Still in reference to FIG. 22, before the z-filter media 474 is put through the darting station 471 and eventually slit at 475, it must be formed. In the schematic shown in FIG. 22, this is done by passing a sheet of media 492 through a pair of corrugation rollers 494, 495. In the schematic shown in FIG. 22, the sheet of media 492 is unrolled from a roll 496, wound around tension rollers 498, and then passed through a nip or bite 502 between the corrugation rollers 494, 495. The corrugation rollers 494, 495 have teeth 504 that will give the general desired shape of the corrugations after the flat sheet 492 passes through the nip 502. After passing through the nip 502, the sheet 492 becomes corrugated across the machine direction and is referenced at 466 as the corrugated sheet. The corrugated sheet 466 is then secured to facing sheet 464. (The corrugation process may involve heating the media, in some instances).
Above it was discussed that flow could be opposite to the direction shown in FIG. 19. An example is shown in FIG. 24.
G. General Background Regarding Air Cleaner Systems.
The principles and arrangements described in US Publ. 2005/0166561 and PCT WO 05/63361 are useable in a variety of systems. One particular system is depicted schematically in FIG. 25, generally at 650. In FIG. 25, equipment 652, such as a vehicle 652 a having an engine 653 with some defined rated air flow demand, for example in the range of 50 cfm to 2000 cfm (cubic feet per minute) (i.e., 1.4-57 cubic meters/minute) is shown schematically. Although alternatives are possible, the equipment 652 may, for example, comprise a bus, an over-the-highway truck, an off-road vehicle, a tractor, a light-duty or medium-duty truck, or a marine vehicle such as a power boat. The engine 653 powers the equipment 652 upon fuel combustion. In FIG. 25, air flow is shown drawn into the engine 653 at an air intake at region 655. An optional turbo 656 is shown in phantom, as optionally boosting the air intake to the engine 653. The turbo 656 is shown downstream from an air cleaner 660, although alternate arrangement are possible.
III. An Example Filter Cartridge in Accord with U.S. Pat. No. 6,150,432 and EP 1 159 052 FIGS. 26-27 In U.S. Pat. No. 6,150,432 and EP 1 159 052, an earlier variation of the z-filter cartridge was described. One such example is shown herein in FIG. 26 at reference numeral 700. The air filter cartridge 700 comprises a media pack 701 with opposite ends 702, 703. The media pack is generally in accord with the media pack 2 previously discussed and described. At end 703 a seal arrangement 704 is positioned comprising preform 705 and molded in place seal member 706. The preform 705 includes a cross-piece arrangement 708 which provides: radial strength to the structure of the preform 705; and, inhibition against telescoping of the media at face 703.
A typical air flow direction is indicated at arrows 710. In FIG. 27, a portion of the seal arrangement 704 is shown in cross-section. This portion of the seal arrangement comprises support 720 and molded-in-place seal member 706. The seal arrangement 706 includes an outer surface 706 o, with the stepped radial seal area 706 s; a thickest portion being represented at 706 b, comprising the region of greatest compression during sealing. Structure 720 is a support to the radial seal 706 and projects axially outwardly from media pack end 703, FIG. 26, in a direction away from the media pack 701. Referring to FIG. 27, outwardly directed skirt 721, extends between support 720 and an outer rim 722 (FIG. 26) of the preform 705, which fits around an outer periphery of the media pack 701. The media pack 701 can be glued or otherwise adhesively secured to the preform 705. The seal 706 would typically be premolded on the preform 704, in particular on support 720, before the preform 705 (comprising support 720, frame 708, skirt 721 and rim 722) is attached to the media pack 701, for example, adhesive.
The seal member 706 would operate similarly to those described above, but without the advantages of the overmolded portion of the seal member.
The type of seal arrangement described in connection with FIGS. 26 and 27 can be applied on a variety of shapes of cartridges. The example shown in FIGS. 26 and 27 is a media pack 701 which is generally cylindrical in shape and has a circular cross-section. The same type of seal can be provided on an oval shaped arrangement, such as for example a racetrack arrangement, if desired. This is described in U.S. Pat. No. 6,190,432 and EP 1 159 052 incorporated herein by reference.
Media pack 701 can generally be in accord with the descriptions herein above, and can be made in accord with the descriptions herein above.
IV. Selected Modifications of the Housing Seal Arrangements Shown and Described in FIGS. 1, 3, 4, 7, 9, 10, 26 and 27 A. A Modified Housing Seal Profile FIGS. 28-31 In FIGS. 28-31, a modified housing seal profile from those described in FIGS. 1, 3, 4, 7, 9, 10, 26 and 27, is presented. A commonality among the housing seals of FIGS. 1, 3, 4, 7, 9, 10, 26 and 27, is that the seal region is a stepped region, in each instance showing a total of three steps between an outer tip and a thickest part of the seal. In some instances, the amount of force needed to install an element having a seal profile in accord with FIGS. 1, 3, 4, 7, 9, 10, 26 and 27, can be undesirable. To provide for reduction in this force, a variation in the housing seal profile of these Figs. is provided herein. The modifications described can be applied on a variety of perimeter shapes of seals and media packs including, for example, ones having a circular media pack and seal outer periphery (perimeter); and, ones having a media pack and seal of oval, for example racetrack, outer periphery (perimeter). This will be understood from the following.
In FIGS. 28-31, only the molded seal member itself is depicted. That is, the seal member is shown schematically, without the preform member on which it is mounted in use being present. It should be understood that the preform member can be in accord with those previously described in FIGS. 1-27, or in accord with the improvements described herein below, in connection with FIGS. 32-40.
In typical arrangements, the seal member 800, FIG. 28, would not exist separately from the preform on which it is mounted. Rather the seal member 800 would typically be molded-in-place on a preform with which it would be used.
The seal member 800, FIG. 28, can be provided in the form of a seal member otherwise in accord with FIGS. 26, 27, which is molded onto a preform that is attached (adhered) to a media pack; or in accord with FIGS. 1, 3, 4, 7, 9 and 10, that is molded as part of an overmold with portion thereof providing for attachment of the housing seal member and support, to a media pack, by an adhesive separate from the seal member. In FIGS. 28-30, an example is shown in which the housing seal member is in a form as it would be if molded-in-place on support 720, FIG. 27.
In FIG. 31 a similar housing seal profile is shown, as a portion of a seal member molded in the form of an overmold, such as in FIGS. 1, 3, 4, 7, 9 and 10. In the arrangement of FIG. 31, the seal member would be an integral part of an overmold that also secures the seal member and preform to a media pack.
Attention is now directed to FIG. 28. In FIG. 28, reference numeral 800 indicates the housing seal member. Seal member 800 is shown with a circular perimeter shape, but could be formed with alternate perimeter shapes such as oval, an example being racetrack.
In FIG. 29, housing seal member 800 is depicted in cross-section. Housing seal member 800 includes an outer seal portion 801. The outer seal portion 801 is a portion which compresses to form a housing seal between an outer annular housing portion (when installed), and a support such as support 720. Outer portion 801 includes a single, chamfered or beveled, forward edge region 803. The chamfered or beveled forward edge region 803 is discussed in greater detail below.
The term �single� as used in the context of the previous paragraph, is meant to refer an outer portion 801 that includes only one beveled region 803 between a thick part 801 t of the radial seal region 801 that overlaps a support (for example support 720), and tip 805. This is different from previous arrangements discussed in connection with FIGS. 1, 3, 4, 7, 9, 10, 26 and 27, in which two, small, spaced, beveled regions, forming several steps, are positioned.
Still referring to FIG. 29, housing seal member 800 further includes tip 805 and inner region 807. The inner region 807 would be positioned against an inside surface of a support, such as support 720, FIG. 27, when housing seal member 800 is used. Alternately stated, inner portion 807 is positioned on an opposite side of a support from region 801, during use. Tip 805 extends between regions 807 and 801, typically over an outermost tip, remote from media pack, of a support on which housing seal member 800 is positioned in use.
Attention is now directed to FIG. 30, in which a portion of FIG. 29 is shown in an enlarged fragmentary view. Instead of possessing multiple steps, as do the seal profiles of the arrangement shown in FIGS. 1, 3, 4, 7, 9, 10, 26 and 27, housing seal member 800 includes, at outer portion 801, a single beveled or chamfered edge 803 extending between tip 805 and outer surface 810 of region 801, which is the thickest portion 801 t that forms an outwardly directed radial seal, backed up by a support such as support 720, in use. Edge 803 typically extends at an angle, HE, relative to a plane perpendicular (indicated at P) to air flow through a filter cartridge in use, indicated by axial arrow 820, within the range of 30� to 60�, inclusive typically 35�-55�, inclusive usually 40�-50�, inclusive. (In some instance air flow could be in a direction opposite to arrow 820, but the plane perpendicular would be the same). It is anticipated that in a typical arrangement, a cartridge utilizing seal 800 would be installed such that air flow of filtered air from a media pack would be in the direction of arrow 820. The use of a single chamfered or beveled surface 803, extending at an angle, HE, to a direction perpendicular to flute direction in a corresponding media pack is advantageous for installation in certain applications.
Typically, surface 803 is straight over a distance of at least 4 mm, usually at least 6 mm, typically 6-16 mm, inclusive. Forming radiused portions at ends 803 o and 803 i facilitates installation.
Generally speaking, region 801 would be about 6 to 18 mm thick, inclusive, at its thickest portion 801 t (in thickness from region 809, where a support would be positioned in use). Typically the thickness is in the range of 8-14 mm, inclusive.
In FIGS. 29 and 30, example dimensions are provided to facilitate understanding. Alternate dimensions can be utilized, with principles described herein. The dimensions indicated in FIGS. 29 and 30 are as follows: GA=226.5 mm; GB=194 mm; GC=5.7 mm; GD=3.0 mm radius; GE=4.0 mm radius; GF=4.0 mm radius; GG=225.7 mm; HA=20.9 mm; HB=14.9 mm; HC=6.4 mm and HD=45�.
At region 801 t, the outer surface 810 is generally parallel or approximately parallel to central axis 827, i.e., an axis parallel with air flow through a filter cartridge in use. Angle HD, FIG. 30, is an acute angle between surfaces 803 and surface 810 in region 801 t. It is typically no greater than 60�, usually no less than 30�, often within the range of 35�-55�, inclusive. Usually the angle HD is within the range of 40�-50� inclusive, for example 45� as shown.
In FIG. 31, an additional housing seal arrangement 830 is depicted, with outer portion 831, inner portion 837, tip 835 and chamfered surface 833. These regions may be generally as described for example 800, FIGS. 29 and 30, except region 831 is shown fragmented at 840, indicating that housing seal arrangement 830 is a housing seal portion of an overmold otherwise analogous to that described above in connection with FIGS. 1, 3, 4, 7, 9 and 10. Thus, the principles described in connection with FIGS. 29 and 30, can also be applied for the profile of a housing seal member in an arrangement involving an overmold to secure the housing seal member to the media pack, as described above in connection with FIGS. 1, 3, 4, 7, 9 and 10.
B. Modifications in the Preform to Define an Advantageous Filter Cartridge for Selected Situations, FIGS. 32-40.
The reference numeral 850, FIG. 32, indicates an alternate filter cartridge including selected improvements described herein. The particular filter cartridge 850 depicted includes a media pack 851 and a housing seal arrangement 852. The media pack 851 may be generally as described hereinabove, comprising z-filter media in accord with the variations discussed. The particular media pack 851 on housing seal arrangement 852 depicted, each have a generally oval, in this instance racetrack, shaped perimeter outer periphery, although the principles described herein can be applied in connection with media packs that have a circular perimeter (outer periphery) if desired. For the example shown, the housing seal 852 comprises a portion of an overmold 855, generally in accord with overmold of seal arrangements, discussed above in connection with FIGS. 1, 3, 4, 7, 9 and 10. However the housing seal 852 could be formed as a seal member molded onto a separate preform which is than secured to a media pack, analogously to the description above for FIGS. 26, 27. Further, the profile of region 852 can be modified in accord with the chamfered or beveled arrangement discussed above in connection with FIGS. 28-31.
Still referring to FIG. 32, the media pack 851 has opposite ends 850 x and 850 y. At end 850 x, the housing seal arrangement 852 is positioned. At end 850 y an optional end skirt (skid skirt) or end piece 860 is positioned. The framepiece or end piece 860 can be used to perform functions similar to those for framepiece 104, discussed above in connection with FIGS. 7 and 9. It is noted that framepiece 860 is improved relative to framepiece 104, by the provision of scallop-shaped finger tip receiving regions 861 therein, around selected portions of framepiece 860. The scallop-shaped regions 861 facilitate handling of cartridge 850 during installation and removal. The scallop-shaped regions 861 can be provided with undercuts at 861 a, and are particularly useful when positioned around the curved ends of a racetrack or oval shaped media pack 851. More specifically, scalloped regions 861 are open in a direction toward the housing seal arrangement and help with removal of cartridge 850 when installed in an arrangement of the general type described in PCT/US2005/014909, incorporated herein by reference, including a loading of the cartridge through a housing side, with a cam or ramp.
In general, certain air cleaners being developed include mass air flow sensors (MAFS) positioned relatively close to the serviceable filter cartridge, at a location downstream therefrom. In typical arrangements, in which the housing seal is positioned on a downstream end of the filter cartridge, this means that the housing seal arrangement comprising a preform in the molded housing seal member, are positioned relatively near the mass air flow sensor and in air flow coming from a downstream end of the media pack. It is preferred that the housing seal arrangement be configured so as to not contribute undesirably and inconsistently to fluctuations in the air flow or mass air flow sensor readings can be unacceptably disturbed.
It has been found that when housing seal arrangements are molded in accord with the profiles of FIGS. 1, 3, 4, 7, 9, 10, 26 and 27, in some instances inwardly positioned regions of molded urethane can provide undesirable levels of inconsistent flash thereby disturbing the stability of flow pass the air flow sensor an unacceptable amount. To inhibit this, cartridge 850 is provided with a housing seal arrangement including a preform having a radially, inwardly directed, usually continuous, seal material resin rise stop or lip therein, that, when used in association with features in mold, reduce this issue.
With respect to this, attention is first directed to FIG. 33. In FIG. 33, cartridge 850 is depicted without end piece 860, (FIG. 32) thereon. Referring to FIG. 33, housing seal arrangement 852 comprises the molded seal member 860 and preform 861. The preform 861, except as discussed below, is generally analogous to preform 35, FIGS. 3, 4 and 5, and includes: seal support 862 which extends generally axially, outwardly, from surface 850 x away from the media pack 851; skirt 863, extending between the support 862 and a perimeter region of the media pack 851; and, cross pieces 864, which provides stability to surface 850 x, and also circumferential strength to the preform 861. The particular preform 861 depicted stops short of outside periphery 851 o, of media pack 851, and includes tip 865 analogous to tip 45 a, FIG. 6. (It is noted that cross-pieces 864 define a different portion than in previously depicted arrangements, but similar functions are accommodated).
Preform 861 includes, like preform 35, FIGS. 3-6, inwardly, radially, projecting stop or lip 870 located at an end support 862, generally at a junction between support 862 and skirt 863. Projection 870, as will be seen, provides for control of rise of seal resin in region 875, during filter cartridge manufacture. This can help create a more uniform region of molded material in overlap with surface 850 x, to reduce production of instability into air flow therefrom. In this context the term �inwardly� and variants thereof, is meant to indicate a direction of extension away from support 862 in a direction also away from a seal region of the molded seal member 860. The term �radially� is meant to indicate a direction of extension generally toward a central axis extending through the media pack 851.
FIG. 34, cross-sectional view analogous of FIG. 33, is depicted, except through a shorter axis of the oval shape. Features depicted have analogous function and are numbered accordingly.
In FIG. 35 a portion of FIG. 34 is shown in enlarged, fragmentary view. The portion depicted in FIG. 35, generally provides an understanding of the housing seal arrangement 852.
Referring to FIG. 35, housing seal arrangement 852 includes molded seal region 855 having a radially, outwardly, directed housing seal surface 852 s thereon and formed integrally therewith. The housing seal arrangement 852 further includes preform 861 having support 862, skirt 863 and lip or projection 870. Referring to FIG. 35, at region 871, it can be understood that projection 870 comprises an angled inner surface adjacent an inner surface 862 i of support 862, typically extending at an angle A1, thereto, within the range is 130� to 155�, typically 135� to 150�.
In the example shown in FIG. 35, surface 821 i extends slightly outwardly, in extension between joint 821 x and tip 821 y, at an angle, relative to a direction parallel with air flow through media pack 851, of about 6�, although variations are possible.
Still referring to FIG. 35, molded overmold 855 includes outer portion 880 and inner portion 881. Surface 871 is provided to cap the mold in the region where inner portion 881 rises, during molding. With respect to this, it is noted that the arrangement of FIG. 35 will be formed analogously to the arrangement of FIGS. 1, 3, 4, 7, 9 and 10, and thus would be inverted relative to FIG. 35, when region 881 and 880 are formed.
Still referring to FIG. 35, region 881 will typically be at least about 1 mm thick, typically at least about 1.5 mm thick and usually within the ranges about 1.6-2.5 mm thick, inclusive, in extension along surface 821 i and inwardly therefrom, although variations from this are possible.
Region 821 i includes beveled tip 821 t, adjacent projection 870.
Projection to lip 870 then typically extends a distance of at least 1 mm, usually at least 1.5 mm and typically a distance within the range of at least 1.6-2.6 mm, although variations are possible. In a completed cartridge 850, lip 870 is positioned between tip 821 t, and the media 851 g with lip 870 adjacent the seal material in region 821 i and spaced from the media 851.
Still referring to FIG. 35, when inverted it will be understood that projection 870 extends over a mold region in which resin can rise to form molded portion 881, of overmold 852, along an inside of support 862. By resting on a mold cavity, region 870 will cap the rise of resin forming region 881. Thus extra flash outwardly, or uneven molding, is reduced. This will facilitate stable air flow and mass air flow sensor operation.
In FIG. 36, preform 861 is depicted. Support 862, skirt 863 and cross pieces 864 are viewable. FIG. 37 is a cross-sectional view taken along line 37-37, FIG. 36. Here radially inwardly directed, projection or lip 870 can be viewed. It is noted that ridge or stop 870 is supported by gussets 870 a. In typical arrangement, lip 870 is radially continuous, around its entire extension, and does not include gaps therein.
In FIG. 39 a cross-sectional view taken along line 39-39, FIG. 36 is depicted. In FIG. 39 preform 861 is depicted inverted, as it would be when positioned when in a mold, for forming molded in place seal arrangement 860, FIG. 33. It can be seen that radially inwardly projecting stop or ridge 870 is positioned to provide a stop to resin flow upwardly along region 862 i, during molding.
FIG. 40 is a viewable molded seal region 860 when made using a preform 861, in accord with a molded process generally otherwise in accord with that described above for FIGS. 11-16. Typically molded seal region 860 would not be formed separately from preform support, but rather would be molded in place thereon. However, in FIG. 40 is depicted separately, so features can be readily seen.
At 880, a surface which defines tip 821 t, resulting from rise into stop 870, FIGS. 37-39, is shown. Surface 880 will typically be beveled to extend downwardly, in extension out from gap 881, FIG. 40, in which a seal support will be positioned in use.
It will be understood that a lip analogous to lip 870 can be used also on preform used in the arrangements of FIGS. 26, 27, to control rise along an inner region while the mold in place seal arrangements used therein, are formed. The principal difference is that such seal arrangements do not include the overmold region 890, FIG. 40.
In FIGS. 32-40, example dimension are provided for an example arrangement utilizing a racetrack shape. The example dimensions are as follows: IA=300.4 mm; IB=310.3 mm; JA=300.4 mm; JB=190 mm; JC=221.1 mm; JD=299 mm; KA=152.4 mm; KB=151 mm; LA=295.6 mm; LB=70�; LC=49.5 mm; LD=24.7 mm; LE=147.6 mm; LF=61.8 mm radius; LG=2 mm; LH=5.0 mm diameter; MA=276.6 mm; MB=2.5 mm; MC=271.6 mm; MD=15.8 mm; ME=27 mm; MF=295.6 mm; NA=128.6 mm; NB=123.6 mm; NC=15.8 mm; ND=147.6 mm; OA=147.6 mm; OB=15.8 mm; OC=125.2 mm; OD=130.2 mm; PA=300.4 mm; PB=28.6�; PC=295.6 mm; PD=4.0 mm radius; PE=269.1 mm; PF=150.8�; PG=25�; PH=271.4 mm; PI=33.3�; PJ=4.2 mm; and PK=304 mm.
Patent CitationsCited PatentFiling datePublication dateApplicantTitleUS7318851 *Nov 2, 2004Jan 15, 2008Baldwin Filters, Inc.Filter elementUS7396376 *Dec 21, 2004Jul 8, 2008Donaldson Company, Inc.Seal arrangement for filter element; filter element assembly; and, methodsUS7931724 *Mar 13, 2009Apr 26, 2011Donaldson Company, Inc.Seal arrangement for filter element; filter element assembly; and, methodsUS7935166 *Jun 30, 2008May 3, 2011Donaldson Company, Inc.Seal arrangement for filter element; filter element assembly; and, methodsUS8409316 *Nov 8, 2006Apr 2, 2013Donaldson Company, Inc.Seal arrangement for filter element; filter element assembly; and, methodsUS8685128 *Aug 13, 2012Apr 1, 2014Donaldson Company, Inc.Seal, arrangement for filter element; filter element assembly; and, methods* Cited by examinerReferenced byCiting PatentFiling datePublication dateApplicantTitleUS7959703 *Jun 30, 2008Jun 14, 2011Baldwin Filters, Inc.Fluted filter with integrated frameUS8048187 *Jun 30, 2008Nov 1, 2011Baldwin Filters, Inc.Filter frame attachment and fluted filter having sameUS8685128Aug 13, 2012Apr 1, 2014Donaldson Company, Inc.Seal, arrangement for filter element; filter element assembly; and, methods* Cited by examinerClassifications U.S. Classification55/498, 55/502International ClassificationB01D46/00, B01D46/52Cooperative ClassificationB01D46/008, B01D46/2411, B01D2279/60, B01D46/525, B01D2271/027, B01D2271/02, B01D46/0005European ClassificationB01D46/52F6, B01D46/00C20, B01D46/00R80, B01D46/24F4Legal EventsDateCodeEventDescriptionAug 15, 2011ASAssignmentOwner name: DONALDSON COMPANY, INC., MINNESOTAFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SCHRAGE, KEVIN;MURPHY, TROY;MORK, DONALD RAYMOND;AND OTHERS;SIGNING DATES FROM 20110317 TO 20110513;REEL/FRAME:026751/0098RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google