Patent Description:
An example of an air filter product utilizes a small, plastic projection that snaps into the center winding core for grasping to pull the filter out of sealing engagement with the housing, such as show in <CIT> and <CIT>, wherein the present embodiments herein may be for same air cleaner housing applications as replacements, such that dimensions, filter packs and housings disclosed therein are useable for the present embodiments. As shown in these patents, the grasping structure is small in relation to the size of the filter. The strength of the snap-fit attachment of the grasping projection may be less than necessary to lift or remove a filter (with or without retained contaminant). If the grasping projection breaks away, it cannot be repaired/replaced leading to significant customer dissatisfaction. The location and shape of the grasping projection is not considered 'user-friendly' by the customer.

Another concept is illustrated in <CIT> entitled "Filter arrangement and method", wherein the present embodiments herein may be for same air cleaner housing applications as replacements, such that dimensions, filter packs and housings disclosed therein are useable for the present embodiments. In this '<NUM> patent, a similar axial flow (inline type flow) air filter pack such as a fluted pack is used, and a flat radially projecting outer flange is discussed as providing a handle, however this acts primarily as a housing stop.

As will be realized by the present invention, improvements over the state of the art may be realized, with an improved handle structure.

Other examples in the filter art that include handles are shown in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT> along with <CIT> and <CIT>. However, some of these are not concerned with similar concerns or not for air filters, or have other drawbacks with respect to occupying extra space and/or considerable space, increasing the size of the filter envelope occupied.

The following documents provide technical background to the present disclosure: <CIT> directed towards air cleaner assemblies; <CIT> directed towards a filter element; <CIT> directed towards a detachable filter insert for a vacuum cleaner; <CIT> directed towards a filter assembly for use in a cleaning appliance; and <CIT> directed towards a filter frame handle construction.

As noted above, the air filter elements according to the various embodiments disclosed herein may be used as replacement filters in the air cleaner housings such as disclosed in<CIT> et al and/or <CIT> For example, the handle structure may also engage the air cleaner housing according to the patent records, to help with filter positioning.

The claimed invention provides a filter element with at least one handle structure configuration, as defined in appended claim <NUM>. Optional features are defined in the appended dependent claims.

On the contrary, the scope of the invention is as defined by the appended claims. The claimed invention is shown in <FIG> of the drawings.

Turning to <FIG>, an air filter element <NUM> with an improved handle structure in the form of a pair of handles <NUM> is illustrated in accordance with a first example. The air filter element <NUM> includes a mass of media such as a filter media pack <NUM> comprising a suitable air filter media (e.g. typically non-woven fibrous media of cellulose and/or synthetic polymeric fibers in a sheet). The filter media pack <NUM> defines an inlet face <NUM>, an outlet face <NUM> and an outer periphery <NUM> that is an annular side (e.g. cylindrical outer wall in the present example). The outer periphery <NUM> faces radially outward and extends axially between the inlet face <NUM> and the outlet face <NUM> to provide a filtered fluid flow path extending axially from the inlet face to the outlet face and through the air filter media for contaminant removal. This may be considered to be an axial flow type filter (also referenced as an inline filter, in that the air can pass through the faces generally along the same direction).

The filter media pack <NUM> in this example is preferably a fluted filter media pack, which is known in the art to comprise a fluted sheet and a facing sheet that are secured together to define inlet flutes occluded a the outlet end and outlet flutes occluded at the inlet end so that unfiltered air must pass through one of the sheets of filter media to remove contaminants from the airflow. For example, a suitable fluted filter media pack and method of manufacture useable for the media pack herein is shown for example in the aforementioned <CIT> and/or <CIT> entitled "Method and apparatus for winding a filter media pack,".

Optionally but preferably, an outer wrapper <NUM> such as provided in <CIT> and entitled "Surface Coated Filter Method" may be utilized. For example, outer wrapper <NUM> may be an integrally formed outer layer such as by spray or roller coating of polyurea material, however adhesively attached preformed wrappers of plastic sheet and/or of porous material such as a spun-bounded sheet may be used.

The air filter element <NUM> includes a frame <NUM> secured to the filter media pack <NUM> and in surrounding relation of the outer periphery <NUM>. For example, the filter media pack <NUM> can be secured to the frame <NUM> through an annular adhesive of polyurethane that attaches the frame <NUM> through the outer wrapper <NUM>.

The frame is preferably a rigid structure such as made from rigid plastic and preferably nylon reinforced with glass fibers.

The frame <NUM> can comprise an annular band <NUM> secured to the outer periphery <NUM> of the filter media pack via an adhesive <NUM>. The annular band <NUM> extends axially but in radially spaced relation to the filter media pack <NUM> to define a potting well <NUM> therebetween, with the adhesive <NUM> being disposed in the potting well <NUM> for securement. The frame <NUM> may also include an annular shutoff lip <NUM> closing the potting well <NUM> at bottom of the annular band <NUM> while leaving an adequate fillable entrance region at the top for receipt of the adhesive, which is preferably a curable resin such as urethane that can also seal between the annular band and the filter media pack.

Further, preferably, the air filter element <NUM> includes a seal ring such as provided by a gasket <NUM> that is arranged in surrounding relation of the filter media pack <NUM>. As illustrated, the gasket <NUM> may be supported by and mounted on the frame <NUM>.

In this example, the gasket <NUM> is considered a "dust seal" in that it serves to prevent dust penetrating along the side during use to help for cleaner change-out and/or as a back-up for a primary seal provided by radial seal gasket <NUM> secured proximate the outlet face <NUM>. The dust seal type gasket <NUM> may be arranged proximate the inlet face <NUM> as illustrated. As shown, the gasket <NUM> is preferably an axial seal gasket but may alternatively be a radial seal like radial seal gasket <NUM>, or as is the case in the embodiment of the claimed invention in <FIG>.

Further, the frame <NUM> can include a seal support flange <NUM> extending radially outwardly from the annular band <NUM>. The gasket <NUM> (e.g. a dust seal) can be mounted around the seal support flange <NUM> to cover top bottom and outer sides thereof. As illustrated, the gasket <NUM> circumscribes a radially outward facing face of the annular band <NUM>.

Secured to the frame <NUM> is a handle structure such as provided by the handles <NUM>. The handles <NUM> can be secured to the frame integrally such as being unitarily molded therewith as single monolithic structure.

The handles <NUM> can be grasped by the service mechanic to assist with installation and/or removal and are preferably sized large enough to receive two or more fingers of a mechanics hand therethrough, often typically with gloves upon the fingers. To provide such functionality, each of the handles <NUM> include handle aperture <NUM> having a horizontal length of between <NUM> and <NUM> centimeters and a vertical/axial width of between <NUM> and <NUM> centimeters to provide for manual grasping manipulation. To provide the aperture, the handles may be in the form of a closed loop strap with vertical legs <NUM> extending integral with the annular band <NUM> and a connecting bar <NUM> extending horizontally and connected tops of the vertical legs <NUM>. The connecting bar <NUM> can provide for the handle top <NUM> that can be arranged in a preferred location relative to the inlet face.

While providing functionality for handling, the handles <NUM> can also be arranged to provide for space savings and yet apply the force directly proximate to the periphery where the frame is located for reliable manipulation. As shown, the handles <NUM> are secured to the frame <NUM> proximate the outer periphery <NUM>, with the handle structures extending to a region inside of an outer perimeter of the gasket <NUM>, and the handles are primarily contained between the inlet face <NUM> and the outlet face <NUM> in that a majority of the axial span of the handle is disposed between inlet and outlet faces <NUM>, <NUM>. Preferably, a top <NUM> of the handles <NUM> are generally flush with the inlet face. In certain arrangements, the handle top <NUM> can be positioned to provide stop structure to coact and/or abut with a corresponding air cleaner housing surface for proper positioning therein. Also, by having this arrangement, space savings can be realized, while providing a good and reliable handle structure for grasping. By "generally flush" or "generally flat" or similarly, it is meant that it may be flush/coplanar or within <NUM> centimeters of being flush/coplanar.

Space savings may also be realized by the perimeter occupied. The handle structures are interposed in an annular region <NUM> between the gasket <NUM> and the filter media pack <NUM> and extend axially along the outer periphery <NUM> generally parallel therewith (generally parallel being parallel or within <NUM> degrees of parallel), and with a radial air gap <NUM> providing a radial clearance region between the handle <NUM> and the pack <NUM> to allow a user to easily maneuver ones hand into the handle. Also as noted, the handle structures are preferably flush with or recessed below the inlet flow face <NUM>. Finally, the handle structures need not interact with the winder core <NUM> used for winding a fluted type filter media pack <NUM>, and force can be more directly applied to the seal support frame at the periphery rather than at a center region.

Turning to the embodiment of the claimed invention shown in <FIG>, a secondary air filter element <NUM> is illustrated, which may be usable in fluidic series with the primary air filter element <NUM> of the first embodiment. This second air filter element <NUM> also may incorporate an improved handle <NUM>. In this second embodiment, the air filter element <NUM> also comprises a filter media pack <NUM> comprising an air filter media and having an inlet face <NUM>, an outlet face <NUM> and an outer periphery <NUM>. Similarly, the outer periphery <NUM> extends between the inlet face <NUM> and the outlet face <NUM>, to provide a filtered fluid flow path extending axially from the inlet face to the outlet face and through the air filter media for contaminant removal. However, in this embodiment, the air filter media preferably is in the form of a pleated sheet <NUM> having folds with creased pleat tips at the inlet and outlet faces, but it is also an axial and inline direct flow filter arrangement like the first embodiment, just that the filter media sheet is configured and gathered differently. This type of filter pack is sometimes referred to as a pleated panel filter.

This air filter element <NUM> includes a frame <NUM> secured to the outer periphery <NUM> of the filter media pack <NUM> and in surrounding relation of the outer periphery <NUM>. Also, a gasket <NUM> is arranged in surrounding relation of the filter media pack <NUM> and that is preferably a radial seal gasket having an outer radial seal surface <NUM> that is compressible radially for radially sealing with a housing.

The handles <NUM> are secured to the frame <NUM> proximate the outer periphery <NUM>, with the handle structures similarly extending to a region inside of an outer perimeter of the gasket <NUM>. Here however, the handles <NUM> structures lying substantially flat with the inlet face <NUM> across and over the inlet face <NUM>.

The handles <NUM> are pivotable structures secured integral with the frame <NUM>, with the handles being sufficiently thin and flexible to provide an integral hinge <NUM>. The frame <NUM> can comprise an annular band <NUM> sealingly secured to the outer periphery <NUM> of the of the filter media pack <NUM> such as with an annular application of adhesive <NUM> therebetween. The annular band <NUM> has an outer peripheral face <NUM> facing radially outward, with the gasket <NUM> circumscribing and mounted to the outer peripheral face <NUM>.

To provide for convenient manufacture, on opposite sides the frame further includes handle mount blocks <NUM> along an inner periphery of the annular band <NUM>. The blocks <NUM> may define slits <NUM> that receive tabs <NUM> of the handles <NUM> with an integral arrangement such as via bonding or welding (e.g. sonic application or heat staking) to secure the handles in place. Such slits and tabs may also take the form of cylindrical pins and receiving holes. Each handle <NUM> can comprise a resilient handle loop <NUM> to provide a handle aperture <NUM>. The loops <NUM> extend from a mounting base <NUM> (that includes insertion tab <NUM>), with the base preferably integrally formed such as being welded to one of the mounting blocks <NUM>. The loop <NUM> can provide a handle strap extending therefrom that lies substantially flat with the inlet face <NUM> when installed, thereby not occupying space, but is resilient pivotable from the mounting base via the flexibility allowed in the thinness of material at the hinges <NUM> to provide clearance to be grasped when pivoted.

Turning to a third example, <FIG> illustrate a primary air filter element <NUM> with an alternative handle arrangement to that of the first example of <FIG>. However, this third example is otherwise the same as the first example such that the same reference numbers are used for the same structures, and it is understood that the description for the first example is fully applicable to this example other than as indicated.

The air filter element <NUM> of <FIG> also includes the same fluted filter media pack <NUM> with inlet face <NUM>, outlet face <NUM> and outer periphery <NUM>, as well as the same axial seal gasket <NUM> and radial seal gasket <NUM>. Optional outer wrapper <NUM> may also be employed.

The frame <NUM> is mostly the same in that it also includes annular band <NUM> adhesively mounted in the same way such as via a urethane pour, however, the handle structures in this embodiment are in the form of handle mounts provided by vertically and axially projecting ears <NUM> that project from the annular band <NUM>. The ears <NUM> pivotably support a bail handle <NUM> that is pivotably mounted to the pair support ears <NUM>.

The bail handle <NUM> is pivotable between an extended position providing a loop over the inlet face <NUM> for manual manipulation and a retracted position in which the bail handle is generally flush or below the inlet face <NUM>, with the retracted position show in <FIG>. An annular clearance region <NUM> is defined radially between the frame <NUM> and the filter media pack <NUM>. As shown best in <FIG>, the bail handle in the retracted position occupies the annular clearance region <NUM>, and in particular the bail handle can be retracted to one side or the other side of the support ears <NUM> due to symmetry.

To provide for a pivotable connection, a hinge structure <NUM> is provided and may be formed between ends of the bail handle <NUM> and the support ears <NUM>. For example, each of the ears <NUM> may have apertures <NUM> (which may include an insert slot <NUM> and a pivot aperture <NUM>, with a snap project rib <NUM> therebetween), while the bail handle <NUM> may have pivot projections <NUM> including a neck portion <NUM> and a retainer head portion <NUM>. For assembly, the pivot projections <NUM> can be assembled due to the resiliently flexible nature of the bail handle <NUM> due to its length and thinness (which also may be a molded plastic member), with the head portions <NUM> insertable into the enlarged insert slot <NUM> and with the neck portions <NUM> then snapped and slid past the snap rib <NUM> to position the neck regions in the pivot aperture <NUM> and retained therein due to the enlarged head portion <NUM> being larger than the pivot aperture <NUM>). As such the bail handle <NUM> comprises a pair of projections snap fit into respective apertures of the support ears.

Claim 1:
A filter element (<NUM>) including i) a mass of media (<NUM>) having an inlet face (<NUM>) at one end and an outlet face (<NUM>) at another end, and ii) a gasket assembly (<NUM>, <NUM>) circumferentially surrounding the mass of media (<NUM>) of the filter element along an outer surface (<NUM>) thereof, the gasket assembly including a rigid frame (<NUM>) fixed to and supporting the mass of media (<NUM>) of the filter element, and at least one handle (<NUM>) integral with an annular body portion of the frame (<NUM>) and projecting freely from the body portion across one of the ends of the mass of media (<NUM>) of the filter element, where the at least one handle (<NUM>) is located and sized for grasping by a user to remove the filter element (<NUM>) from a housing;
wherein the rigid frame (<NUM>) comprises an annular band (<NUM>) secured to the outer periphery (<NUM>) of the mass of media of the filter element, and the annular band (<NUM>) having an outer peripheral face (<NUM>) facing radially outward, the gasket (<NUM>) circumscribing and mounted to the outer peripheral face (<NUM>), and wherein the mass of media (<NUM>) comprises a pleated filter panel (<NUM>);
wherein on opposite sides the rigid frame (<NUM>) further includes at least one handle mount block (<NUM>) along an inner periphery of the annular band (<NUM>), and wherein each handle (<NUM>) comprises a resilient handle including a mounting base (<NUM>) integrally integral to one of the at least one mounting block (<NUM>) and a handle strap (<NUM>) extending therefrom that lies substantially flat with the inlet face (<NUM>) and is resiliently pivotable from the mounting base (<NUM>) to be grasped.