Patent Description:
Air streams can carry contaminant material such as dust and other particulates. For example, air flow streams being provided to engines for construction equipment, motorized vehicles, power generation equipment, combustion furnaces, and the like can carry particulate contaminant therein that can damage and/or negatively impact the performance of such equipment. In many instances, it is necessary and/or desired to filter some or all of the incoming contaminant material from the air stream. A large number of air filter arrangements have been developed for contaminant removal and are often particularly designed to cooperate within certain spaces within or adjacent to the equipment. However, there is a continuous need to improve the effectiveness and efficiency of the air filtration equipment.

<CIT>, <CIT> and <CIT> each show filter cartridges with a peripheral seal.

In one aspect of the invention, a filter cartridge according to claim <NUM> is provided. The filter cartridge can be used in combination with a housing comprising an inlet end, an outlet end, and an inner opening between the inlet and outlet ends defined by a housing wall having an inner peripheral shape. At least one of the shell wall and the frame wall can have an outer shape that generally matches the inner peripheral shape of the housing wall. When a frame member is provided, it can include an inner opening at least partially defined by an upper lip extending inwardly from the frame wall at its upper edge in at least one location across a gap located between the frame wall and the outer surface of the media pack when the media pack is positioned at least partially within the inner opening of the frame member. The frame member can also include a handle and/or at least one notch extending along at least a portion of the height of the frame wall and/or at least one projection or stand-off extending from the bottom edge of the frame wall.

In another aspect of the invention, an air cleaner assembly is provided that includes a housing comprising an inlet end, an outlet end, an inner opening between the inlet and outlet ends defined by a housing wall having an inner surface, a filter cartridge removably positioned within the inner opening of the housing. The filter cartridge includes a media pack having an inlet end, an opposite outlet end, and an outer surface, and a sealing member secured to an inlet end of the media pack, wherein the sealing member comprises a pinch seal portion that is spaced from the outer surface of the media pack, and wherein the sealing portion is positionable within the channel of the housing when the filter cartridge is positioned within the inner opening of the housing. The assembly further includes a precleaner assembly positionable between the filter cartridge and the inlet end of the housing, the precleaner including a base member comprising a lower edge, and an access cover that is removably attachable to the inlet end of the housing, wherein the precleaner assembly is sealable within the air cleaner assembly by pressing the lower edge of the base member against a top surface of the sealing member and pressing the gasket of the access cover against the inlet end of the housing.

In another aspect of the invention, an air cleaner assembly is provided that includes a housing comprising an inlet end, an outlet end, and an inner opening between the inlet and outlet ends; and a precleaner assembly at an inlet end of the housing. The precleaner assembly includes a precleaner main body, an access cover removably attachable to the inlet end of the housing, and a plurality of contaminant separator tubes extending in a first direction from the access cover in a flow tube arrangement, wherein the flow tube arrangement comprises multiple pairs of tubes arranged in rows that are spaced from each other along a length of the access cover, wherein the tubes of each row are offset from the tubes of each adjacent row. The access cover may be removably mounted on the housing over the inlet end and with the contaminant separator tubes projecting toward the outlet end of the housing. In addition, the contaminant separator tubes can include an ejection slot positioned between its inlet end and outlet end, wherein each of the ejection slots is rotationally positionable for directional movement of contaminant from the precleaner assembly. In one configuration, a first plurality of contaminant separator tubes are rotationally positioned with their ejection slots facing in a first direction, and a second plurality of contaminant separator tubes are rotationally positioned with their ejection slots facing in a second direction that is different from the first direction.

The present invention will be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views, and wherein;.

Referring now to the Figures, wherein the components are labeled with like numerals throughout the several Figures, and initially to Figures <NUM>-<NUM>, an exemplary configuration is illustrated of fluted filter media that can be used in embodiments of filter systems of the invention. In particular, fluted filter media (also known as media having media ridges) can be used to provide fluid filter constructions in a variety of manners. One well known manner is characterized herein as a z-filter construction. The term "z-filter construction" as used herein, is meant to refer to a type of filter construction in which individual ones of corrugated, folded or otherwise formed filter flutes are used to define sets of longitudinal, typically parallel, inlet and outlet filter flutes for fluid flow through the media; the fluid flowing along the length of the flutes between opposite inlet and outlet flow ends (or flow faces) of the media. Some examples of z-filter media are provided in <CIT>; <CIT>;<CIT>;<CIT>; <CIT>; <CIT>;<CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

One type of z-filter media utilizes two specific media components joined together to form the media construction. The two components include a fluted (typically corrugated) media sheet and a facing media sheet. The facing media sheet is typically non-corrugated, although it is possible for it to also be corrugated (e.g., perpendicular to the flute direction) as described in <CIT>, and published as <CIT>.

The fluted media sheet and the facing media sheet are used together to define media having parallel inlet and outlet flutes. In some instances, the fluted sheet and facing sheet are secured together and are then coiled as a media strip to form a z-filter media construction. Such arrangements are described, for example, in <CIT> and <CIT>. In certain other arrangements, some non-coiled sections or strips of fluted (typically corrugated) media secured to facing media, are stacked with one another, to create a filter construction.

Corrugated media is a specific form of fluted media, wherein fluted media has individual flutes or ridges (for example formed by corrugating or folding) extending thereacross. The term "corrugated" is used herein to refer to structure in media, such as media having a flute structure resulting from passing the media between two corrugation rollers (e.g., into a nip or bite between two rollers, each of which has surface features appropriate to cause corrugations in the resulting media).

Serviceable filter element or filter cartridge configurations utilizing z-filter media are sometimes referred to as "straight through flow configurations" or by variants thereof. In general, serviceable filter elements or cartridges have an inlet flow end (or face) and an opposite exit flow end (or face), with flow entering and exiting the filter cartridge in generally the same straight through direction. The term "serviceable" in this context is meant to refer to a media containing filter cartridge that is periodically removed and replaced from a corresponding fluid (e.g. air) cleaner.

Figure <NUM> illustrates exemplary media <NUM> useable in z-filter media constructions for filter systems of the invention. The term "z-filter media construction" is generally meant to refer to a web of corrugated or otherwise fluted media secured to or facing media with appropriate sealing to allow for definition of inlet and outlet flutes, and/or a media pack constructed or formed from such media into a three dimensional network of inlet and outlet flutes; and/or, a filter cartridge or construction including such a media pack. The media <NUM> is formed from a fluted or ridged sheet <NUM> and a facing sheet <NUM>. A construction such as media <NUM> is referred to herein as a single facer or single faced strip.

In general, the corrugated fluted or ridged sheet <NUM> is of a type characterized herein as having a regular, curved, wave pattern of flutes, ridges or corrugations <NUM> arranged in a pattern of alternating troughs 7b and ridges 7a, wherein each trough 7b is substantially an inverse ridge for each ridge 7a. In general, the corrugation pattern is not the result of a folded or creased shape provided to the media, but rather the apex 7a of each ridge and the bottom 7b of each trough can be formed along a radiused curve. An exemplary radius for such z-filter media would be between <NUM> and <NUM>.

With continued reference to Figure <NUM>, the media <NUM> has first and second opposite edges <NUM> and <NUM>. When the media <NUM> is formed into a media pack, edge <NUM> will generally provide an inlet end or face for the media pack, and edge <NUM> will provide an outlet end or face, although an opposite orientation is possible. Adjacent edge <NUM> may be provided with a sealant bead <NUM> that seals the corrugated sheet <NUM> and the facing sheet <NUM> together. Such a sealant bead <NUM> seals closed individual flutes <NUM> adjacent edge <NUM> to passage of air.

Another seal bead <NUM> can be provided adjacent to edge <NUM>, which generally closes flutes <NUM> to passage of unfiltered material. Bead <NUM> can be applied as media <NUM> is configured into a media pack. If the media pack is made from a stack of strips, for one example, bead <NUM> will form a seal between a back side <NUM> of facing sheet <NUM>, and side <NUM> of the next adjacent corrugated sheet <NUM>.

Once the filter media <NUM> is incorporated into a media pack, such as by stacking or coiling, it can be utilized as follows. First, air in the direction of arrows <NUM> can enter open flutes <NUM> adjacent end <NUM>. Due to the closure at end <NUM> by bead <NUM>, the air can pass through the filter media <NUM>, such as is shown by arrows <NUM>. It could then exit the media or media pack by passage through open ends 15a of the flutes <NUM> adjacent end <NUM> of the media pack. Operation can instead occur with air flow in the opposite direction.

For the exemplary arrangement illustrated in Figure <NUM>, the corrugations 7a, 7b extend generally straight along the media from edge <NUM> to edge <NUM>. Straight flutes, ridges or corrugations can be deformed or folded at selected locations, such as at the ends. Modifications at flute ends for closure are generally disregarded in the above definitions of "regular," "curved" and "wave pattern.

Z-filter constructions which do not utilize straight, regular curved wave pattern corrugation shapes can also be used in the assemblies of the invention. For several examples, <CIT>) provides for corrugation patterns that utilize somewhat semicircular (in cross section) inlet flutes adjacent narrow V-shaped (with curved sides) exit flutes; <CIT>) provides for circular (in cross-section) or tubular flutes defined by one sheet having half tubes attached to another sheet having half tubes, with flat regions between the resulting parallel, straight flutes; <CIT>) provides for flutes folded to have a rectangular cross section and that taper along their lengths; <CIT> provides for flutes or parallel corrugations that have curved wave patterns (from adjacent curved convex and concave troughs) but that taper along their lengths; and <CIT> provides for flutes that have curved wave patterns, but with different sized ridges and troughs. Also, flutes that are modified in shape to include various ridges can be utilized in assemblies of the invention.

In general, the filter media used is a relatively flexible material, such as a non-woven fibrous material (of cellulose fibers, synthetic fibers or both) that can include a resin therein, sometimes treated with additional materials. Thus, it can be conformed or configured into the various corrugated patterns, without unacceptable media damage. Also, it can be readily coiled or otherwise configured for use without unacceptable media damage. The media will generally be of a nature such that it will maintain the required corrugated configuration during use.

During the corrugation process, the media can be inelastically formed such that it is prevented from returning to its original shape. However, once the tension is released, the flute or corrugations may still tend to spring back slightly, recovering only a portion of the stretch and bending that has occurred. Therefore, the facing media sheet is sometimes tacked to the fluted media sheet to inhibit this spring back in the corrugated sheet, such as at the location designated by reference numeral. The media of the corrugated (fluted) sheet <NUM> and/or facing sheet <NUM> can also be provided with a fine fiber material on one or both sides thereof, for example in accordance with <CIT>. In some instances when such fine fiber material is used, it may be desirable to provide the fine fiber on the upstream side of the material and inside the flutes. When this occurs, air flow will typically be into the edge comprising the tacking bead.

<FIG> illustrates an exemplary configuration of a z-filter media construction <NUM>, which includes a regular, curved, wave pattern corrugated sheet <NUM>, and a non- corrugated flat sheet <NUM>. A distance D1 between points <NUM> and <NUM> defines the extension of flat media <NUM> in region <NUM> underneath a given corrugated flute <NUM>. The length D2 of the arcuate media for the corrugated flute <NUM> over the same distance D1 is larger than D1 due to the shape of the corrugated flute <NUM>. For an exemplary regular shaped media used in fluted filter applications, the linear length D2 of the media <NUM> between points <NUM> and <NUM> can be at least <NUM> times D1, such as in a range of <NUM> - <NUM> times D1. In a particular exemplary air filter configuration, D2 is about <NUM> - <NUM> times D1. Such media has been used commercially in Z-filter arrangements, such as those sold commercially by Donaldson under the trade designation "Powercore," for example. Another media variation comprising fluted media with facing media secured thereto can be used in arrangements according to the present invention, such as is described in <CIT>.

Coiled media or media pack arrangements can be provided with a variety of outer perimeter shapes, such as circular, obround, and oval, wherein some oval shapes have opposite curved ends attached by a pair of opposite sides that are also curved. In other oval shapes, sometimes called racetrack shapes, the opposite sides between opposite curved ends are generally straight. Racetrack shapes are described for example in <CIT>, and <CIT>, published as <CIT>.

<FIG> illustrates an exemplary coiled media pack (also referred to as coiled media) <NUM> constructed by coiling a single strip of single faced media. The particular coiled media pack depicted is an oval media pack 130a, which may be more specifically referred to as a racetrack shaped media pack <NUM>. The tail end 131x of the media is shown at the outside of the media pack <NUM>. A hot melt seal bead or seal bead can be positioned along that tail end to ensure sealing. In the media pack <NUM>, the opposite flow (end) faces are designated at <NUM>, <NUM>. Additional media types can be used in filter arrangements of the invention, wherein the media is typically stacked or coiled into an arrangement that includes opposite inlet and outlet flow ends or faces, such as media described in <CIT> and owned by the Assignee of the present disclosure, for example.

Many of the techniques characterized herein will used with media that is oriented for filtering between opposite flow ends of the cartridge, such as media having flutes or pleat tips that extend in a direction between those opposite ends. However, techniques characterized herein with respect to seal arrangement definitions can be applied in other filter cartridges that have opposite flow ends, with media positioned to filter fluid flow between those ends, even when the media does not include flutes or pleat tips extending in a direction between those ends. The media, for example, can be depth media, can be pleated in an alternate direction, or it can be a non-pleated material.

<FIG> illustrate exemplary embodiments of an air cleaner assembly in accordance with the invention, which can include filter cartridges having media and/or a media pack, as previously discussed relative to Figures <NUM>-<NUM>, or other appropriate media. Referring first to <FIG>, different views are illustrated of an exemplary air cleaner assembly <NUM> according to the present invention, which assembly generally includes a housing <NUM> with a removable access cover <NUM> that provides access to the inner area of the housing, such as for placement and removal of filter cartridges. The air cleaner assembly <NUM> further includes an outlet <NUM> that is positioned for exit of filtered air. The outlet <NUM> can be made separately from the housing <NUM> and attached thereto, or it can be integrally constructed as a portion of the housing <NUM>. The outlet <NUM> can be provided as a separate component in assemblies where it may be desired to allow for a selection of different outlet configurations. The housing <NUM> further includes an air inlet end <NUM> through which air to be filtered enters the assembly <NUM>.

The housing <NUM> can be constructed using a variety of materials or combinations of materials, and using a number of different construction techniques. In one exemplary embodiment, the housing <NUM> is a molded plastic component, which can include optional ribbing members extending from its outer surface to provide structural strength to the housing <NUM> and/or for aesthetic purposes. Thus, when optional ribbing is provided, it can have a wide variety of configurations to meet the desired function of the ribbing, including different shapes, sizes, and quantities.

The particular air cleaner assembly <NUM> illustrated is a two-stage air cleaner assembly that includes a precleaner <NUM> adjacent to its inlet end. The general location and configuration of the precleaner <NUM> is shown in <FIG>, while the components that make up the precleaner <NUM> are better illustrated in <FIG> and <FIG>, for example, and will be described in further detail below. The precleaner <NUM> generally is used to clean selected material or contaminants carried by an air stream into the air cleaner assembly <NUM> before the air reaches the filter cartridge positioned therein. Such precleaning can provide for substantial removal of liquid particulate such as rain water or splashed water, etc. and/or various dust or other particles (e.g., larger particles). In the illustrated example, the precleaner <NUM> includes the access cover <NUM> that is attachable to the housing <NUM>. It is contemplated that the air cleaner assembly <NUM> may not include a precleaner, in an embodiment of the invention. In such a case, an access cover will be directly attachable to the housing <NUM> and provide direct access to the inner area of the housing <NUM> and any components contained therein.

In the illustrated embodiment, the access cover <NUM> is attachable to and removable from the housing <NUM> by connecting and disconnecting multiple connectors or latches <NUM> that are moveably attached to the access cover <NUM>. In the illustrated embodiment, two latches <NUM> are symmetrically positioned on opposite edges of the access cover <NUM>. However, it is understood that a different number and/or location for the latches <NUM> can be used, such as two latches on each edge of the access cover <NUM>, a different number of latches on opposite edges of the access cover <NUM>, or latches positioned in different location(s) around the perimeter of the access cover <NUM>. It is further understood that alternate connector arrangements can be used instead of or in addition to latches <NUM>, including bolts or other fasteners, for example.

The housing <NUM> further includes a mounting pad arrangement by which the air cleaner assembly <NUM> can be secured to equipment for use. The exemplary mounting pad arrangement illustrated in <FIG> includes multiple mounting feet or pads <NUM> that extend from the outer surface of the housing <NUM>. In this exemplary embodiment, the mounting feet <NUM> are configured for engagement with connectors, such as screws or other extending members that can engage with a central aperture of the feet. Although this embodiment is provided with four mounting feet or pads <NUM> on each side of the housing <NUM>, a different number of feet or pads can instead be provided.

As can best be seen in <FIG>, housing <NUM> further includes a utility port <NUM> adjacent to the outlet <NUM>. The port <NUM> can be used for a restriction indicator or other equipment. In addition, a mass air flow sensor (MAFS) arrangement can optionally be mounted at the outlet <NUM> or in other ducting that is located further downstream.

With continued reference to <FIG>, housing <NUM> further includes an evacuation or outlet port <NUM> at its lower end or bottom area when the filter is positioned in this orientation. The port <NUM> is positioned for removal of particulate and/or water (i.e., contaminants) collected by the precleaner from the housing <NUM>, and therefore may be referred to as an evacuation port. In an embodiment of the invention, this port <NUM> is oriented in a portion of the housing <NUM> that causes it to be directed downwardly in use. In many applications, the outlet port <NUM> will be directed downwardly in this way so that gravity can assist in material evacuation from the precleaner <NUM>. However, if it is desired to mount the air cleaner assembly <NUM> differently than shown, such as along one of its sides, mounting structure(s) can be provided on that side, or the port <NUM> can be positioned at a different location relative to the housing body or in a portion of an access cover. In any of these arrangements, port <NUM> can be provided with an evacuator valve assembly therein, or it may be attached to a scavenge duct to facilitate removal of material from the precleaner <NUM>.

Referring now to <FIG>, an exploded perspective view of an exemplary embodiment of the air cleaner assembly <NUM> of the invention is illustrated, which generally includes a housing <NUM>, a precleaner <NUM>, a filter cartridge <NUM>, and an optional safety filter <NUM>, wherein these components and their relationships to each other are discussed in further detail below. Each of these components is illustrated in this exploded view of <FIG>, in individual figures in the drawings, and also described above and/or below.

One exemplary embodiment of housing <NUM> was discussed above with regard to the overall assembly shown in <FIG>; however, housing <NUM> is also shown in further detail in <FIG> without a corresponding air cleaner assembly <NUM> positioned therein. As shown, housing <NUM> includes the inlet <NUM> at an opposite end from the outlet <NUM>, wherein the elements of the system are insertable into the inlet <NUM> for assembling the air cleaner assembly <NUM>. Housing <NUM> further includes an inner lip <NUM> extending around the perimeter and spaced from the inlet <NUM>, and at least one protrusion <NUM> extending inwardly from the wall of the housing <NUM>. In addition, housing <NUM> includes at least one securing member <NUM> on the outside of its outer wall and adjacent to the inlet <NUM>, which is provided for engagement with a latching mechanism <NUM> of the access cover <NUM>. The inner lip <NUM> is positioned to provide one side of a channel or pocket <NUM>, wherein the channel is also defined by the inner wall of the housing <NUM> and a bottom channel surface extending between the inner lip <NUM> and the inner wall of the housing <NUM>. The channel <NUM> generally extends around the perimeter of the housing <NUM>, as will be described in further detail below.

The precleaner <NUM> illustrated in <FIG> is also illustrated in its exploded configuration in <FIG>, and includes access cover <NUM> that is engageable with a base member <NUM> (along with being attachable to the housing <NUM> via latches). In embodiments of the air cleaner assembly <NUM>, the access cover <NUM> can be engaged with the base member <NUM> via an attachment configuration, such as a snap-fit arrangement, to secure the two parts to each other as a single unit that is then attachable to the housing <NUM> via latches <NUM>. In this embodiment, the access cover <NUM> of the precleaner <NUM> is also separable from the base member <NUM> to facilitate cleaning, for example. However, in another embodiment of the precleaner <NUM>, the access cover <NUM> is secured permanently to base member <NUM> or molded as a single piece that is provided to the assembly <NUM> as a single unit. In any case, the precleaner <NUM> is generally used to remove a portion of the dust or other particulate material (e.g., liquid particulate material) that enters the air cleaner through the air flow inlet before that material can reach internally positioned filter cartridge <NUM>. The precleaner <NUM> can thereby help extend the lifetime of operation of the assembly without servicing, as well as protect the filter cartridge against damage.

In one exemplary embodiment, the base member <NUM> of precleaner <NUM> is secured to the access cover <NUM> by engagement of at least one tab member <NUM>, which extends from an edge of the access cover <NUM>, with an engagement member <NUM> that is located on the outside of the base member <NUM>. Alternatively, the tab member(s) and other features may extend from the base member <NUM> while the engagement member(s) extend from the access cover <NUM>. In the illustrated embodiment, the tab members <NUM> each include an aperture <NUM> that is sized and shaped to accept at least a portion of a corresponding engagement member <NUM> simply by pushing the access cover <NUM> and base member <NUM> toward each other with the tab members <NUM> sliding over the top of corresponding engagement members <NUM> until the apertures <NUM> are engaged with the engagement members <NUM>. It is contemplated, however, that a number of different configurations and features can be used to secure the components of the precleaner <NUM> to each other.

<FIG> provide various views of the precleaner <NUM> as it is assembled and positioned within a housing <NUM>. The access cover <NUM> includes a perimeter mounting flange <NUM>, which is aligned within the end of the housing <NUM> during installation. A seal member or gasket <NUM>, which may be an O-ring seal, for example, can be positioned between the access cover <NUM> and the housing <NUM>.

The access cover <NUM> further includes multiple inlet tubes or contaminant separator tubes <NUM> extending from an inner surface of the cover <NUM> toward the inner area of the housing <NUM>. The tubes <NUM> can be sized to project at least <NUM> or more than <NUM> from an inner surface of the access cover <NUM> and into the housing body, although larger or smaller lengths are contemplated. Tubes <NUM> can be preformed and press-fit into apertures in the cover <NUM> during assembly, or can be attached in another way (e.g., with adhesive). In general, each separator tube <NUM> includes an upstream inlet end <NUM>, into which unfiltered air entering the air cleaner assembly <NUM> passes. Each tube <NUM> can include a vane arrangement in or adjacent to the inlet end <NUM>, and is configured to import and direct a cyclonic flow for the inlet air. The tubes <NUM> also include an opposite end <NUM> spaced from inlet end <NUM>. Each separator tube <NUM> further includes a side slot <NUM> between the ends <NUM>, <NUM> through which contaminant (dust, particulate contamination ejector or water) that is separated by the contaminant separator arrangement can exit for eventual ejection through housing contamination ejection port <NUM>, which is described above relative to <FIG>.

Although a number of arrangements of the tubes <NUM> are contemplated, an exemplary embodiment includes tubes <NUM> arranged in rows that each include two tubes along the length of the access cover <NUM>, with each row of tubes <NUM> being offset at least slightly from each adjacent row of tubes <NUM> (see <FIG>, for example). As shown in this exemplary embodiment of an access cover <NUM>, each row of tubes <NUM> is offset so that the centerline of each of the tubes of one row falls at approximately the center of the space between two tubes in an adjacent row of tubes; however, a larger or smaller amount of offset is also contemplated. Some or all of the tubes <NUM> also can include an arrangement of vanes that are used to direct the air flow in a desired manner. The arrangement of vanes can vary considerably, depending on the desired air flow, and it is contemplated that tubes <NUM> of a single access cover <NUM> can have different vane arrangements.

With regard to exemplary vane arrangements, it is understood that each tube <NUM> can operate with a centrifugal separation of contaminant conducted internally. To accomplish this, the air entering the inlet ends <NUM> of tubes <NUM> can be generally directed into a cyclonic pattern by the vanes. Side slot(s) <NUM> of each tube <NUM> can be an arcuate opening in a sidewall portion adjacent to and spaced from end <NUM> of each tube <NUM>. The size and shape of the side slots <NUM> are generally selected to provide for maximum efficiency of operation. The end <NUM> of each tube <NUM> can be understood to be a cyclonic outlet, and swirling material will generally exit in a right angle direction relative to a center of the associated slot.

In order to achieve efficient separation of contaminant from the incoming contaminated air in the illustrated orientation of the air cleaner assembly <NUM>, the tubes <NUM> are installed with their associated slots <NUM> positioned to generally direct the contaminant toward the outer walls, so that it will eventually move downwardly toward the evacuation port <NUM>. To accomplish this, it is contemplated to orient the tubes <NUM> on one side of the access cover <NUM> differently than the tubes <NUM> on the other side of the access cover <NUM> (e.g., the tubes closer to the left versus. the tubes closer to the right in <FIG>). In one example, for the tubes <NUM> on the right, each outlet slot <NUM> can be directed away from the port <NUM>, wherein the tubes 460on the left can be oriented (centered) with their outlet slots <NUM> directed opposite or downwardly, i.e., toward port <NUM>. However, if the air cleaner assembly <NUM> is differently oriented (e.g., at <NUM> degrees from that shown), the outlet slots <NUM> of the tubes <NUM> can instead all be directed toward the middle of the access cover <NUM>.

The base member <NUM> of the precleaner <NUM> further includes a base plate <NUM> (indicated generally in <FIG>) having multiple outlet tubes <NUM> extending therefrom. The outlet tubes <NUM> are positioned relative to the base plate <NUM> so that when the base member <NUM> and the access cover <NUM> are assembled to make up the precleaner <NUM>, each of the outlet tubes <NUM> will extend into one of the inlet tubes <NUM>. The outlet tubes <NUM> may be molded or otherwise integrally formed with the base member <NUM>, or can be separately made and then attached to the base plate <NUM>.

Referring now to <FIG> and <FIG>, an exemplary embodiment of filter cartridge <NUM> of air cleaner assembly <NUM> is illustrated, with <FIG> further illustrating an enlarged view of a frame member <NUM> of the filter cartridge <NUM>. The filter cartridge <NUM> can be considered to be the main or primary filter cartridge, and is used to selectively separate a desired amount of particulate or containment material that was not filtered out of the system by the precleaner <NUM>. Cartridge <NUM> is generally a service part or removable component, such that it is periodically removable and replaceable as desired or necessary during the lifetime of the air cleaner <NUM>. In particular, when the cartridge <NUM> becomes occluded or otherwise needs to be replaced, the access cover <NUM> is detached from the housing <NUM>, the precleaner <NUM> is removed (if one is used), and the occluded filter <NUM> is removed. After such removal, a new filter <NUM> can be placed in the housing <NUM>, or the filter <NUM> that was removed can be refurbished and replaced in its previous position within the housing <NUM>. The precleaner <NUM> and/or cover <NUM> can then be repositioned and secured to the housing <NUM> so that the air cleaner assembly <NUM> is again ready for use.

As shown in the exploded view of <FIG>, the filter cartridge <NUM> generally includes a media pack <NUM>, a shell <NUM>, a frame member <NUM>, and a sealing member <NUM>, which will generally be made of a relatively flexible material and may be referred to herein as a "flexible sealing member. " When assembled, a lower portion of the media pack <NUM> is positioned within an inner opening of the shell <NUM>, with a top portion of the media pack extending above the top surface of the shell <NUM>. This top portion of the media pack <NUM> will then be positioned within an inner opening of the frame member <NUM>, and then the flexible sealing member <NUM> will be formed to fill in spaces between the frame member <NUM> and the outer surface of the media pack <NUM> and to connect the frame member <NUM> to the shell <NUM> and the media pack <NUM>, as will be described below. It is noted that while this figure illustrates the configuration in which the filter cartridge <NUM> includes both frame member <NUM> and shell <NUM>, it is contemplated that only one of these two components <NUM>, <NUM> may be provided for a particular embodiment of the filter cartridge of the invention, and that the below description contemplates all of these configurations.

The media pack <NUM> comprises filtration media that may be any of a variety of types, such as the fluted filter media described above, for example. In an exemplary embodiment, the filtration media is provided as an elongated sheet of filter media that is wrapped or coiled to provide an oblong or racetrack outer shape of a predetermined size for the media pack <NUM>, as shown in <FIG>. The amount of filtration media in a particular media pack is designed and selected to provide for certain filtration characteristics during the filtration process. For example, the filtration media may be tightly packed for greater density in certain applications, but may be more loosely wound in other applications.

Referring again to <FIG> and <FIG>, the depicted filter cartridge <NUM> includes an optional shell <NUM>. Such a shell <NUM> surrounds the media pack <NUM> and protects the media during handling and use. The shell <NUM> can include a preformed molded plastic piece, for example, into which the media pack <NUM> is positioned during assembly of the cartridge <NUM>. As shown, the outer surface of the shell <NUM> can have a shape that generally matches that of the outer shape of the frame member <NUM> (e.g., a racetrack oval), or it can instead have a different shape.

The exemplary cartridge <NUM> illustrated is considered to be a "straight through flow" arrangement in that it includes a first (inlet) flow face or end <NUM> and opposite outlet (flow) face or end <NUM>, with filtering flow of air through the filter cartridge <NUM> generally being from the inlet end <NUM> to the outlet end <NUM>. In more general terms, the main filter cartridge <NUM> includes permeable filtration media through which the air passes with filtering. In typical applications, the filter media will be configured in a media pack that conducts filtration of air, as the air passes in a flow direction from an inlet end of the filter media pack to an opposite outlet end of the filter media pack. Thus, in general, the filter cartridge <NUM> can be a straight-through flow construction in that air enters one end and exits the other without making a substantial turn within the media pack.

Frame member <NUM> includes a frame wall <NUM> having an outer shape that generally matches the inner peripheral shape of a housing wall of a housing in which it will be positioned. In this particular embodiment, the outer shape of the frame wall <NUM> is generally an elongated octagonal shape, although it is understood that the outer shape may be any desired polygonal shape that matches the inner shape of the housing wall. The frame member <NUM> further includes an inner opening <NUM> at its top edge defined by an upper lip <NUM> that extends inwardly from the frame wall <NUM> in at least one location to fill at least one gap space between the frame wall and the outer surface of the media pack when the media pack is positioned in the frame member <NUM>. That is, because the shape of the frame wall <NUM>(e.g., an elongated octagon) is different from the outer shape of the media pack <NUM> (e.g., a racetrack oval), there will be gaps between these elements in the areas where the shapes diverge from each other (e.g., in the areas where the angled corners of the frame wall <NUM> are that are spaced from the curved outer surface of the filter cartridge <NUM>). In this embodiment, extensions <NUM> of upper lip <NUM> from the frame wall <NUM> will fill in the gap to approximate an inner oblong or racetrack oval shape for the inner opening <NUM> of the filter sealing member along its top edge.

In other embodiments of the invention, the shape of the frame wall <NUM> is the same or nearly the same as the outer shape of the media pack <NUM>. Because the same gap will not be present as that discussed above, the frame member will not have an upper lip that extends inwardly from the frame wall to fill such a gap space.

Frame member <NUM> further includes multiple stand-offs or extension members <NUM> extending from the bottom edge of the frame wall <NUM>. Each of the stand-offs <NUM> extend from a the bottom edge of the frame wall 471and have a distal end that will rest on a flange <NUM> that extends around at least a portion of the top edge of the shell <NUM>, wherein the length of the stand-offs <NUM> corresponds to the distance that the bottom edge of the frame wall <NUM> will be spaced from the flange <NUM>. The size, shape, and quantity of stand-offs can vary widely, and are generally selected to provide sufficient space between them through which a desired volume of sealing material can flow during manufacture and assembly of the flexible sealing member <NUM>. Another consideration for the size, shape, and quantity of stand-offs is the desire to provide sufficient structural integrity to the system during and after manufacturing.

In an exemplary configuration, the number of stand-offs chosen will provide sufficient structural integrity to keep the frame wall <NUM> at a desired distance from the flange <NUM> during formation of the flexible sealing member <NUM>, while allowing enough material to flow and form the flexible sealing member <NUM>. In one embodiment, at least two stand-offs <NUM> are located along the straight edges of the frame wall <NUM>, and at least one stand-off <NUM> is located along each of the angled edges of the frame wall <NUM>. Further, the stand-offs or extension members <NUM> can have a length that provides for a gap greater than <NUM> from the flange <NUM>, or can instead be less than <NUM>. In any case, the stand-offs or extension members <NUM> should be a size that allows for sufficient material flow during the manufacturing process, yet ensures that the frame member <NUM> is captured by the seal material.

Still referring to <FIG>, the illustrated filter cartridge <NUM> includes an optional handle <NUM> having ends that extend from opposite sides of the frame wall <NUM> and oriented adjacent the cartridge inlet end <NUM> and projecting therefrom in a direction away from the outlet end <NUM>. This positions and orients the handle <NUM> so that it can be grasped by an operator to manage servicing of the cartridge <NUM>. The particular handle <NUM> of this embodiment includes a central handle bridge structure defining a space through which a person's fingers can extend during grasping of the handle member <NUM>. A variety of shapes, sizes and features for the optional handle <NUM> can be used. In addition, one or more optional additional support members <NUM> can be spaced from the handle <NUM> and extend across the opening in the frame wall <NUM> in the same general direction as the handle <NUM>.

The exemplary filter cartridge <NUM> has a non-circular cross-sectional shape, as described above, although alternative shapes are possible. In many applications of the present techniques, the filter cartridge will have a cross-sectional shape with a long cross-sectional axis in a plane perpendicular to air flow, and a short axis perpendicular to the long axis and located along a mid-point of the layer axis, with the ratio of the length of the long axis to the short axis (at a location half-way along the length of the long axis) being at least <NUM>. While alternatives are possible, such ratios will often be used for arrangements according to the present invention because they relate to an air cleaner having an overall profile that is relatively low in one cross-dimensional to an opposite cross-dimension. In an exemplary embodiment, the media pack is at least <NUM> long in extension between flow ends, and can be at least <NUM> long.

The flexible perimeter sealing member <NUM> of filter <NUM> extends generally around the perimeter of the shell <NUM> adjacent to the frame member <NUM>. When the filter cartridge <NUM> is positioned within a housing, as described above, the sealing member <NUM> is configured and positioned to function as a pinch seal. Such a pinch seal extends around a perimeter of the cartridge <NUM> at a position so that it can be pinched between two housing components under sealing pressure during use. The illustrated sealing member <NUM> is sometimes referred to in the industry as an "axial" pinch seal, since it is configured for sealing pressure between two housing components to be applied in an axial direction (i.e., in a direction of extension of an axis extending through the media from its inlet end to its outlet end). Other types of seal arrangements can be used, however, with selected principles of the present invention.

In more particularity, the sealing member <NUM> is configured such that a channel <NUM> (see <FIG>, for example) is provided between a portion of sealing member <NUM> and the shell <NUM>, wherein the channel <NUM> is positioned to mate with inner lip <NUM> of housing <NUM>. The channel <NUM> can be located between the shell <NUM> and an axially directed portion <NUM> of the sealing member <NUM>. This portion <NUM> of the sealing member <NUM> is sized and shaped to provide a leak-resistant seal with the inner surface of housing <NUM> when the air cleaner assembly <NUM> is in operation. To facilitate this, the sealing member <NUM> can be a resilient material of a type typically used for such sealing purposes. One exemplary material from which the flexible sealing member can be made is a urethane molded to an appropriate hardness, such as to a shore A hardness of no greater than <NUM>. The flexible sealing member <NUM> can be molded in place with the media pack <NUM> positioned inside the shell <NUM> and frame member <NUM> positioned in its desired configuration. As a result, the sealing member <NUM> will have embedded therein the frame wall <NUM> of the frame member <NUM>.

With particular reference to <FIG>, sealing member <NUM> includes a transition region <NUM> that includes a portion of its inner surface that takes the shape of the media pack <NUM> and a portion that takes the shape of the frame member <NUM> and/or the shell <NUM>. Such an area provides the transition from one shape to another for this sealing member <NUM>.

The axially directed portion <NUM> of sealing member <NUM> can be contoured around portions of its perimeter to provide for selective engagement with other portions of the housing <NUM>. In particular, the axially directed portion <NUM> can be contoured to have "steps" around its perimeter, wherein these steps can be recessed and/or projecting relative to the areas between these steps, and can also project further toward the outlet <NUM> of the cartridge <NUM> than the remainder of the sealing member <NUM>. Such step portions can vary widely, wherein exemplary configurations of these steps are described in <CIT>. In an exemplary embodiment of the invention, the same amount of material is used for each portion of the sealing member around its perimeter such that in areas where the step portions are thicker, the axial dimension is shorter. With such an exemplary embodiment, the opposite is also true in that in areas where the step portions are thinner, the axial dimension of the step portions will be longer.

In order to accommodate these steps of the sealing member <NUM>, the channel or pocket <NUM> (see <FIG>) between housing <NUM> and lip <NUM> can have portions that are more deep or shallow than other areas. In addition, as referred to above, the housing <NUM> includes an inner lip <NUM> extending around its perimeter and spaced from the inlet <NUM>, and at least one protrusion <NUM> extending inwardly from the wall of the housing <NUM>. Further to this construction, the protrusion(s) <NUM> of housing <NUM> can be arranged in various locations around the inner perimeter of the housing <NUM>, and are generally positioned at least partially within the pocket or channel <NUM>. The protrusion(s) <NUM> are each provided with a specific size, shape, and location to align with a corresponding feature or configuration of the sealing member <NUM>, such as the stepped or contoured areas of the sealing member <NUM>. It is contemplated that one or more protrusions <NUM> extend from opposite sides of the housing in a symmetric configuration (so that the corresponding filter cartridge with symmetric protrusions/recesses can be inserted in either of two orientations for seating within the channel <NUM>) or in a non-symmetric configuration (so that the corresponding filter cartridge with non-symmetric protrusions/recesses can only be inserted in one orientation for seating within the channel <NUM>).

With continued reference to <FIG>, access cover <NUM> is secured to the outside of the housing <NUM>, with a filter cartridge <NUM> and precleaner <NUM> positioned within the inner opening of the housing <NUM>. The access cover <NUM> is configured so that when it is secured to the housing <NUM>, the precleaner <NUM> will be pressed toward the filter cartridge <NUM>. In this way, if the elements within the housing <NUM> are not yet seated in their final locations, the pressure of the precleaner structure will "push" the elements toward the outlet <NUM> and into their seated positions. For example, this movement can ensure that the channel <NUM> of the flexible sealing member <NUM> will seat properly with the inner lip <NUM> of the housing <NUM>. In addition, when the components are positioned in their desired locations, a bottom edge <NUM> of the base member <NUM> will press against the flexible sealing member <NUM>. With this positioning of the precleaner <NUM>, it will effectively be "isolated" as a component that is independently sealable from contaminants via the seal <NUM> at one end of the precleaner and the bottom edge <NUM> of the base member in the area of the sealing member <NUM>.

Referring now to <FIG>, an exemplary embodiment of a filter cartridge <NUM> is illustrated, which is similar to the filter cartridge <NUM> discussed above, with <FIG> further illustrating an enlarged view of a frame member <NUM> of the filter cartridge <NUM>. Thus, similar applications and structures described above relative to filter cartridge <NUM> may also apply to the filter cartridge <NUM>.

As shown in the exploded view of <FIG>, the filter cartridge <NUM> generally includes a media pack <NUM>, a shell <NUM>, a frame member <NUM>, and a flexible sealing member <NUM>. When assembled, a lower portion of the media pack <NUM> is positioned within an inner opening of the shell <NUM>, with a top portion of the media pack extending above the top surface of the shell <NUM>. This top portion of the media pack <NUM> will then be positioned within an inner opening of the frame member <NUM>, and then the flexible sealing member <NUM> will be formed to fill in spaces between the frame member <NUM> and the outer surface of the media pack <NUM> and to connect the frame member <NUM> to the shell <NUM> and the media pack <NUM>, as will be described below. It is noted that while this figure illustrates the configuration in which the filter cartridge <NUM> includes both frame member <NUM> and shell <NUM>, it is contemplated that only one of these two components <NUM>, <NUM> is provided for a particular embodiment of the filter cartridge of the invention, and that the below description contemplates all of these configurations.

Referring again to <FIG>, the depicted filter cartridge <NUM> includes an optional shell <NUM>. Such a shell <NUM> surrounds the media pack <NUM> and protects the media during handling and use. The shell <NUM> can include a preformed molded plastic piece, for example, into which the media pack <NUM> is positioned during assembly of the cartridge <NUM>. As shown, the outer surface of the shell <NUM> can have a shape that generally matches that of the outer shape of the frame member <NUM>, or it can instead have a different shape.

Frame member <NUM> includes a frame wall <NUM> having an outer shape that generally matches the inner peripheral shape of a housing wall of a housing in which it will be positioned. In this particular embodiment, the outer shape of the frame wall <NUM> is generally an elongated octagonal shape. The frame member <NUM> further includes an inner opening <NUM> at its top edge defined by an upper lip <NUM> that extends inwardly from the frame wall <NUM> in at least one location to fill at least one gap space between the frame wall and the outer surface of the media pack when the media pack is positioned in the frame member <NUM>. In this embodiment, extensions <NUM> of upper lip <NUM> from the frame wall <NUM> will fill in the gap to approximate an inner oblong or racetrack oval shape for the inner opening <NUM> of the filter sealing member along its top edge.

The frame wall <NUM> of frame member <NUM> can be solid around its perimeter, or can instead include notches or slots <NUM> at one or more locations around its perimeter. The size, shape, and quantity of notches or slots <NUM> can vary considerably, such in the range of between <NUM> and <NUM>. The size and shape of the slots or notches <NUM> can be chosen or designed depending on their positions relative to the media pack to provide control of the volume of sealing material of the flexible sealing member <NUM> that can flow during manufacture and assembly of the filter cartridge <NUM>. In an exemplary embodiment, at least one notch is located along the straight edges of the frame wall <NUM>, and at least one notch <NUM> is located along each of the angled edges of the frame wall <NUM>.

It is understood that the size, shape, and placement of the slots or notches <NUM> for a particularly frame wall can include slots <NUM> that are all the same configuration as each other, can include slots that are all have different configurations, or can include some slots that have the same configurations and others that have different configurations. For instance, the slots <NUM> that are provided in the curved sections of a frame member can be larger or more numerous than those provided on the straight edges of the frame member <NUM>. It is further contemplated that the spacing between adjacent slots <NUM> around the perimeter of the frame member <NUM> can be the same or different, depending on the desired flow of material that is being facilitated by these slots.

Still referring to <FIG>, the illustrated filter cartridge <NUM> includes an optional handle <NUM> having ends that extend from opposite sides of the frame wall <NUM>. A variety of shapes, sizes and features for the optional handle <NUM> can be used. In addition, one or more optional additional support members <NUM> can be spaced from the handle <NUM> and extend across the opening in the frame wall <NUM> in the same general direction as the handle <NUM>.

The filter cartridge <NUM> further includes a flexible perimeter sealing member <NUM> extending generally around the perimeter of the shell <NUM> adjacent to the frame member <NUM>. The filter cartridge <NUM> further includes a flexible perimeter sealing member <NUM> extending generally around the perimeter of the shell <NUM> adjacent to the frame member <NUM>. When the filter cartridge <NUM> is positioned within a housing, as described above, the sealing member <NUM> is configured and positioned to function as a pinch seal. Such a pinch seal extends around a perimeter of the cartridge <NUM> at a position so that it can be pinched between two housing components under sealing pressure during use. The illustrated sealing member <NUM> is sometimes referred to in the industry as an "axial" pinch seal, since it is configured for sealing pressure between two housing components to be applied in an axial direction (i.e., in a direction of extension of an axis extending through the media from its inlet end to its outlet end). Other types of seal arrangements can be used, however, with selected principles of the present invention.

In more particularity, the sealing member <NUM> is configured such that a channel is provided between a portion of sealing member <NUM> and the shell <NUM>, wherein the channel is positioned to mate with a portion of the housing in which it will be inserted. The flexible sealing member <NUM> can be molded in place with the media pack <NUM> positioned inside the shell <NUM> and frame member <NUM> positioned in its desired configuration. As a result, the sealing member <NUM> will have embedded therein the frame wall <NUM> of the frame member <NUM>.

Referring again to the air cleaner assembly <NUM> illustrated in <FIG>, for example, it is noted that for desired sealing and placement of the components within the housing <NUM>, the inner lip <NUM> is positioned at a distance from the inlet end <NUM> of the housing <NUM> so that certain components will be securely positioned and engaged with each other without undesirable spaces between the components. That is, for the air cleaner assembly <NUM> shown and described relative to <FIG>, for example, the access cover <NUM> is part of precleaner <NUM>, and thus the inner lip <NUM> is recessed sufficiently far to accommodate structure and operation of the precleaner <NUM>. In general, the inner lip <NUM> will not be recessed further than an amount necessary to accommodate the various housing and inlet features and their operation. Although this is not a requirement with respect to operation of the air cleaner assembly, it is advantageous with respect to having the air cleaner housing <NUM> not be larger and heavier than necessary.

Referring again to <FIG>, the exemplary air cleaner assembly <NUM> includes an optional secondary or safety filter <NUM>, which is also illustrated in <FIG>. The safety filter <NUM> is generally positionable between the main filter cartridge <NUM> and the outlet <NUM> of the housing <NUM>. In a typical arrangement, the safely filter <NUM> is removably positioned within the air cleaner assembly <NUM> and would also typically be considered to be a service component that is removable and replaceable, as desired and/or necessary. However, because the safety filter is typically not subject to very significant dust load in use, it is typically not replaced very frequently, and is instead more useful to provide additional protection from dust for the internal components, such as when the main filter cartridge <NUM> is removed from the housing <NUM>.

The exemplary embodiment of safety filter <NUM> includes an outer frame <NUM> that generally matches the size and shape of the inner area of the housing <NUM> adjacent to the outlet <NUM>, preferably with no gaps. In this way, the safety filter <NUM> can be pressed into the housing with a friction fit against the wall of the housing <NUM> so that no air can reach the outlet <NUM> without first going through the safety filter <NUM>. Safety filter <NUM> further includes an upper face <NUM> from which at least one handle <NUM> extends. Each handle <NUM> provides an easy way for a user to remove the safety filter <NUM>, in that each handle preferably includes an aperture or other feature that facilitates engagement by one or more fingers that can pull the safety filter <NUM> from the housing <NUM>. Each handle <NUM> also helps to locate and position the filter cartridge <NUM> when it is inserted into the housing <NUM>.

The safety filter <NUM> can further include multiple louvers <NUM> across at least a portion of the upper face <NUM>, wherein such louvers <NUM> have slots between them through which air can enter the filter <NUM> and contact filter media (not visible). The filter media for this safety filter may be pleated media, with the pleats extending in a long dimension of the frame <NUM>. The frame <NUM> may include pleat spacers to help maintain spacing integrity of adjacent pleats.

As is discussed above, the access cover <NUM> is secured to the housing <NUM> via at least one latch <NUM>, wherein latches <NUM> are shown in a number of the Figures as attached to securing members <NUM> extending from the outer surface of housing <NUM>. Such attachments of a latch <NUM> to housing <NUM> are shown in enlarged views in <FIG>, and a single latch <NUM> is shown as a separate component from the access cover <NUM> in <FIG>.

Latch <NUM> includes a latch body <NUM> and multiple (e.g., two) u-shaped wire members <NUM> engaged within the latch body <NUM>. Latch body <NUM> includes a number of contours for engagement with surfaces and features of the access cover <NUM> and the housing <NUM>, such as a channel <NUM> having a lower lip <NUM>. Channel <NUM> is configured to accept an edge of the access cover <NUM> along with securing member <NUM> of housing <NUM> to secure these components to each other. In particular, lip <NUM> is positionable under the securing member <NUM>, and an upper area of the channel <NUM> will be adjacent to an upper surface of the access cover <NUM>. Latch body <NUM> further includes a lower concave area in which a series of ribs <NUM> are spaced from each other. These ribs <NUM> can be molded into the latch body <NUM> or can be made separately and secured to the latch body <NUM>. Each of the ribs <NUM> includes an aperture that is engageable with a straight portion of one of the u-shaped wire members <NUM>. As shown, one of the straight portions of each of the wire members <NUM> is rotatably positioned within the apertures of the ribs <NUM>, while the other straight portion of each of the wire members <NUM> is attached for pivoting/rotating movement with the access cover <NUM>.

In order to secure the access cover <NUM> to the housing <NUM>, the latches <NUM> are rotated away from the access cover <NUM> as the access cover <NUM> is pressed toward the inlet end <NUM> of housing <NUM>. After the cover <NUM> is properly located, the lip <NUM> of channel <NUM> of each latch <NUM> is moved into engagement with one of the securing members <NUM> and rotated about the u-shaped wire members <NUM> with the securing member <NUM> and edge of the access cover <NUM> located within the channel <NUM>. The top surface <NUM> is then pressed toward the top surface of the access cover until the latch <NUM> "snaps" into engagement with the access cover <NUM>.

The filter cartridges of the invention can be configured to be positionable within the housing in one or more rotational orientations. With a cartridge of the type depicted, in which the cartridge has a long cross-sectional access and a short cross-sectional access, the cartridge can be configured to be positioned in only one appropriate rotational orientation, or can be configured to be properly positionable in two rotational orientations. An indexing arrangement can be used between the cartridge and the housing to accommodate either one rotational orientation or two, as may be desired.

Referring now to <FIG>, an exploded perspective view of another exemplary embodiment of the air cleaner assembly <NUM> of the invention is illustrated, which is differently shaped than other air cleaner assemblies described herein, but includes a number of the same or similar features as other embodiments. Air cleaner assembly <NUM> generally includes a housing <NUM>, a precleaner <NUM>, a filter cartridge <NUM>, and an optional safety filter <NUM>. As shown, the general outer shape of at least a portion of some of these components is an octagon, wherein each of the eight sides is approximately the same length, which provides for certain options for assembling the components with each other that are not otherwise available. For example, the filter cartridge <NUM> may have multiple orientations in which it can fit into the housing <NUM>, as is discussed further below.

The exemplary housing <NUM> includes an inlet <NUM> at an opposite end from an outlet <NUM>, wherein the elements of the system are insertable into the inlet <NUM> for assembling the air cleaner assembly <NUM>. Housing 601can further include an inner lip (not visible) extending around the perimeter and spaced from the inlet <NUM>. In addition, housing <NUM> includes at least one securing member <NUM> on the outside of its outer wall and adjacent to the inlet <NUM>, which is provided for engagement with a latching mechanism <NUM> of the precleaner <NUM>. The inner lip of the housing <NUM> is positioned to provide one side of a channel or pocket, wherein the channel is also defined by the inner wall of the housing <NUM> and a bottom channel surface extending between the inner lip and the inner wall of the housing <NUM>. The channel generally extends around the perimeter of the housing <NUM> to provide for sealing with a feature of the filter cartridge, as is described below.

The precleaner <NUM> can include an access cover that is engageable with a base member (along with being attachable to the housing <NUM> via latches), or the precleaner <NUM> can be generally a single-piece component that also includes latches. That is, in certain embodiments of the air cleaner assembly <NUM>, the precleaner can include an access cover that is engaged with a base member via an attachment configuration, such as a snap-fit arrangement, to secure the two parts to each other as a single unit that is then attachable to the housing <NUM> via latches <NUM>. In such an embodiment, the access cover would be separable from the base member to facilitate cleaning, for example. However, in another embodiment of the precleaner <NUM>, the access cover can be made as a single piece that is provided to the assembly <NUM> as a single unit. In any case, the precleaner <NUM> is generally used to remove a portion of the dust or other particulate material (e.g., liquid particulate material) that enters the air cleaner through the air flow inlet before that material can reach internally positioned filter cartridge <NUM>.

The precleaner <NUM> further includes multiple inlet tubes or contaminant separator tubes <NUM> extending from an inner surface of the cover toward the inner area of the housing <NUM>. The tubes <NUM> can be preformed and press-fit into apertures in the cover during assembly, or can be attached in another way (e.g., with adhesive). In general, each separator tube <NUM> includes an upstream inlet end into which air (to be filtered) entering the air cleaner assembly <NUM> passes. Each tube <NUM> can include a vane arrangement in or adjacent to the inlet end, and is configured to import (direct) a cyclonic flow for the inlet air. Like other embodiments described herein, the tubes <NUM> can also include a side slot between the tube ends, through which contaminant (dust, particulate contamination ejector or water) that is separated by the contaminant separator arrangement can exit for eventual ejection through a housing contamination ejection port.

Although a number of arrangements of the tubes <NUM> are contemplated, an exemplary embodiment includes tubes <NUM> arranged in two intersecting or overlapping "rings"<NUM>, <NUM>, each of which includes two tubes at the top and bottom of the ring, and one tube at either side of the ring. The two bottom tubes of the first ring <NUM> are the same two tubes that make up the top two tubes of the second ring <NUM>. As shown in this exemplary embodiment, the tubes <NUM> are preferably arranged so that a desired pattern is achieved for air exiting the tubes. Some or all of the tubes <NUM> also can include an arrangement of vanes that are used to direct the air flow in a desired manner. The arrangement of vanes can vary considerably, depending on the desired air flow, and it is contemplated that tubes <NUM> of a single precleaner <NUM> can have different vane arrangements.

Referring more particularly to <FIG>, filter cartridge <NUM> can be considered to be the main or primary filter cartridge, and is used to selectively separate a desired amount of particulate or containment material that was not filtered out of the system by the precleaner <NUM>. Cartridge <NUM> is generally a service part or removable component that is periodically removable and replaceable as desired or necessary during the lifetime of the air cleaner <NUM>. The filter cartridge <NUM> comprises filter or filtration media <NUM> that may be any of a variety of types, such as the fluted filter media described above, for example. The exemplary cartridge <NUM> is considered to be a "straight through flow" arrangement in that it includes a first (inlet) flow face or end <NUM> and opposite outlet (flow) face or end <NUM>, with filtering flow of air through the filter cartridge <NUM> generally being from the inlet end <NUM> to the outlet end <NUM>.

The filter <NUM> may further include a filter sealing member (not visible) that has an inner opening at its top edge defined by an upper lip that extends inwardly from a frame wall in at least one location to fill at least one gap space between the frame wall and the outer surface of the media pack when the media pack is positioned in the filter sealing member. That is, because the shape of the frame wall (e.g., an octagon) is different from the outer shape of the filter cartridge <NUM> (e.g., a circle), there will be gaps between these elements in the areas where the shapes diverge from each other (e.g., where the angled corners of the frame wall are spaced from the curved outer surface of the filter cartridge <NUM>). In this embodiment, extensions of upper lip from the frame wall will fill in the gap to approximate an inner octagon shape for the inner opening of the filter sealing member along its top edge.

The filter cartridge <NUM> further includes a flexible perimeter sealing member <NUM> extending generally around the perimeter of the top of the cartridge <NUM>. The sealing member <NUM> further includes an axially directed portion <NUM> that is sized and shaped to provide a leak-resistant seal with the inner surface of housing <NUM> when the air cleaner assembly <NUM> is in operation. To facilitate this, the sealing member <NUM> can be a resilient material of a type typically used for such sealing purposes. The flexible sealing member <NUM> can be molded in place with the media <NUM> positioned inside of the shell of the cartridge <NUM> such that the sealing member <NUM> will have embedded therein the frame wall of the filter sealing member discussed above. When the cartridge <NUM> is positioned within a housing, its sealing member <NUM> can provide a pinch seal type of arrangement, as is discussed above relative to other configurations of cartridges.

The axially directed portion <NUM> of sealing member <NUM> can be contoured around portions of its perimeter to provide for selective engagement with other portions of the housing <NUM>. In an embodiment of the filter cartridge <NUM>, because all of the sides are of the sealing member <NUM> are the same length, the filter cartridge <NUM> can be "clocked" or rotated to any of eight different orientations within the housing <NUM>. However, it is possible that the axially directed portion <NUM> on one or more of the sides includes contours or extensions that make the shape different from that of the other sides. In such an embodiment, the inner area of the housing <NUM> may be designed such that only certain orientations of the cartridge <NUM> will provide proper seating of the sealing member within the housing <NUM>.

In accordance with the invention, it is contemplated that another exemplary air cleaner assembly does not include a precleaner that requires a contaminant ejection port, and therefore the air cleaner body can include a side air flow inlet rather than an end inlet. The outlet arrangement of such an embodiment could be made as a separate component from a remainder of the body and be secured thereto, or it can be molded integrally with a remainder of the body. In such an arrangement, the access cover will not be secured to a precleaner base member or body, but can instead be mounted directly to the housing. This access cover can be used to secure the filter cartridge within the housing.

Claim 1:
A filter cartridge (<NUM>, <NUM>) configured to be removably positionable within an inner opening of a housing (<NUM>), wherein the filter cartridge (<NUM>, <NUM>) comprises:
a media pack (<NUM>, <NUM>, <NUM>) comprising an inlet end, an outlet end, and an outer surface having an outer peripheral shape;
at least one of:
(a) a frame member (<NUM>, <NUM>) at least partially surrounding the media pack, the frame member (<NUM>, <NUM>) comprising a frame wall (<NUM>, <NUM>) having a shape that is different from the outer perimeter shape of the media pack; and
(b) a shell (<NUM>, <NUM>) at least partially surrounding the media pack, the shell (<NUM>, <NUM>) comprising a shell wall having a shape that is different from the outer perimeter shape of the media pack (<NUM>, <NUM>); characterized by
a sealing member (<NUM>, <NUM>) extending at least partially around the inlet end of the media pack, wherein the sealing member comprises a pinch seal portion that is spaced from the outer surface of the media pack, wherein the sealing member (<NUM>, <NUM>) connects the media pack to at least one of the frame member (<NUM>, <NUM>) and the shell (<NUM>, <NUM>);
wherein the sealing member (<NUM>) comprises an axially directed portion (<NUM>) being sized and shaped to provide a leak-resistant seal with the inner surface of housing (<NUM>), wherein the axially directed portion (<NUM>) is contoured to have steps around its perimeter defining a stepped area, the stepped area being defined by recesses or protrusions.