Patent ID: 12186697

DETAILED DESCRIPTION OF THE INVENTION

FIG.1illustrates a filter assembly100in cross-section. The filter assembly100is an air cleaner assembly in this embodiment. The filter assembly100includes a housing102formed from first and second housing components104,106that define an internal cavity108. A replaceable filter cartridge110(also referred to simply as a filter or as a filter element110) is located within the internal cavity108to filter particulates from the air as it flows from a first fluid port in the form of inlet112in the housing102to a second fluid port in the form of clean air outlet114provided by fluid port component146. In this embodiment, both the inlet112and outlet114are formed by or attached to the first housing component104.

The air inlet112is offset from a central axis116such that it enters the filter housing102in a tangential manner, which causes the air to spin within the filter housing102. Further, the filter housing102and particularly the first housing component104includes a shield member118that prevents the air from directly impinging on the filter media of the replaceable filter cartridge110as it enters the filter housing102.

A primary filter cartridge110(also referred to as a primary filter) is illustrated inFIGS.2,7and8. The primary filter110includes a contoured end member120that will mate with corresponding structure of the housing102. The contoured end member120of the primary filter110is an open member that provides fluid communication with an internal cavity122of the cylinder of filter media124of the primary filter110. A closed endcap126is attached to an opposite end of the filter media124of the primary filter110.

The contoured end member120includes a plurality of axially extending projections130and intermediate valleys131that define an axially undulating first wave profile. The axially extending projections130also form an annular wall that surrounds central axis116defined by the filter media124. The thickness t (seeFIG.8) of the projections130tapers in the radial direction when moving axially away from the filter media124towards tips132of the projections130. Further, a second axially undulating wave profile135is provided by inner projections134and intermediate valleys137of the contoured end member120on a radially inner side136of the annular wall formed by the axially extending projections130.

In some embodiments, the outer projections130are formed from a first pour of material and the inner wave profile is provided by a second pour of material (order is not important and first and second do not mean order of pouring). Preferably, the first pour (outer pour) is formed from a rigid urethane forming a support/alignment structure and the second pour (inner pour) is formed from a softer seal material, e.g. a FOAM seal/media potting compound. The first pour could be a preformed component attached to the filter media124by the second pour. Alternatively, all of the structure provided by the first and second pours could be preformed and then secured to the filter media by potting or embedding. Further yet, all of the structure provided by the first and second pours could be formed as a single component from a single pour, such as from a foamed urethane

FIG.3illustrates the first housing component104in partial cut-away form.FIG.3illustrates that the first housing component104has a corresponding contoured arrangement of axially extending projections140and intermediate valleys141. The axially extending projections140also form an axially undulating wave profile. This wave profile mates with the outer wave profile provided by the axially extending projection130of contoured end member120of the primary filter110. Some radially extending ribbing142is also illustrated that is positioned radially outward from the axially extending projections140to provide radial support. Some shorter axially extending flexible fingers144are positioned radially inward of the axially extending projections140.

FIG.4illustrates a snap-in outlet component146with a corresponding axially undulating wave profile148provided by axially extending projections147and intermediate valleys149, as well. Being “snap in” is simply a feature of this particular embodiment. However, other embodiments may not use snap-in connections or this component146could be integrally or unitarily formed with first housing component104. This wave profile148will correspond with the inner wave profile135for sealing with the primary filter110. The snap-in outlet component146may include axially extending ribbing152,154,156on inner and outer radial surfaces158,160for structural strength. The ribbing154,156may not extend the entire axial extension of the outer radial surface160. A portion of the outer radial surface160that does not include ribbing154,156provides the axially undulating wave profile148and a radially outward directed sealing surface that has a axially undulating wave profile that will mate with the similarly shaped radially inward directed sealing surface or the filter cartridge, e.g. provided by the axially undulating wave profile135radially inner surface136of the contoured end member120.

With additional reference toFIG.13, it is notable that the depth of the valleys149is such that the ends155of ribbing154and valleys149are at a same axial location (see e.g. dashed line157inFIG.13), or such that the ends155are positioned axially between peaks145and valleys149. This arrangement prevents a standard non-undulating seal, e.g. all at a same axial location to be used with the sealing surface provided by the undulating wave profile148of the snap-in outlet component146. It is noted that full ribs such as ribbing154is not necessary. For instance, a short nib located proximate ends155would be sufficient to force the use of an undulating seal for the filter element110.

Further, while projections140and valleys141are illustrated as being formed by the first housing component104, these components could be formed by the snap-in outlet component146.

FIGS.5,6and11illustrate the first housing component104with the snap-in outlet component146mounted therein. It can be seen that the shorter axially extending flexible fingers144engage and hold the snap-in outlet component146in the first housing component104by being positioned axially between two radially outward extending flanges162,164formed by the snap-in outlet component146.

Ideally, the housing projections140forming the axially undulating wave profile are at least twice as high (in an axial direction) as the projections147on the snap-in outlet component146defining the axially undulating wave profile148for the snap-in outlet component146. Similarly, as illustrated inFIG.9, the axially extending projections130defining the outer wave profile defined by the first pour, in some embodiments, are preferably at least two times as high (in an axial direction, e.g. parallel to axis116) as the inner projections134defining the inner wave profile135. This allows the wave profiles of the primary filter110to mate with the wave profiles of the housing components (e.g. the first housing component104and the snap-in outlet component146) prior to engagement of the wave profiles that ultimately provide the seal between the filter element110and snap-in outlet component146.

The outer mating wave profiles defined by projections130and140are higher and formed, preferably, of a rigid material (relative to the inner material) to prevent any seal engagement prior to proper alignment as well as to aid in guiding the user to the proper angular alignment (see e.g.FIG.10). If the filter element110is not properly angularly aligned in the first housing component104, the axial projections130formed from the rigid urethane material will bottom out on (e.g. axially engage) projections140defining the outer wave feature at the bottom of the first housing component104before allowing the inner wave profiles defined by projections134,147to engage to form a seal, e.g. to radially overlap and form a radial seal therebetween in the illustrated embodiment.

FIGS.12and13illustrates the filter cartridge110in correct axial and angular alignment and properly seated. For simplicity,FIG.13only illustrates the sealing component of the filter element110and the snap-in outlet component146. The proper alignment between undulating wave profile135and undulating wave profile148allows for full seal engagement between the contoured end member120and the snap-in outlet component146. In this embodiment, a radial seal is provided between the inner surface136of the filter element110of the contoured end member120and radially outer surface160of the snap-in outlet component146. The outer surface disruption in the form of ribbing154,156of the snap-in outlet component146corresponds to the wave profile of the filter cartridge110to further ensure seal integrity and positive axial location. Notably, when properly installed, the peaks or tips of one set of projections will align with the valleys between adjacent projections of the cooperating wave profile. For example, the tips132of the outer wave profile provided by projections130of the contoured end member120of filter element110will angularly align with the valleys formed between adjacent projections140of the first housing component104.

FIGS.14-16illustrate an alternative embodiment of a filter element210with a contoured end member220where the rigid seal support that provides rigidity to the outer wave profile of the filter cartridge is provided by a preformed plastic insert231. A foam urethane or other soft urethane encapsulates the rigid preformed plastic insert231. In this embodiment, both the outer wave profile that provides for angular alignment and projections230and the inner wave profile that provides for sealing with the snap-in outlet component146and projections234are formed from a single continuous material, e.g. a foamed urethane that is molded around plastic insert231. Not only can the plastic insert231provide rigidity to the projections230, the insert231can provide radial rigidity to the inner wave profile to promote radial sealing with undulating sealing surface provided by the snap-in outlet component146.

FIG.17illustrates a further filter assembly300in partial cross-section. This filter assembly300is similar to the filter assembly100ofFIG.1. However, a different engagement with the primary filter310is provided.

With additional reference toFIGS.19-22, the first housing component304again has the radially inner flexible fingers344for attaching the snap-in outlet component346. The first housing component304does not have the same axially extending projections that form the axially undulating curved wave profile. Instead, the first housing component304includes a plurality of axially extending projections340that define slots341angularly therebetween that are used for proper angular filter alignment. The axially extending projections340again circumscribe a central axis.

The snap-in outlet component346includes an axially undulating wave profile defined by projections347and a plurality of ribs352,354radially inward of the undulating wave profile. The ribs352,354have varying axial heights. The heights correspond to the axial projections347and valleys349of the axially undulating wave profile. Radially extending annular flanges362,364again cooperate with the radially inner flexible lingers344of the first housing component304for mounting purposes.

The height (h2) of the slots341between the axially extending projections340of the housing component304is at least two times greater than the height (h1) of the projections347of the axially undulating wave profile of the snap-in outlet component346.

FIGS.18and22A-23illustrate the primary filter310. In this embodiment, the contoured end member320includes an axially undulating wave profile defined by a plurality of projections334that extend angularly about a central axis316. Further, at least one radially outward extending projection330is positioned/extends radially outward from the projections334that define the axially undulating wave profile. There are four projections330in this embodiment. These four projections330are formed from a rigid material. In this embodiment, a rigid seal support331is molded into an outer poured foam or soft urethane with the projections330extending radially outward from the poured urethane. The rigid projections330will align with the slots341in the first housing component304for proper angular alignment.

The rigid projections330, in this embodiment, extend axially at least two times the axial extension of the projections334defining the undulating wave profile formed from the softer material. This allows the size of the wave profile and projections334of the filter cartridge310to mate with the corresponding axially undulating structure of the snap-in outlet component346and particularly the undulating sealing surface thereof and slots341of the first housing component304. Further, projections340and slots341could be formed as part of the snap-in outlet component346.

With reference toFIGS.24-26, the slots341(housing component304) and radially outward extending rigid projections330(cartridge310) ensure that the seal (e.g. soft urethane) does not engage the sealing surface of the snap-in component346prior to proper angular alignment. When properly aligned, the rigid radial projections330can fall into the receiving slots341and allow the radially directed seal to engage the radially outer surface of the wave profile of the snap-in outlet component346. The rigid projections provide an axially undulating profile that allows for proper angular orientation.

FIGS.27-32illustrate the inclusion of a secondary filter410. While not illustrated, the secondary filter410fits inside the primary filter310in the filter assembly300ofFIG.17. The secondary filter410includes a radially outward directed sealing surface435that is illustrated as being straight, e.g. it does not axially undulate, but could have an axially undulating wave profile. This sealing surface435seals with an inner surface437, seeFIGS.25and26, of the snap-in outlet component346.

The secondary filter410includes a contoured end member420that includes a plurality of axially castellated projections430that mate with the axially extending ribs352,354that are radially inward of the wave profile of the snap-in outlet component346. As such, the castellated projections430define alternating axially extending slots456,458that have differing heights. Slots456receive ribs352while slots458receive ribs354. The ends of the ribs352,354are axially offset from one another while the valleys of slots456,458are similarly axially offset to mate with the corresponding ribs352,354.

The castellated projections430could be two pours of a first rigid material and then a second soft material over the top of the rigid material. Further, the rigid material could be provided by a preform over which the second soft material is poured to secure the preformed structure to the filter media and provide sealing surface435.

When the castellation projections430and corresponding slots456,458properly receive the axially extending ribbing352,354of the snap-in outlet component346, the seal of the secondary cartridge is allowed to engage the radially inward facing sealing surface437of the snap-in outlet component346(seeFIGS.31and32).

It should be noted that the “snap-in outlet component” could be formed as an integral one piece construction with the first housing component. Alternatively, portions of the snap-in outlet component could be provided the first housing component while other portions are still provided by a snap-in component.

FIG.33illustrates a further embodiment of a filter assembly500. The filter assembly500is similar in many respects to the prior filter assemblies and will incorporate an axially undulating wave seal arrangement. Any and all features of the wave seal arrangements described above can be incorporated into embodiments of the filter assembly500.

With additional reference toFIGS.34-37, the filter assembly500includes a housing502(also referred to as a filter housing assembly) that includes a housing body503illustrated as being formed from a first housing component504and a second housing component506that are axially connected to one another to define an internal cavity508(seeFIGS.35and37) that receives a filter element510(illustrated in simplified form inFIGS.34and37).

With principle reference toFIGS.34,35, the housing body503includes first and second openings511,513opening into internal cavity508. In this embodiment, the first and second openings511,513are at opposed ends of the housing body503. Further, each of the first and second housing components504,506define one of the first and second openings511,513, respectively.

The first and second housing components504,506are operably connectable together at ends opposite of first and second openings511,513. A mounting bracket515for mounting the filter assembly500to a device for which the filter assembly500will be filtering a desired fluid, typically air, secures the first and second housing components504,506to one another. The mounting bracket515generally circumscribes the ends of the first and second housing components504,506. The first and second housing components include grooves517,519that receive clamping segments521,523of the mounting bracket to secure the two housing components504,506axially together. The clamping segments521,523are axially spaced apart forming a gap therebetween which receives a portion of the two housing components504,506therebetween to secure the components together. Further, the clamping segments521,523are generally annular broken rings with a break525in the rings which allows for the inner diameter of the clamping segments521,523to be changed so as to allow for passing the housing components504,506into the clamping segments521,523. A buckle arrangement527is carried by the mounting bracket515and releasable pulls the free ends of the clamping segments521,523toward one another (see e.g. arrows529) to tighten the clamping segments521,523around the housing components504,506and into grooves517,519. The buckle arrangement527can be released to separate the housing components504,506.

With reference toFIGS.34and35, the first and second openings511,513are sized for receipt of filter element510there through to all for mounting the filter element510within the internal cavity508through either opening511,513. The filter housing assembly502includes a fluid port component514that defines an outlet port for the housing assembly503. The outlet port is provided by a tubular connector528that is configured for connecting to downstream piping such as rubber houses that will carry away cleaned air after passing through the filter assembly500. The outlet is in fluid communication with cavity508through the fluid port component514.

The first housing component504also defines a second fluid port in the form of a dirty fluid inlet512. This is where dirty fluid enters the internal cavity508. The filter element510operably seals to the fluid port component514to prevent dirty fluid from operably bypassing the filter element510and passing through the outlet. A shield518is positioned adjacent inlet512to prevent direct impingement of dirty fluid on the filter media524of the filter element510.

When installed, the filter element510is thus positioned within the internal cavity508between the inlet and the outlet.

A dust evacuation port516can be provided and includes a valve534that allows dust that has been separated from the dirty fluid upstream of the filter media524to be evacuated from the filter housing502. In this embodiment, the inlet512is provided by the first housing component504while the dust evacuation port516is provided by the second housing component506.

Opposite the fluid port component514is a cover member530. The cover member is selectably movable between a closed state that prevents removal of the filter element510from the internal cavity and an open state that allows a user to remove a filter element510from the internal cavity508and to install a new filter element510into the internal cavity508.

While comparingFIGS.35,36,40and41, the filter housing assembly502is reconfigurable between at least two separate configurations. More particularly, the fluid port component514and cover member530may be attached proximate either of the first and second openings511,513. For example, inFIG.36, the fluid port component514is attached to the first housing component504proximate first opening511. Additionally, the cover member530is attached to the second housing component506proximate second opening513. In this embodiment, the filter element510would be selectively insertable into and removable from the filter housing502through the second opening513.

However, inFIG.40, the fluid port component514is attached to the second housing component506proximate second opening513. Additionally, the cover member530is attached to the first housing component504proximate first opening511. In this embodiment, the filter element510would be selectively insertable into and removable from the filter housing502through the second opening513.

This allows the same filter housing assembly502to be used in different locations having different sized and shaped spaces for mounting the filter housing assembly502, e.g. different sized and shaped engine compartments of vehicles.

With reference toFIGS.35and37, the first housing component504includes a first attachment interface531proximate first opening511and the second housing component506includes a second attachment interface533proximate the second opening513. The housing interfaces531,533, in this embodiment, are substantially, if not, identical.

Further, the fluid port component514includes a first housing attachment interface535and the cover member530includes a second housing attachment interface537.

In the first configuration, the first housing attachment interface535is engaged with the first attachment interface531to secure the fluid port component514to first housing component504of the housing body503proximate the first opening511. When so attached, the outlet port provided by the tubular connector528fluidly communicates with internal cavity508through the first opening511. Further, the second housing attachment interface537is engaged with the second attachment interface533to secure the cover member530to the second housing component506of the housing body503proximate the second opening513. As noted above, the cover member530is selectively movable. e.g. pivotable about an axis539illustrated inFIG.36, between a closed state (see solid lines inFIG.36) and an open state (see dashed liens inFIG.36). In the closed state, the cover member530will engage the filter element510and prevent it from being removed from internal cavity508through the second opening513. In the open state, the cover member530has pivoted about axis539sufficiently out of the way of opening513to permit removal of the filter element510and insertion of a new filter element510. The openings511,513define central axis extending through the openings511,513. Axis539is perpendicular to the central axes defined by openings511,513.

In the second configuration, the first housing attachment interface535is engaged with the second attachment interface533to secure the fluid port component514to the second housing component506of the housing body503proximate the second opening513. When so attached, the outlet port provided by the tubular connector528fluidly communicates with internal cavity508through the second opening513. Further, the second housing attachment interface537is engaged with the first attachment interface531to secure the cover member530to the first housing component504of the housing body503proximate the first opening511. As noted above, the cover member534) is selectively movable, e.g. pivotable about an axis, between a closed state and an open state. This is the same as illustrated inFIG.36, but with the cover member530pivoted relative to the first housing component504rather than the second housing component506as inFIG.36. In the closed state, the cover member530will engage the filter element510and prevent it from being removed from internal cavity508through the first opening511. In the open state, the cover member530has pivoted about the axis sufficiently out of the way of opening511to permit removal of the filter element510and insertion of a new filter element510.

With reference toFIG.35, in addition to the tubular connector528, the fluid port component514includes a base member541from which the tubular connector528extends.

Further, the first attachment interface531of the first housing component504includes an axially extending projection in the form of ring543that includes a radially projecting projection. Similarly, the second attachment interface533includes an axially extending ring545that includes a radially projecting projection. These projections project radially outward, but it is contemplated that they could project radially inward.

To cooperate with the first and second attachment interfaces531,533, the first housing attachment interface535and second housing attachment interface537include radially projecting projections547,549. These projections extend radially inward but could extend radially outward.

To allow for the hinged connection of the cover member530to allow for selective servicing of the system, the first attachment interface531and second attachment interface533include hinge components551,553that operably cooperate with the cover member530depending on the configuration of the filter housing502and which end of the housing body503to which the cover member530and fluid port component514are attached. With additional reference toFIG.42, it is noted that radially inward extending projection549of the cover member is provided as part of a user operable latch550(see alsoFIG.36). If a user applies a force in the direction of arrow556, the latch will bend disengaging the radially extending projection of the cover member530from the radially extending projection of the corresponding one of the first and second attachment interfaces531,535. Further, the radially extending projections are configured to allow the latch to flex appropriately when closing the cover to allow the radially extending projections to slide past one another and then resiliently engage when sufficiently passed to allow for latching the cover member530to the housing body530.

It is noted that the attachment interfaces531,533,535,537need not be perfectly identical or that the various engagements occur in identical fashion. Thus, the attachment interface of the fluid port component514need not engage the attachment interfaces of the housing body503in a same manner as the attachment interface of the cover member530engages the attachment interfaces of the housing body503. It simply needs to be that the attachment interfaces of the housing body503be configured to correctly and operably attach each of the cover member530and fluid port component514at either end as desired by the user.

While cooperating radially extending projections are illustrated, other connections could be provided such as for example buckles.

With reference toFIG.35, the housing body503includes first and second seal surfaces552,554. In this embodiment, the seal surfaces552,554are formed by radially inner surfaces or axially extending annular rings543,545. With reference toFIG.34, the filter element510includes a tubular extension of filter media524that extends between opposed ends. A closed end cap526is attached to one end of the filter media524. The closed end cap526defines a seal555that cooperates with the first and second seal surfaces552,554, depending on the particular configuration of the system. More particularly seal555is a radial seal that will radially engage seal surface554in the first configuration and seal surface552in the second configuration.

With additional reference toFIG.42, seal555includes an annular projection557(also referred to as an annular ring) that is axially received in an annular groove559(see alsoFIG.35for groove559) formed by the cover member530when the closed state. Further, the axially extending rings543,545of the housing body503proximate first and second openings511,513are axially received in annular groove559depending on the configuration when the cover member530is in a closed state.

The cover member530includes an axially extending projection561, which may be an annular wall, preferably radially engages annular projection557of seal555to force, radially in this embodiment, seal555into seal surface552or554(depending on the configuration). The annular wall may or may not form a complete annular structure but even if it is a segment that generally forms an annular structure, it shall be considered to be annular. While this design uses an annular groove559, a simple annular projection561(also referred to as a ring) could be used to provide the radial biasing. Further, as noted above, such an annular projection561need not be continuous but could be formed from a plurality of wall segments. Further, while radial seals are provided, axial seals and axial compression of the seal into an axially facing sealing surface of the filter housing502could be incorporated in alternative embodiments. Again, whileFIG.42only shows one of the configurations, the operation would be identical for the other configuration with the cover member530attached to the opposite end proximate the other opening in the housing body.

The annular groove559is formed in an annular collar of the cover member530. In some embodiments, the annular collar forms the entire cover member530.

The closed end cap526can be formed from a combination of components such as a soft foamed outer rim that provides the seal and a rigid inner component. The presently illustrated design includes such a construction. Alternatively, the closed end cap could be formed continuously from the soft material molded directly to the filter media or having the filter media embedded therein. Further, the soft material could be preformed and then subsequently attached to either a rigid support or directly to the filter media. Further, any rigid material could be preformed or molded directly to the filter media.

A handle could be provided by the closed end cap526. This handle could be an axially extending projection or a recess that is engageable by a service technician.FIG.26illustrates the inclusion of a handle560. This handle560is an axial projection that is formed from a rigid component of the closed end cap526. The rigid portion of the closed end cap is an imperforate end portion of a rigid central core used to support the filter media. However, the imperforate end portion could have a recess that is used to help remove a filter element from the filer housing body503.

In this embodiment, the cover member530includes an annular ring member for securing the filter element510within the housing body503. As such, in this embodiment, the actual filter element510is visible through the opening defined by the annular construction of the cover member530when the cover member520is in a closed state.

It shall be readily apparent that the inner diameter of the annular ring member of the cover member530is smaller than an outer diameter of the closed end cap526such that when in the closed state there is sufficient overlap between the closed end cap526and the cover member530to secure the filter element510within the housing body530. Thus, the cover member530is configured such that it will extend radially inward relative to the openings511,513of the housing body in the closed state for securing the filter element510. Additionally, the hinged connection of, at least the ring portion of the cover member530that secures the filter element510in the housing body503, is such that the ring portion can pivot sufficiently out of the way to the open state such that the filter element510can be installed and removed as necessary for maintenance purposes. Again, such pivoting is provided about axis539.FIG.36illustrates these orientations of the cover member530.

With additional reference toFIG.43, a contoured end member520is provided at an opposite end of the filter element510as the closed end cap526. As noted above, the filter assembly500can incorporate any of the iterations of the axially undulating wave features of the prior embodiments.

However, in this embodiment all of the axially undulating mating features of the filter housing502are provided by the fluid port component514. More particularly, the features for providing angular orientation and sealing with the contoured end member520are provided by fluid port component514.

The engagement of the filter element510with the filter housing502is similar to the design illustrated inFIGS.17-21,22A, and22-26. In this embodiment, the contoured end member520defines a radially inner surface570that defines a radially inward directed sealing surface572that defines an axially undulating wave profile for operably radially sealing on sealing surface574provided by a radially outer surface of ring member576of the fluid port component514. The ring member576has an axially undulating wave profile that matches that of the sealing surface572of the contoured end member520. The axially undulating wave profile of ring member576is provided by projections578and valleys580formed between adjacent projections578. The cooperating wave profiles of the ring member576and contoured end member520have sufficient axial dimension to allow for a positive seal between the filter element510and the housing502. The contoured end member520includes a plurality of axially extending projections582and valleys584formed angularly between adjacent projections582provide the wave profile for the contoured end member520. Projections578and582generally surround a central axis and form generally annular walls. The depth of the valleys580and height of the projections578are, preferably, such that an simple a-ring style seal that does not have axial undulations cannot be installed into the filter housing and form a continuous seal completely around the central axis.

A plurality of radially extending projections586extend radially outward from the projections582of the contoured end member520. These projections586are axially received in axially extending grooves588formed by the fluid port component514. The grooves588are formed between axially extending, angularly spaced apart wall segments590. Wall segments590form a generally annular wall that has angularly spaced apart interruptions formed by grooves588. In accordance with the discussions above, the positioning of the ends592of the projections586is such that these ends592will abut axial free ends594of the wall segments590prior to full sealing engagement between the contoured end member520and the filter housing502, e.g. fluid port component514. Instead, the projections586must be axially received in grooves588for the filter element to be properly seated into the filter housing502. Further, the length of the filter element510(e.g. between ends592and the distal end of the closed end cap526) is such that if the projections586are abutting free ends594rather than being inserted into grooves588, the cover member530cannot be transitioned to the closed state. More particularly, the length is such that the wave profile of the radially engaging sealing surfaces572and574will not fully engage unless the filter element510is properly angularly oriented and axially inserted into the filter housing502with the projections586received in grooves588.

With reference toFIGS.44and45, the contoured end member520is formed from multiple components. In this embodiment, the contoured end member520has an outer soft component596that defines the sealing surface572. Further, the contoured end member520includes an inner rigid component598that provides support to the projections586. More particularly, the rigid component598includes a plurality of angularly spaced apart legs600that angularly and axially align with projections582and projections586. Typically, the rigid component598will have an annular base member602from which the legs600axially project to provide further stability to the contoured end member520.

Typically, the rigid component598is formed from a preformed material. The outer soft component596, such as a urethane and more particularly a foamed urethane, will encapsulate the rigid component598. In some embodiments, an end of the filter media524and the rigid component598will be placed in a mold and the soft component596will be molded around the rigid component598and to the filter media524to secure the components to one another. Further, the rigid component598is formed from a material that is more rigid than the material for forming the soft component596. In some embodiments, this would be a rigid plastic material or could be formed from other material such as metal. Further yet, it could be formed from a more rigid urethane material.

The rigid component598provides rigidity to prevent the projections586from deforming if a user applies excessive axial force to the filter element510during installation without properly aligning projections586with grooves588.

FIGS.46and47illustrate a filter assembly700according to an embodiment in cross-section and in partially exploded form. The filter assembly700includes a housing702formed from first and second housing components704,706that define an internal cavity708. A replaceable filter cartridge710is located within the internal cavity708. The filter assembly700includes first and second fluid ports712,714, either of which may be an inlet port or an outlet port depending on the flow of fluid through the assembly700. In this embodiment, the fluid flow is radially outward through the filter media such that port712is the inlet and port714is the outlet. In this embodiment, structure712is formed as part of the fitter cartridge710. Filter cartridge710seals against housing component706. In this embodiment, second housing component706may be permanently or removably attached to first housing component704.

With reference toFIG.48, the filter cartridge710includes a contoured end member720that mates with corresponding structure of housing702. The contoured end member720is attached to an end of a cylindrical tube of filter media724. The contoured end member720may additionally function as an end cap for the filter cartridge710. An open end cap726is attached to an opposite end of the filter media724. The open end cap726may provide or carry a seal for sealing with housing702. The filter cartridge defines an internal cavity722.

In this embodiment, similar to the embodiment ofFIGS.17-22, the first housing component704includes a plurality of axially extending projections740that define slots741angularly therebetween that are used for proper angular filter alignment. The axially extending projections340angularly circumscribe a central axis. Further, the axially extending projections740are tapered to a point or tip743that define valleys745that have sides that taper down towards the slots741to further assist proper alignment of the filter cartridge710during installation.

In this embodiment, the axially extending projections740include an angularly extending wall segment740aand radially direct wall segments740b. The radially directed wall segments740bprovide increased strength to the projections740. In this example, the wall segments740bextend radially inward from the angularly extending wall segment740a, but could, in other embodiments, extend radially outward. A radially extending wall segment740bof one axially extending projection740and a radially extending wall segment740bof an immediately adjacent axially extending projection740define the slot741therebetween.

The first housing component704further includes an axially undulating wave profile defined by projections747that form pan of an annular wall748. Valleys751are formed between adjacent axially extending projections747. The annular wall748circumscribes the central axis. Annular wall748is radially spaced from axially extending projections740. In this embodiment, the annular wall748is spaced radially outward form projections740forming an annular gap749radially therebetween. Either radially facing surface of annular wall748provides an axially undulating sealing surface for cooperating with the filter cartridge720.

A plurality of ribs752,754extend on both radially inner and outer sides of annular wall748. The ribs752and754have different axial heights such that the flat surface is not adjacent the base of annular wall748. The taller ribs752are proximate the tips of the projections747while the shorter ribs754are closer to or proximate the bottom of valleys751.

The heights of the slots741and axially extending projections740can correspond to or be similar to the relative heights of projections340and slots341discussed previously.

With reference toFIG.48, the contoured end member720of filter cartridge710includes a contoured alignment portion and a contoured seal portion. In this example, the contoured alignment portion and the contoured seal portion are formed from separate components (see e.g.FIG.52), with the contoured alignment portion being formed of a more rigid material than the contoured seal portion.

The contoured seal portion defines an axially undulating wave profile defined by a plurality of projections734that extend angularly about a central axis716. The radially inner or outer surfaces of the contoured seal portion provide radially directed seal surfaces. Only a single seal surface can be provided in other embodiments. The plurality of projections734form part of an annular wall735and form an axially undulating end of annular wall735.

The contoured alignment portion includes at least alignment projection730. In this example, a plurality of alignment projections730that are angularly spaced apart about axis716are provided. The alignment projections730are radially offset from the projections734. In this example, the alignment projections730are offset radially inward of the contoured seal portion and particularly projections734and annular wall735as well as the seal surface(s) of the contoured seal portion provided by projections734and annular wall735.

In this example, contoured alignment portion is formed form a rigid material, such as plastic. The contoured seal portion is formed from a poured foam or soft urethane that is molded over at least a portion of the contoured alignment portion. Thus, the contoured alignment portion may be considered a preform. In one example, the contoured alignment portion is formed from a material that is more rigid than the contoured seal portion. In one example, the material used to form the contoured seal portion is molded to the end of the tube of filter media724to form an end cap that seals the end of the tube of filter media724to which it is attached. The contoured alignment portion may be preformed and then the molded material used to form the contoured seal portion may be molded directly to filter media724and contoured alignment portion simultaneously to secure the contoured alignment portion to the filter media724.

The alignment projections730extend radially from an annular wall731. In this example, the alignment projections730extend radially outward from the annular wall731towards annular wall735. In this example, alignment projections730are unitarily formed with annular wall731such that they are formed from a continuous piece of material, but this is not required in all examples.

Radial gaps736are formed between the radially outer edge of the alignment projections730and the radially inner surface of annular wall735. Further, an annular gap737is formed between annular wall735and annular wall731. In this example, the annular wall731is radially inward of annular wall735. Thus, annular gap737is formed between an outer surface of annular wall731and an inner surface of annular wall735.

In one embodiment, the tips738of axial projections734are spaced a distance D1(seeFIG.47) from an end of the filter media724. The tips739of alignment projections730may be spaced a distance D2from the end of the filter media724. In this example, distance D2is less than distance D1.

In this example, adjacent ones of the plurality of axially extending projections734of the contoured seal portion define a valley733therebetween. The valleys733have a bottom, which is the closest portion of the valley733to the end of the filter media724. The bottom of the valley733is spaced a third axial distance D3from the filter media724. The second axial distance D2is greater than the third axial distance D3.

With reference to the cross-sectional illustrations ofFIGS.50and51, the interface between the contoured seal portion of the filter cartridge with the first housing component704and particularly annular wall748is provided. More particularly, the inner surface of wall735and the wave profile defined by the valleys and projections thereof engage and seal with the outer surface of wall738and the wave profile defined by the valleys and projections thereof.

In operation, when the user installs the filter cartridge710, the tips of projections730will cooperate with the projections740and valleys745of the housing component704to properly angularly align the filter cartridge and particularly the wave profiles of annular walls748and735so that the sealing surfaces thereof properly align.

The operation of insertion of the filter cartridge710and alignment of the contoured end member720and associated seal with the housing component704is illustrated with reference toFIGS.53-56. More particularly, the projections740are used to auto align the contoured end member720with the corresponding projections740of the housing component704.

InFIG.53, the filter cartridge710has been initially inserted into the housing component704. Here, the end731aof annular wall731has axially abutted the tapered axial ends of the radially directed wall segments740b. The tapered axial ends of the radially directed wall segments740bcenter the annular wall731relative to axis716. This properly radially positions the alignment projections730relative to axis716. Here, the seal portion provided by projections734and wall735have not contacted the housing but are properly radially aligned with annular wall748.

With reference toFIG.54, as the filter cartridge710is further axially inserted into housing component704as illustrated by arrow770, the tips730a(e.g. axial ends) of the alignment projections730engage and slide on the tapered surfaces/axial ends of the angularly extending wall segment740aof the axially extending projections740. This sliding action imparts a torque on the filter cartridge710causing it to rotate angularly about axis716as illustrated by arrow771. In a preferred embodiment, annular wall735providing the seal does not yet engage the housing so as to limit or avoid providing increased friction between the filter cartridge710and the housing component704.

With reference toFIG.55, the filter cartridge710will rotate until the alignment projections730align with the slots741formed between adjacent axially extending projections740of the housing component704. In one embodiment, the friction between the alignment projections730and the axially extending projections740is small enough that the weight of the filter cartridge710itself is sufficient to cause the filter cartridge710to rotate such that alignment projections730align with slots741. When this occurs, the annular wall735that provides projections734forming the wave profile and providing the sealing surface is now properly angularly aligned with annular wall748and the wave profile thereof so that a mating seal can occur.

With reference toFIG.56, the filter cartridge710has been fully inserted into housing component704. The end731aof annular wall731abuts end wall774of the housing component704. Further, alignment projections730have been axially received into slots741between adjacent axially extending projections740, Further, annular wall or at least the projections734thereof are in sealing engagement with wall748.

The filter cartridge710further includes a drain valve776formed in the contoured end member720. The drain valve776allows water that may collect within the filter cartridge to drain out of the filter cartridge710. The housing component704, in this embodiment, includes a drain port778with which the drain valve776aligns when properly installed.

All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.