Patent Document

FIELD OF THE INVENTION 
     The present invention relates generally to an air cleaner for motor vehicles. In particular, the present invention relates to devices and methods for inserting a cam operated drawer style air filter element in a housing and positioning the filter in the housing. 
     BACKGROUND OF THE INVENTION 
     It is well known to provide an air cleaner for purifying raw air before mixing the raw air with fuel. Such known air cleaners typically include an air filter element disposed between a top shell and a bottom shell. The bottom shell typically includes an air intake and the top shell typically includes an air exhaust, which leads to an intake manifold of an internal combustion engine. In operation, such known air cleaners provide for the intake of raw air, the purification of the raw air and the routing of the purified air to the air exhaust. However, a problem with such known air cleaners is the leakage of raw air from the bottom shell to the air exhaust before passing through the filter element. 
     In an attempt to overcome the problem of air leakage, some known air cleaners include a seal disposed between abutting top and bottom shells. Compression of the seal is accomplished by exerting a significant compressive force on the shells and coupling the shells together to maintain the compressive force. According to some known arrangements, the shells may be permanently coupled, such as by welding, to maintain the compressive force. However, permanently coupling the shells with a filter inside has the disadvantage of preventing access to the filter element for repair or replacement. 
     According to other known arrangements, the shells may be temporarily coupled together using many screws evenly spaced around the periphery of the air cleaner to maintain the compressive force. To repair or replace the filter element, the screws are unfastened, the filter element is repaired or replaced and the screws are then refastened. However, this operation has the disadvantage of requiring a significant amount of time and may result in the uneven compression of the seal, which compounds the problem of air leakage. 
     What is needed, therefore, is an improved air cleaner that is capable of establishing an adequate seal to impede raw air from bypassing a filter element. It would also be advantageous to have an air filter element capable of rapid replacement in an air cleaner. It would further be advantageous to have a method of rapidly installing a filter element in an air cleaner. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention relates to an air cleaner for purifying air. The air cleaner includes a housing having a first shell coupled to a second shell. The air cleaner also includes an air filter element disposed within the second shell and having a first side and a second side. Also, the air cleaner includes a flexible seal disposed between the first side of the filter and the first shell of the housing. At least one cam is rotatably mounted to the second shell and adapted to selectively engage the second side of the filter to compress the seal between the first side of the filter and the first shell of the housing. 
     The present invention further relates to an air filter for filtering combustion air for an internal combustion engine disposed in a housing, the housing has a first shell mounted to a second shell. An inlet is mounted to the first shell, and an outlet is mounted to the second shell. At least one cam is rotatably mounted to the second shell. The air filter includes a container adapted to be selectively engaged by the cam. The air filter also includes a filter element adopted to filter the combustion air having a first side and a second side, the second side of the filter element being supported by the container. Also, the air filter includes a flexible seal disposed between the first side of the filter element and the first shell. The seal forms a closure between the filter element and the first shell to increase the amount of air directed through the air filter. 
     The present invention further relates to a method of installing an air filter in an air cleaner. The air cleaner includes a housing. The housing has a first shell with an inlet and mounted to a second shell having an outlet. The air cleaner also includes an air filter having a first side and a second side. The air cleaner also includes a flexible seal disposed between the first side of the air filter and the first shell of the housing. Also, the air cleaner includes at least one cam rotatably mounted in the housing. The method includes sliding the filter into the second shell. The method also includes rotating the cam to engage the second side of the filter. Also, the method includes moving the filter toward the first shell. The method also includes compressing the seal between the first side of the filter and the first shell. 
     It is an object of this invention to provide an air cleaner that is capable of establishing an effective seal to impede the leakage of air in the air cleaner. It is also an object of this invention to provide an air filter element capable of rapid replacement in an air cleaner. It is a further object of this invention to provide a method of rapidly installing an air filter in an air cleaner. Other objects, features and advantages of the invention will become apparent to those skilled in the art upon review of the following FIGURES, the detailed description and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an air cleaner in accordance with a preferred embodiment of the present invention; 
     FIG. 2 is an exploded perspective view of the air cleaner of FIG. 1; 
     FIG. 3 is a fragmentary front elevation view of an air cleaner showing a seal in an engaged position according to an exemplary embodiment of the present invention; 
     FIG. 4A is a fragmentary cross-sectional view of the air cleaner about line  4 A— 4 A of FIG. 1 showing a container extended relative to a housing; 
     FIG. 4B is a fragmentary cross-sectional view of the air cleaner about line  4 B— 4 B of FIG. 1 showing the seal in a disengaged position; 
     FIG. 5A is a fragmentary cross-sectional view of the air cleaner about line  4 A— 4 A of FIG. 1 showing the container retracted relative to the housing; and 
     FIG. 5B is a fragmentary cross-sectional view of the air cleaner about line  4 B— 4 B of FIG. 1 showing the seal in an engaged position. 
     Before explaining in detail at least one preferred embodiment of the subject matter recited in the claims, it is to be understood that the subject matter recited in the claims is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or shown in the FIGURES. The subject matter recited in the claims is capable of other embodiments or being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, an air cleaner  10  is shown according to a preferred embodiment of the present invention. Air cleaner  10  includes a housing  12  providing an upper shell  20  coupled to a lower shell  30 . A container (shown as a drawer  40 ) supporting a replaceable filter element  50  is disposed between upper shell  20  and lower shell  30 . A cam shaft  60  (shown in FIG. 2) is provided within the interior of housing  12 . 
     In the operation of air cleaner  10 , raw air enters an air conduit or intake (shown as an air inlet  32 ) of lower shell  30 . The raw air is routed to a cavity (shown as a reservoir  34 ) of lower shell  30  through an air receiving surface  52  of filter element  50 . While passing through filter element  50 , impurities (e.g., particulates, gasses, dirt, pollution, etc. and shown as debris  92 ) may be removed from the raw air and embedded in a cleaning medium  56 . (See FIG.  5 B.). The purified air exits filter element  50  through an air emitting surface  54  to a cavity (shown as a reservoir  24 ) of upper shell  20 . The purified air is routed through an air conduit or exhaust (shown as an air outlet  22 ) of upper shell  20 . An arrow  94  shows the general directional flow of the air. 
     After a period of time, the effectiveness of filter element  50  may be decreased due to various factors (e.g., deposition of debris, age, time, wear, etc.). Accordingly, air cleaner  10  may be configured for the selective extension and retraction of drawer  40  relative to housing  12 . Referring to FIG. 4A, filter element  50  is shown in a position extended from housing  12 . The extension of filter element  50  is accomplished by applying a force (e.g., in the horizontal direction) on an exterior wall (shown as a handle  44 ) of drawer  40  and sliding or extending drawer  40  from housing  12 . Handle  44  includes a generally triangular-shaped aperture  46  configured to permit drawer  40  to slide past a stem  64  of shaft  60  extending from the interior of housing  12  when shaft  60  is in an unlocked position  78 . (See FIG. 3.) An expired or used filter element may be removed from the extended drawer and replaced with a new or repaired filter element. A force (e.g., in the horizontal direction) may be applied to handle  44  of drawer  40  to slide or retract drawer  40  into lower shell  30  of housing  12 . In retracting drawer  40  into housing  12 , a generally flexible or resilient seal  48 , which is mounted to and integral with the periphery of filter element  50 , is oriented in a disengaged position relative to a sealing surface (shown as a flange  26 ) of upper shell  20  as shown in FIG.  4 B. In its disengaged position, seal  48  is not in adequate contact with flange  26  to reduce the leakage of raw air around the periphery of seal  48  (see FIG.  4 B). 
     Cam shaft  60  assists in providing adequate contact between seal  48  and flange  26  of upper shell  20  to reduce the leakage of air around the periphery of seal  48 . When seal  48  is pressed against flange  26  as shown in FIG. 5B, an effective seal or closure is created between filter element  50  and flange  26  to reduce the amount of air that may bypass air receiving surface  52  of filter element  50 . Referring to FIG. 5A, shaft  60  is shown disposed adjacent to the base of drawer  40 . Shaft  60  may be generally tubular shaped (e.g., a solid or hollow rod) generally extending the length of drawer  40  and lower shell  30 . Shaft  60  may be bent in the general shape of an M having a major width  66  greater than a minor width  68 . Shaft  60  acts as a cam when rotated because of the differences in width between major width  66  and minor width  68 . (Stem  64  provides an operator with the mechanical advantage necessary to rotate shaft  60 .) To engage seal  48  against flange  26 , stem  64  of shaft  60  is rotated about ninety degrees in the counterclockwise direction. Such rotation of shaft  60  causes a major portion  72  of shaft  60  to engage the base of drawer  40  and minor portion  70  engages a tab  74  of the drawer  40 . As shaft  60  is rotated, drawer  40  is moved toward upper shell  20 . As drawer  40  is moved toward upper shell, the compression of seal  48  creates a seal or closure to reduce the leakage of raw air from around the periphery of filter element  50  without first passing through air receiving surface  52  of filter element  50 . 
     When shafts  60  are rotated from their unlocked position in FIG. 4A to their locked positions in FIG. 5B, they lift the filter element toward the sealing surface compressing seal  48  therebetween. Eventually, shafts  60  are rotated over-center, permitting seal  48  to decompress and wedge shafts  60  against an inner wall of housing  12 , as shown in FIG.  5 B. In this position, the seal causes pressure to be applied to shafts  60 , preventing them from rotating and releasing the filter element. 
     Referring to FIG. 2, drawer  40  has sides  84 , is generally rectangular-shaped, and is configured to receive filter element  50 . An opening (shown as an aperture  36 ) may be provided across a side of lower shell  30 , through which drawer  40  may be extended and retracted relative to housing  12 . Filter element  50  is adapted to fit or nest within the interior of drawer  40 . Filter element includes a panel (shown as a sidewall  58 ) that circumscribes cleaning medium  56 . Filter material  56  may be constructed of a porous material (e.g., cardboard, corrugated paper, carbon block, etc.) or a natural or synthetic fibrous material (e.g., spun polyethylene, glass wool, microbial filter, etc.) preferably fan folded to provide a large filtering area. Air receiving portion  52  of filter element  50  is supported by a support member (shown as a brace  42 ) integral with the base of drawer  40  such that air receiving surface  52  is accessible to raw air located or stored in reservoir  34  of lower shell  30 . 
     Inlet  32  of lower shell  30  provides a convenient mounting point for conduits routing raw air from the exterior of housing  12  to reservoir  34  of lower shell  30 . The raw air routed to the interior of housing  12  through inlet  32  may be held in reservoir  34  of lower shell  30  for storage, heating, preprocessing, etc. An upward surface  82  of lower shell  30  is mounted to a downward surface  80  of upper shell  20  by a fastener such as a mechanical weld (not shown). According to an alternative embodiment of the present invention, the upper shell may be temporarily coupled to the lower shell by a fastener such as a clasp or a screw. According to other alternative embodiments, the upper shell may be hinged to the lower shell to permit the shells to be pivotally opened and closed. 
     Outlet  22  of upper shell  20  provides a convenient mounting point for conduits leading the purified air to a location for further processing (e.g., to an intake manifold of an internal combustion engine where the purified air may be mixed with fuel). The purified air may be held in reservoir  24  of upper shell  20  before being routed to outlet  22 . Upper shell  20  may include structural irregularities such as an indentation  86  for the placement of accessories (e.g., valves, tubes, pipes, automotive hardware, etc. (not shown)) adjacent or attached to air cleaner  10 . Ribs or fins  88  may be provided on lower shell  30  and upper shell  20  to give structural support for housing  12 . 
     According to a particularly preferred embodiment, the air cleaner is used to purify air before the air is routed to an automotive or vehicular engine. The upper shell and the lower shell are preferably constructed of metal or plastic. The filter is preferably constructed of paper folded in a zigzag configuration. The seal is preferably constructed of foam rubber. The cam shaft is preferably constructed of metal. The stem of the cam shaft is preferably covered with a rubber or plastic sleeve or glove. When the cam shaft is rotated to the locked position, the shaft is preferably positioned “over-center” such that the major width is not perpendicular to the base of the drawer. Alternatively, clips, catches or other releasable fasteners may be provided to keep the shaft in a locked position. 
     It should be noted that the use of the term “conduit” is not meant as a term of limitation, insofar as any “valve” or like structure providing a channel or passageway through which air may flow is intended to be included in the term. It should be noted that the use of the term “routed” is not meant as a term of limitation, insofar as any “direction” or leading of raw or purified air into, through and out of the air cleaner is intended to be included in the term. 
     While a preferred embodiment of the invention is as described above, there are several substitutions that may be made without departing from the beneficial features of the above-described invention such as variations in sizes, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, or use of materials. For example, the mechanical weld of the housing may be replaced with such well known substitutions as an interlocking tab and slot arrangement, which would have the added benefit of permitting the upper shell to be removed entirely from the lower shell. The shells may be fastened by screws, rivets, clamps, welding or other conventional methods. According to alternative embodiments of the present invention, the air cleaner may be rotated such that the filter element is top-loaded into the housing, rather than side-loaded into the housing. The opening in housing  12  for the filter may be provided in either or both shells. The cam shaft may engage the bottom side or flange of the filter element or container. According to other alternative embodiments, the seal may be mounted to the upper shell, fixed to a rigid or semi-rigid framework that also extends about the periphery of the filter element, or detached from both the upper shell and the filter element 
     Thus, it should be apparent that there has been provided in accordance with the present invention a cam operated drawer style air cleaner that fully satisfies the objectives and advantages set forth above. Although the invention has been described in conjunction with specific embodiments thereof, it is evidence that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred embodiments without departing from the spirit of the invention as expressed in the appended claims.

Technology Category: b