US20010003893A1 - Air cleaner, filter element, and methods - Google Patents
Air cleaner, filter element, and methods Download PDFInfo
- Publication number
- US20010003893A1 US20010003893A1 US09/771,779 US77177901A US2001003893A1 US 20010003893 A1 US20010003893 A1 US 20010003893A1 US 77177901 A US77177901 A US 77177901A US 2001003893 A1 US2001003893 A1 US 2001003893A1
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- United States
- Prior art keywords
- housing
- air cleaner
- filter element
- media
- seal member
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/0084—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours provided with safety means
- B01D46/0086—Filter condition indicators
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/0002—Casings; Housings; Frame constructions
- B01D46/0004—Details of removable closures, lids, caps or filter heads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/42—Auxiliary equipment or operation thereof
- B01D46/44—Auxiliary equipment or operation thereof controlling filtration
- B01D46/446—Auxiliary equipment or operation thereof controlling filtration by pressure measuring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
- B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
- B01D46/525—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material which comprises flutes
- B01D46/527—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material which comprises flutes in wound arrangement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/56—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition
- B01D46/62—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/88—Replacing filter elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/02—Air cleaners
- F02M35/0201—Housings; Casings; Frame constructions; Lids; Manufacturing or assembling thereof
- F02M35/0202—Manufacturing or assembling; Materials for air cleaner housings
- F02M35/0203—Manufacturing or assembling; Materials for air cleaner housings by using clamps, catches, locks or the like, e.g. for disposable plug-in filter cartridges
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/02—Air cleaners
- F02M35/024—Air cleaners using filters, e.g. moistened
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2267/00—Multiple filter elements specially adapted for separating dispersed particles from gases or vapours
- B01D2267/40—Different types of filters
Definitions
- This disclosure describes air cleaners for engines and methods.
- this disclosure describes an air cleaner having a straight-through flow, sealing system, resonator, and methods for servicing and use.
- Gas streams often carry particulate material therein.
- air intake streams to engines for motorized vehicles or other motorized equipment often include particulate material therein.
- the particulate material should it reach the internal workings of the various mechanisms involved, can cause substantial damage thereto. It is therefore preferred, for such systems, to remove the particulate material from the gas flow upstream of the engine or other equipment involved.
- a variety of air filter or gas filter arrangements have been developed for particulate removal. In general, however, continued improvements are sought.
- an air cleaner including a housing having first and second opposite ends.
- the housing defines an inlet adjacent to the first end and an outlet adjacent to the second end.
- a media pack is preferably oriented within the interior volume of the housing.
- the media pack will have a first and second opposite flow face and be constructed and arranged for air to flow into the media pack through the first flow face, and for air to exit the media pack through the second flow face.
- the air cleaner will include a seal member forming a seal between the media pack and the housing.
- a secondary filter element is oriented within the interior volume of the housing.
- the housing is constructed and arranged as a resonator.
- Certain preferred embodiments will include seal constructions that engage the secondary filter element to help hold the secondary filter element axially within the housing.
- FIG. 1 is a perspective view of one embodiment of an air cleaner, according to principles of this disclosure
- FIG. 2 is an exploded, perspective view of the air cleaner of FIG. 1 and its internal components
- FIG. 3 is a cross-sectional view of the air cleaner housing taken along the line 3 - 3 of FIG. 1;
- FIG. 4 is a schematic view of one embodiment of a system in which air cleaners according to the present disclosure are used;
- FIG. 5 is an enlarged, fragmented, schematic cross-sectional view of one embodiment a compressible seal member utilized to form a seal between a media pack and the air cleaner housing of FIG. 1;
- FIG. 6 is an end elevational view of one embodiment of a cup of the air cleaner housing shown in FIG. 1;
- FIG. 7 is a cross-sectional view of the cup depicted in FIG. 6 taken along the line 7 - 7 of FIG. 8;
- FIG. 8 is an opposite end elevational view of the cup depicted in FIG. 6;
- FIG. 9 is a cross-sectional view of one embodiment of a body member of the air cleaner housing depicted in FIG. 1 taken along the line 9 - 9 of FIG. 2;
- FIG. 10 is an exploded, perspective view of one embodiment of a secondary filter element usable in the air cleaner depicted in FIG. 1, according to the principles of the present disclosure
- FIG. 11 is a schematic, perspective view of a portion of filter media usable in the media pack shown in FIGS. 2 and 3;
- FIG. 12 is a schematic, end view of the media pack depicted in FIGS. 2 and 3, according to principles of the present disclosure.
- FIG. 4 One particular type of system is depicted schematically in FIG. 4 generally at 700 .
- equipment 702 such as a vehicle, having an engine 703 with some defined rated air flow demand, for example at least 35 cfm, and typically 45-65 cfm is shown schematically.
- the equipment 702 may comprise a lawn tractor, golf cart, power boat, or other powered equipment.
- the engine 703 powers the equipment 702 , through use of an air and fuel mixture.
- air flow is shown drawn into the engine 703 at an intake region 705 .
- An air cleaner 710 having a filter construction 712 and a secondary element 713 is upstream of the engine 703 .
- the air cleaner 710 can be constructed to have a resonator 706 integral therewith to reduce the sound pressure level exiting the system 700 upon which the air cleaner 710 is installed.
- air is drawn in at arrow 714 into the air cleaner 710 and through the primary element 712 and the secondary element 713 . There, particles and contaminants are removed from the air.
- the cleaned air flows downstream at arrow 716 into the intake 705 . From there, the air flows into the engine 703 for use in powering the equipment 702 .
- FIGS. 1 - 3 illustrate an embodiment of an air cleaner, generally designated as reference no. 1 .
- the air cleaner 1 is usable in engine air intake systems, such as system 700 , described above.
- an air cleaner housing 2 is depicted.
- the air cleaner housing 2 holds or contains internal components for filtering or cleaning air that flows through the housing 2 .
- FIG. 2 is an exploded, perspective view of an assembly of the air cleaner 1 .
- the air cleaner 1 includes the housing 2 and an indicator system 5 .
- the housing 2 holds, or contains within it, a media pack 3 and a secondary element 6 .
- the media pack 3 has a filter construction 100 and a sealing system 4 .
- the air cleaner 1 depicted in FIG. 2 When the particular air cleaner 1 depicted in FIG. 2 is operably constructed and assembled together, the air cleaner 1 will have the cross-section as shown in FIG. 3.
- FIG. 3 By the term “operably,” it is meant that during use in the system 700 (FIG. 4), when the air cleaner 1 is removing particulate matter from an air stream, the air cleaner 1 will be configured and arranged as illustrated in FIG. 3.
- the housing 2 is constructed and arranged to act as a resonator 14 . As such, when air moves through the housing 2 , the resonator 14 will decrease the sound pressure level exiting the system 700 (FIG. 4).
- the optional indicator system 5 typically a conventional restriction indicator, is used with the air cleaner 1 , the indicator system 5 will provide an indication of when the media pack 3 is occluded and requires servicing.
- the media pack 3 When constructions of the type shown in FIG. 3 are used, the media pack 3 will be removable and replaceable from the housing 2 . After a period of use, when the media pack 3 is serviced, debris and contaminants may be knocked from the media pack 3 .
- the secondary element 6 operates to catch debris and contaminants and prevent these contaminants from being sucked into the engine.
- FIG. 1 A variety of embodiments of housings for the air cleaner 1 are possible.
- a preferred housing construction 2 is illustrated in perspective in FIG. 1.
- An exploded view of the housing 2 is shown in FIG. 2.
- the housing 2 preferably includes a body member or portion 12 and a cover or cup portion 13 . Attention is directed to FIG. 9.
- FIG. 9 is a cross-sectional view of the body 12 .
- the body 12 includes a first media chamber exterior wall 15 , a sealing chamber exterior wall 16 , a secondary element exterior wall 17 , and an outlet exterior wall 18 .
- the first media chamber exterior wall 15 will define a first media chamber 20 .
- the first media chamber 20 is configured for receiving, holding, and containing a portion of the media pack 3 . This can be seen in the cross-section of FIG. 3.
- the first media chamber exterior wall 15 will have a cross-sectional configuration selected by the system designer, based on space considerations, manufacturing techniques, and other factors.
- the first media chamber 20 is cylindrical, or has a slight frusto-conical shape, with a circular cross-section, having a first diameter D 1 and a first axial length L 1 .
- the use of the term “cylindrical” herein denotes a general shape. After demolding, during manufacture, a draft angle may cause the housing 2 to have a slight angle or frusto-conical shape rather than a cylindrical shape.
- the sealing chamber exterior wall 16 defines a sealing chamber 21 .
- the sealing chamber 21 defines a sealing surface 82 .
- the sealing surface 82 provides a rigid surface for receiving compression pressure of the sealing system 4 . This will be described in further detail below, in conjunction with the description of the sealing system 4 .
- the sealing chamber 21 is cylindrical with a circular cross-section having a second diameter D 2 and a second axial length L 2 .
- the sealing surface 82 in the particular embodiment shown, is an annular, radial sealing surface 82 .
- the diameter D 2 is smaller than the diameter D 1 of the first media chamber 20 .
- the body member 12 also defines a first seat 84 .
- the seat 84 is preferably configured for acting as a stop for properly positioning and orienting the media pack 3 within the body member 12 .
- the seat 84 includes a surface 85 angled relative to the sealing surface 82 .
- the surface 85 of the seat 84 can be angled between 60°-120°, typically 70-110°, and in the particular embodiment illustrated about 90°, relative to the sealing surface 82 .
- the stop surface 85 will axially engage, or abut, an end axial surface 86 (FIG. 3) of the sealing system 4 .
- the secondary element chamber 22 Adjacent to the stop surface 85 is a secondary element chamber 22 .
- the secondary element chamber 22 is defined by the secondary element exterior wall 17 .
- the secondary element chamber 22 has an inner wall 269 , which corresponds to an opposite side from the exterior wall 17 .
- the inner wall 269 acts as an engagement surface such that a portion of the secondary filter element 6 can be compressed thereagainst. This will be discussed in further detail below, in connection with the discussion of the secondary filter element 6 .
- the secondary element chamber 22 also includes a seat 86 for helping the proper orientation and positioning of the secondary filter element 6 in the body member 12 .
- the secondary filter element seat 86 has a surface 87 that will axially engage or abut an axial surface of the secondary filter element 6 .
- the stop surface 87 is angled relative to the engagement surface 269 , in order to provide the stopping or engagement purposes.
- the surface 87 can be angled relative to the engagement surface 269 in a range between about 60°-120°, typically 70°-110°, and in the particular embodiment illustrated, about 90°.
- the secondary element chamber 22 is cylindrical with a circular cross-section, which has a third diameter D 3 and a third axial length L 3 .
- D 3 is smaller than the diameter of D 2 (the sealing chamber 21 ) and D 1 (the diameter of first media chamber 20 ).
- the outlet exterior wall 18 is depicted as adjacent to the secondary element chamber 22 .
- the outlet exterior wall 18 defines an outlet 23 , through which air exits the air cleaner assembly 1 .
- the outlet 23 in the embodiment illustrated, is angled relative to the stop surface 87 by an angle of between 70-110°, and in the one shown in the drawing, about 90°.
- the outlet 23 is cylindrical with a fourth axial length L 4 and a circular cross-section of a fourth diameter D 4 .
- the first media chamber exterior wall 15 includes integral ridges or ribs 24 .
- the ribs 24 are continuous around the outside circumference of the first media chamber exterior wall 15 .
- the ribs 24 provide additional structural integrity or strength to the overall housing 2 .
- the ribs 24 are ornamental, eye-catching, and distinctive to Donaldson, the assignee.
- FIG. 7 is a cross-sectional view of the cup portion 13 of the housing 2 (FIG. 2).
- the cover or cup 13 includes a body chamber exterior wall 25 , a second media pack exterior wall 26 , and a top wall, or inlet, 27 .
- the body chamber exterior wall 25 defines a body chamber 30 arranged and configured to receive the body portion 12 (FIG. 2) of the housing 2 (FIG. 2).
- the first media pack exterior wall 15 of the body portion 12 is designed to fit within the body chamber 30 .
- the body chamber 30 is cylindrical and has a fifth diameter D 5 and a fifth axial length L 5 .
- the second media pack exterior wall 26 defines a second media pack chamber 31 arranged and configured to receive a portion of the media pack 3 (FIG. 2).
- the second media pack chamber 31 is cylindrical and has a sixth diameter D 6 and a sixth axial length L 6 .
- the top wall 27 secures the media pack 3 (FIG. 2) within the housing 2 (FIG. 2) and allows air to enter the air cleaner assembly 1 (FIG. 1) while preventing large objects, such as sticks, leaves, and butterflies, from entering the housing 2 .
- the cup portion 13 further includes a support structure 35 .
- the support structure 35 provides support for holding the media pack 3 (FIG. 2) placed within the housing 2 (FIG. 2) and prevents axial slippage of the media pack 3 during use.
- the support structure 35 is not in touchable engagement with the media pack 3 .
- a gap 106 having an eighth axial length of L 8 , exists between the media pack 3 and the support structure 35 . During use, this gap 106 helps distribute the inlet air stream 306 throughout the face 105 of the media pack 3 . During use, forces exerted on the air cleaner assembly 1 may cause the media pack 3 to vibrate loose.
- the media pack 3 may become dislodged from its sealing engagement, described in detail below, with the housing 2 .
- the support structure 35 prevents the media pack 3 from becoming completely dislodged and thereby ensures a sealing engagement between the media pack 3 and the housing 2 .
- the gap 106 may be partially filled with a ring or gasket (not shown) to ensure minimal axial slippage of the media pack 3 , thereby ensuring that the media pack 3 remains in sealing engagement with the housing 2 .
- the support structure 35 also helps to maintain an air space 37 between the top wall 27 of the cup portion 13 and the media pack 3 when assembled.
- the support structure 35 partially creates an expansion chamber 65 for sound, as will be discussed in more detail below.
- This air space 37 improves the air flow through the media pack 3 , as will be described in more detail below.
- the support structure 35 generally extends from the top wall 27 of the cup 13 into the second media pack chamber 31 a first distance K 1 .
- the support structure 35 comprises a plurality of fins or ribs 36 as illustrated in FIGS. 7 and 8 .
- FIG. 8 is an end elevational view of the inside of the cup portion 13 .
- the fins 36 extend from the top wall 27 of the cup 13 and typically are integral with the top wall 27 .
- the housing 2 includes a securing system 39 for securing the cup 13 to the body 12 .
- the securing system 39 includes first and second latches 42 , 43 . Latch connections such as those described in U.S. Pat. Nos. 5,547,480, 5,545,241, and Des. 399,119, incorporated herein by reference, can be used.
- the securing system 39 may include a twist lock mechanism as described in co-pending, commonly assigned, U.S. patent applications Ser. No. 08/928,684, filed Sep. 12, 1997, and Ser. No. 09/146,291, filed Sep. 3, 1998, entitled “Air Cleaner Assembly; and Method,” hereby incorporated by reference.
- the cup portion 13 includes first and second latch supports 40 , 41 .
- the latches 42 , 43 are mounted on the first and second latch supports 40 , 41 (FIG. 7).
- the body portion 12 also includes first and second latch extensions 44 , 45 .
- the latches 42 , 43 are designed to hook or latch the first and second latch extensions 44 , 45 to secure the cup 13 to the body 12 of the housing 2 .
- the body chamber 30 of the cup 13 is arranged and configured to receive the first and second latch extensions 44 , 45 .
- the body chamber exterior wall 25 includes first and second latch extension regions 46 , 47 , axially aligned with the latch supports 40 , 41 , respectively.
- the first and second latch extension regions 46 , 47 are arranged and configured to receive the first and second latch extensions 44 , 45 , respectively as illustrated in FIG. 1. In this manner, the first and second latch extension regions 46 , 47 and the first and second latch extensions 44 , 45 helps to ensure that the cup 13 is appropriately aligned with the body 12 prior to securing the cup 13 to the body 12 .
- the housing 2 further includes an optional radial alignment system 46 .
- the alignment system includes an alignment ridge, protrusion, or bump 48 on the body 12 and an alignment region or channel 47 in the body chamber 30 of the cup 13 .
- the alignment channel 47 is arranged and configured to receive the alignment ridge 48 .
- the alignment ridge 48 and the alignment channel 47 ensure that the cup can be oriented only in one direction with respect to the body member 12 . This ensures proper air flow through the air cleaner assembly 1 , as will be described in more detail below.
- the ridge 48 may be on the cup 13 , while the channel 47 is on the body member 12 .
- FIG. 6 is an end elevational view of one embodiment of the cup portion 13 of the air cleaner assembly 1 shown in FIG. 1.
- the top wall 27 defines an inlet arrangement 27 a for intaking air flow into the housing 2 .
- the inlet arrangement 27 a will include a radial diffuser 49 for distributing the air flow through the media pack 3 (FIG. 2).
- the radial diffuser 49 comprises a plurality of slots 50 .
- the slots 50 allow a fluid, such as air, to enter the air cleaner assembly 1 (FIG. 1) while restricting large objects, such as sticks, from entering the air cleaner assembly 1 .
- the slots 50 are designed for efficient air flow through the air cleaner assembly 1 .
- the slots are diverging-converging openings or tear shaped.
- tear shaped it is meant that the slots 50 have a wider opening at a first end 51 than at a second end 52 .
- the wider opening at the first end 51 allows more air to enter the assembly 1 around the outer circumference of the assembly 1 .
- the narrower opening at the second end 52 restricts the air entering the assembly 1 near the center of the assembly 1 .
- Each of the slots 50 is tapered from the wider opening at the first end 51 , down toward the opening at the second end 52 .
- This particular arrangement improves air flow and filtration capacity since a larger surface area of media exists at the outer circumference of the media pack 3 (FIG. 2) than at the center of the media pack 3 . By directing a larger volume of air around the outer circumference of the media pack 3 , greater filtration capacity is achieved.
- the slots 50 are placed in generally the upper half 90 of the top wall 27 of the cup 13 .
- upper half it is meant that when the air cleaner assembly 1 is installed in the system 700 (FIG. 4), the top wall 27 will be arranged to be within a vertical plane such that the top wall 27 will have an upper half with a higher vertical elevation than a lower half 91 of the top wall 27 .
- the air cleaner assembly 1 is oriented such that the slots 50 align with an opening (not shown) in a shroud or hood of equipment for which the air cleaner assembly 1 is designed.
- the hood of the garden tractor contains an opening for air flow.
- the air cleaner assembly 1 is mounted within the hood such that the slots 50 of the cup 13 generally align with the opening in the hood of the garden tractor. This ensures maximum air flow through the air cleaner assembly 1 .
- the top wall 27 includes an arrow 55 and the word “top” 56 to ensure proper orientation by the user of the air cleaner assembly 1 with the openings in the hood of the garden tractor.
- the housing 2 includes the alignment system 46 previously discussed to ensure proper orientation.
- the slots 50 are arranged in a semi-circular array, with each of the slots extending radially from a center 77 of the top wall 27 toward the outer periphery 78 of the top wall 27 .
- the top wall 27 includes a drain hole 60 near the lower half of the top wall 27 of the cup 13 .
- the drain hole 60 allows any liquid, such as water or water condensation, that may enter the air cleaner assembly 1 , to drain out of the air cleaner assembly 1 through the drain hole 60 .
- the alignment system 46 helps to ensure that the drain hole 60 is oriented at or near the bottom of the air cleaner 1 .
- the particular body 12 and cup 13 depicted are preferred for the housing 2 , many different embodiments are possible.
- the embodiment depicted, however, is particularly convenient for manufacturing techniques, such as injection molding.
- the particular housing 2 depicted is preferred because it is attractive in appearance, eye-catching, and distinctive to Donaldson, the assignee.
- Further views of the housing 2 are depicted in co-pending and commonly assigned U.S. patent application Ser. No. ______, filed the same date herewith, and entitled, “In-line Air Cleaner,” which application is incorporated by reference herein.
- the housing 2 is constructed and arranged to act as a resonator 14 . That is, in preferred constructions, the housing 2 is constructed and arranged to reduce the sound pressure level exiting the system 700 (FIG. 4).
- the resonator 14 will reduce the sound pressure level by at least 1 dB(A), typically between 1.5 and 3 dB(A), when compared to an air cleaner with an open end; that is, an air cleaner where an end of a media pack is not covered by a portion of a housing of the air cleaner.
- This sound pressure level decrease can be measured with equipment such as a Larson Davis Real Time Analyzer, with the microphone mounted about 30 inches above the seat of the equipment, such as a garden tractor. Alternatively, equipment such as an Aachen Head can be used, again, with the simulated head mounted about 30 inches above the seat of the equipment.
- FIG. 3 is a cross-sectional view of the assembled air cleaner assembly 1 of FIG. 1.
- the length L 7 of an expansion chamber 65 which includes both the first and second media pack chambers 20 , 31 (FIGS. 7 and 9) of the body 12 and the cup 13 , respectively, and the inlet 27 are constructed and arranged to act as the resonator 14 .
- L 7 extends between the inlet wall 27 and the first seat surface 86 .
- the overall length L 7 of the expansion chamber 65 is equal to the speed of sound divided by 4 times the frequency desired to be removed by the resonator 14 .
- This particular length L 7 of the expansion chamber 65 causes the sounds waves to bounce back and forth, canceling each other, according to sound pressure principles commonly known.
- the frequency desired to be removed by the resonator 14 is dependent on the particular source impedance of the downstream equipment. For example, a Yanmar, twin cylinder diesel engine operating at rated conditions and having a 20 horsepower rating, has a predominate source strength frequency at 500 hertz. Knowing this source strength frequency, the length L 7 of the expansion chamber 65 is determined.
- a ratio of the length L 7 of the expansion chamber 65 to the open area equivalent diameter of the inlet 27 is between about 4.5 and 5.0, for example about 4.7.
- a ratio of the length L 7 of the expansion chamber 65 to the largest outermost sectional dimension (in the particular illustrated embodiment, diameter) is at least 1.5, and typically between about 1.75 and 2.00, for example, about 1.8.
- the inlet arrangement 27 a is arranged and constructed to have an opening that has a smaller cross-sectional area than the opening of the outlet chamber 23 .
- the smaller cross-sectional area of the inlet 27 a acts to restrict the sound from exiting the inlet 27 a .
- the inlet 27 a has a cross-sectional area that is at least 3 percent smaller than the cross-sectional area of the outlet 23 , and typically between 5 and 10 percent smaller.
- the expansion chamber 65 reduces, within the space constraints, the radiated sound of the predominate source strength frequency through the inlet 27 by destructive interference. Sound waves with frequencies above a few hundred Hertz are further attenuated by acoustic attenuation within the media pack 3 , according to sound absorption principles commonly known. The configuration thus provides effective broadband sound absorption and attenuation.
- the expansion chamber 65 is cylindrical and has a diameter about at least 80 percent, and typically 100 to 250 percent larger than the largest cross-sectional dimension (in this case, diameter) of the outlet 23 .
- non-internal tube construction 93 within the interior of the housing 2 between the media pack 3 and the outlet 23 .
- non-internal tube construction it is meant that there are no internal tubular structures for sound attenuation mounted within the housing 2 .
- the housing 2 is constructed and arranged to attenuate sound with the resonator 14 without any additional tubes located therewithin.
- the entire housing 2 includes a non-internal tube construction 94 , in that there are no acoustic tubes located anywhere within the housing interior. While there is a negative cylinder at 95 for supporting the fins 36 , the negative cylinder 95 does not act as a acoustic tube, and is not within the definition of “non-internal tube construction.”
- the resonator 14 is designed to reduce the sound pressure levels exiting the air cleaner assembly 1 without the use of baffles, absorptive packing material, sonic chokes, or other sound attenuating devices.
- the sound pressure level reduction is achieved by the housing 2 consisting essentially of only the structure as described previously herein.
- the filter construction 100 depicted is designed to remove particulates from a fluid, such as air, passing through the filter construction 100 , while the sealing system 4 is designed to seal the media pack 3 against the sealing chamber exterior wall 16 of the housing 2 , as shown in FIG. 3.
- seal it is meant that the sealing system 4 , under normal conditions, prevents unintended levels of fluid from passing through a region between the media pack 3 and the sealing chamber exterior wall 16 of the housing 2 ; i.e., the sealing system 4 inhibits fluid flow from avoiding passage through the media pack 3 .
- the media pack 3 will be configured for straight-through flow.
- straight-through flow it is meant that the media pack 3 is configured in a construction 100 with a first flow face 105 (corresponding to an inlet end, in the illustrated embodiment) and an opposite, second flow face 110 (corresponding to an outlet end, in the illustrated embodiment), with fluid flow entering in one direction 114 through the first flow face 105 and exiting in the same direction 116 from the second flow face 110 .
- an inline-flow housing such as the housing 2 of FIG.
- the fluid will enter through the inlet of the housing in one direction 306 , enter the filter construction 100 through the first flow face 105 in the same direction, exit the filter construction 100 in the same direction from the second flow face 110 , and exit the housing through the housing outlet 11 also in the same direction 307 .
- first flow face 105 is described above as corresponding to an inlet end
- second flow face 110 is described above as corresponding to an outlet end
- the inlet and outlet ends can be reversed. That is, the first flow face 105 depicted in FIG. 2 can correspond to an outlet end, while the second flow face 110 depicted in FIG. 2 can correspond to an inlet end.
- first flow face 105 and the second flow face 110 are depicted as planar and as parallel. In other embodiments, the first flow face 105 and the second flow face 110 can be non-planar, for example, frusto-conical. Further, the first flow face 105 and second flow face 110 need not be parallel to each other.
- the filter construction 100 will be a wound construction. That is, the construction 100 will typically include a layer of filter media that is turned completely or repeatedly about a center point. Typically, the wound construction will be a coil, in that a layer of filter media will be rolled a series of turns around a center point. In arrangements where a wound, coiled construction is used, the filter construction 100 will be a roll of filter media, typically permeable fluted filter media.
- FIG. 11 is schematic, perspective view demonstrating the principles of operation of certain media usable in the filter constructions herein.
- a fluted construction is generally designated at 122 .
- the fluted construction 122 includes: a layer 123 of corrugations having a plurality of flutes 124 and a face sheet 132 .
- the FIG. 11 embodiment shows two sections of the face sheet 132 , at 132 A (depicted on top of the corrugated layer 123 ) and at 132 B (depicted below the corrugated layer 123 ).
- the media construction 125 used in arrangements described herein will include the corrugated layer 123 secured to the bottom face sheet 132 B.
- this media construction 125 When using this media construction 125 in a rolled construction, it typically will be wound around itself, such that the bottom face sheet 132 B will cover the top of the corrugated layer 123 .
- the face sheet 132 covering the top of the corrugated layer is depicted as 132 A. It should be understood that the face sheet 132 A and 132 B are the same sheet 132 .
- the flute chambers 124 form alternating peaks 126 and troughs 128 .
- the troughs 128 and peaks 126 divide the flutes into an upper row and lower row.
- the upper flutes form flute chambers 136 closed at the downstream end, while flute chambers 134 , having their upstream end closed, form the lower row of flutes.
- the fluted chambers 134 are closed by a first end bead 138 that fills a portion of the upstream end of the flute between the fluting sheet 130 and the second facing sheet 132 B.
- a second end bead 140 closes the downstream end of alternating flutes 136 .
- both the first end bead 138 and second end bead 140 are straight along all portions of the media construction 125 , never deviating from a straight path.
- the first end bead 138 is both straight and never deviates from a position at or near one of the ends of the media construction 125
- the second end bead 140 is both straight and never deviates from a position at or near one of the ends of the media construction 125 .
- the flutes 124 and end beads 138 , 140 provide the media construction 125 that can be formed into filter construction 100 and be structurally self-supporting without a housing.
- unfiltered fluid such as air
- the flute chambers 136 have their upstream ends 146 open.
- the unfiltered fluid flow is not permitted to pass through the downstream ends 148 of the flute chambers 136 because their downstream ends 148 are closed by the second end bead 140 . Therefore, the fluid is forced to proceed through the fluting sheet 130 or face sheets 132 .
- the unfiltered fluid passes through the fluting sheet 130 or face sheets 132 , the fluid is cleaned or filtered. The cleaned fluid is indicated by the unshaded arrow 150 .
- the fluid then passes through the flute chambers 134 (which have their upstream ends 151 closed) to flow through the open downstream end 152 (FIG. 12) out the fluted construction 122 .
- the unfiltered fluid can flow through the fluted sheet 130 , the upper facing sheet 132 A, or lower facing sheet 132 B, and into a flute chamber 134 .
- the media construction 125 will be prepared and then wound to form the rolled filter construction 100 (FIGS. 3 and 12) of filter media.
- the media construction 125 prepared includes the sheet of corrugations 123 secured with the end bead 138 to the bottom face sheet 132 B (as shown in FIG. 11, but without the top face sheet 132 A).
- the media construction 125 will include a leading edge at one end and a trailing edge at the opposite end, with a top lateral edge and a bottom lateral edge extending between the leading and trailing edges.
- leading edge it is meant the edge that will be initially turned or rolled, such that it is at or adjacent to the center or core of the rolled construction.
- the “trailing edge” will be the edge on the outside of the rolled construction, upon completion of the turning or coiling process.
- the leading edge and the trailing edge should be sealed between the corrugated sheet 123 and the bottom face sheet 132 B, before winding the sheet into a coil, in these types of media constructions 125 .
- the seal at the leading edge is formed as follows: (a) the corrugated sheet 123 and the bottom face sheet 132 B are cut or sliced along a line or path extending from the top lateral edge to the bottom lateral edge (or, from the bottom lateral edge to the top lateral edge) along a flute 124 forming a peak 126 at the highest point (or apex) of the peak 126 ; and (b) sealant is applied between the bottom face sheet 132 B and the sheet of corrugations 123 along the line or path of cut.
- the seal at the trailing edge can be formed analogously to the process of forming the seal at the leading edge. While a number of different types of sealant may be used for forming these seals, one usable material is a non-foamed sealant available from H. B. Fuller of St. Paul, Minn., identified under the designation HL0842.
- FIG. 12 is a schematic, end view of the media pack 3 .
- the media construction 125 may be wound about a center mandrel or other element to provide a mounting member for winding.
- the center mandrel may be removed or left to plug to act as a core at the center of the cylindrical filter construction 100 .
- non-round center winding members may be utilized for making other filtering construction shapes, such as filter constructions having an oblong, oval, rectangular, or racetrack-shaped profile, and can be usable in filtering systems herein.
- filter constructions with non-circular (as well as circular) cross-sections are described in co-pending, commonly assigned, U.S. patent application Ser. No. ______, entitled, “Filter Arrangement; Sealing System; and Methods,” filed the same date herewith, and herein incorporated by reference. Further view of various filter constructions that may be usable herein are depicted in copending and commonly assigned U.S. patent application Ser. No. ______, filed the same day herewith, and entitled, “Filter Element Having Sealing System,” herein incorporated by reference.
- the media construction 125 can also be wound without a mandrel or center core.
- One method of forming a coreless rolled construction is as follows: (a) the troughs 128 of the first few corrugations of the corrugated sheet 123 spaced from the leading edge are scored from the top lateral edge to the bottom lateral edge (or from the bottom lateral edge to the top lateral edge); for example, the first four corrugations from the leading edge will have a score line cut along the troughs 128 ; (b) the bead 140 of sealant is applied along the top of the sheet of corrugation 123 along the lateral edge opposite from the lateral edge having end bead 138 ; (c) the leading edge is initially turned or rolled over against itself and then pinched together to be sealed with the sealant bead 140 ; and (d) the remaining corrugated sheet 123 having the bottom face sheet 132 B secured thereto is coiled or rolled or turned around the pinched leading edge.
- coreless constructions can be made from the media construction 125 by automated processes, as described in U.S. Pat. Nos. 5,543,007 and 5,435,870, each incorporated by reference herein.
- the media construction can be rolled by hand.
- the system designer will want to ensure that the outside periphery of the construction 100 is closed or locked in place to prevent the filter construction 100 from unwinding.
- the outside periphery is wrapped with a periphery layer.
- the periphery layer can be a non-porous, adhesive material, such as plastic with an adhesive on one side.
- the periphery layer prevents the filter construction 100 from unwinding and prevents the fluid from passing through the outside periphery of the filter construction 100 , maintaining straight-through flow through the filter construction 100 .
- the filter construction 100 is secured in its rolled construction by sealing the trailing edge of the media construction 125 with an adhesive or sealant along a line 179 (FIG. 2) to secure the trailing edge to the outside surface of the filter construction 100 .
- a bead of hot-melt may be applied along the line 179 .
- FIG. 12 Attention is again directed to FIG. 12.
- the second flow face 110 is shown including the open ends 152 and closed ends 148 .
- Top and bottom plan views, as well as side elevational views of the media pack 3 and the sealing system 4 usable in the systems and arrangements described herein are depicted in copending and commonly assigned U.S. patent application Ser. No. ______, filed the same day herewith, and entitled, “Filter Element Having Sealing System,” herein incorporated by reference.
- the media pack 3 is shown installed in a housing 2 .
- sealing system 4 will be needed to ensure that air flows through the media pack 3 , rather than bypass it.
- the particular sealing system 4 depicted includes a frame construction 170 and a seal member 250 .
- the frame construction 170 provides a support structure or backing against which the seal member 250 can be compressed to form a radial seal 172 with the housing 2 .
- FIG. 2 is a schematic, perspective view of the sealing system 4 ;
- FIG. 3 is a schematic, cross-sectional view of the media pack 3 installed in the housing 2 ;
- FIG. 12 is a schematic, end view of the sealing system 4 and the media pack 3 .
- the frame construction 170 will include a frame 205 .
- the frame 205 may be a variety of shapes. In the particular embodiment illustrated in FIG. 3, the shape of the frame 205 is generally circular.
- the frame 205 depicted in FIG. 3 is convenient in that it is arranged and configured for attachment to the second flow face 110 (FIG. 2) of the filter construction 100 .
- the frame 205 has a band, skirt, or depending lip 251 that is generally circular and has an inside diameter. Preferably, the inside diameter is approximately equal to the outside diameter of the filter construction 100 .
- the depending lip 251 depends or extends down a first distance from a bottom 252 surface of cross braces 210 (FIG. 12).
- the depending lip 251 is arranged and configured to extend radially around the second flow face 110 the filter construction 100 .
- the depending lip 251 extends radially around the second flow face 110 of the filter construction 100 , such that the depending lip 251 extends inboard the first distance of the second flow face 110 of the filter construction 100 , defining an overlap region 255 .
- the frame 205 is preferably secured to the filter construction 100 .
- a variety of ways to secure the frame 205 to the filter construction 100 are possible.
- One particularly preferred way to secure the frame 205 to the filter construction 100 is by use of an adhesive.
- the adhesive is oriented in the overlap region 255 between the depending lip 251 and the filter construction 100 .
- the adhesive permanently affixes the frame 205 to the filter construction 100 while preventing the fluid from leaking out through the overlap region 255 between the filter construction 100 and the frame 205 .
- the frame 205 may be temporarily attached to the filter construction 100 .
- temporary it is meant that the frame 205 may be removed from the filter construction 100 without damaging either the sealing system 4 or the filter construction 100 .
- Cross braces 210 support the frame 205 .
- support it is meant that the cross braces 210 prevent the frame 205 from radially collapsing under the forces exerted around the circumference of the frame 205 .
- the particular frame construction 205 depicted preferably includes a tip portion 263 , or annular sealing support.
- the tip portion 263 is generally circular and is arranged and configured for insertion into the housing 2 .
- the tip portion 263 defines an inside diameter.
- the frame 205 includes a step 253 .
- the step 253 provides a transition area between the larger inside diameter of the depending lip 251 and the smaller inside diameter of the tip portion 263 .
- the tip portion 263 provides support for the compressible seal member 250 .
- the compressible seal member 250 is preferably constructed and arranged to be sufficiently compressible to be compressed between the tip portion 263 of the frame 205 and a sidewall 260 of the housing 2 .
- a radial seal 172 is formed between the media pack 3 and the sidewall 260 of the housing 2 .
- a variety of ways are possible to secure the seal member 250 to the tip portion 263 .
- One particularly convenient and preferred way is by molding the seal member 250 to engage, cover, or overlap both the outer radial side 271 of the tip portion 263 and the inner radial side 270 of the tip portion 263 , including the end tip 180 .
- One particular embodiment of this configuration is depicted in FIG. 3.
- the seal member 250 completely covers the tip portion 263 .
- the tip portion 263 of the frame 205 defines a wall or support structure between and against which the radial seal 172 may be formed by the compressible seal member 250 .
- the compression of the compressible seal member 250 at the sealing system 4 is preferably sufficient to form a radial seal under insertion pressures of no greater than 80 pounds, typically, no greater than 50 pounds, for example, about 20-30 pounds, and light enough to permit convenient and easy change out by hand.
- the amount of compression of the compressible seal member 250 is at least fifteen percent, preferably no greater than forty percent, and typically between twenty and thirty-three percent.
- amount of compression it is meant the physical displacement of an outermost portion of the seal member 250 radially toward the tip portion 263 as a percentage of the outermost portion of the seal member 250 in a resting, undisturbed state and not installed within a duct or subject to other forces.
- FIG. 5 is an enlarged schematic, fragmented view of a particular preferred seal member 250 in an uncompressed state.
- the seal member 250 has a stepped cross-sectional configuration of decreasing outermost dimensions (diameter, when circular) from a first end 264 to a second end 265 , to achieve desirable sealing.
- Preferred specifications for the profile of the particular arrangement shown in FIG. 5 are as follows: a polyurethane foam material having a plurality of (preferably at least three) progressively larger steps configured to interface with the sidewall 260 (FIG. 3) and provide a fluid-tight seal.
- the compressible seal member 250 defines a gradient of increasing internal diameters of surfaces for interfacing with the sidewall 260 .
- the compressible seal member 250 defines three steps 266 , 267 , 268 .
- the cross-sectional dimension or width of the steps 266 , 267 , 268 increases the further the step 266 , 267 , 268 is from the second end 265 of the compressible seal member 250 .
- the smaller diameter at the second end 265 allows for easy insertion into a duct or housing, such as the housing 2 of FIG. 3.
- the larger diameter at the first end 264 ensures a tight seal.
- the compressible seal member 250 needs to be compressed when the element is mounted in the housing 2 (FIG. 3). In many preferred constructions, it is compressed between about fifteen percent and forty percent (often about twenty to thirty-three percent) of its thickness, in the thickest portion, to provide for a strong robust seal, yet still be one that can result from hand installation of the element with forces on the order of 80 pounds or less, preferably 50 pounds or less, and generally 20-30 pounds.
- the media pack 3 and sealing system 4 can be arranged and configured to be press-fit against the sidewall 260 of the housing 2 or duct.
- the compressible seal member 250 is compressed between the sidewall 260 and the tip portion 263 of the frame 205 . After compression, the compressible seal member 250 exerts a force against the sidewall 260 as the compressible seal member 250 tries to expand outwardly to its natural state, forming the radial seal 172 between and against the tip portion 263 and the sidewall 260 .
- the media pack 3 also includes a retention system 280 for retaining the secondary element 6 (FIG. 3) within the secondary element chamber 22 (FIG. 3). Stated in other words, the retention system 280 prevents the secondary element from axially slipping out of the secondary element chamber 22 within the housing 2 (FIG. 3).
- the retention system 280 includes first, second, and third retention extensions 281 , 282 , 283 .
- the retention extensions 281 , 282 , 283 are integral with the compressible seal member 250 of the sealing system 4 .
- the retention extensions 281 , 282 , 283 radially extend toward the center of the media pack 3 as illustrated. While a variety of configurations are contemplated, the particular embodiment illustrated shows the retention extensions 281 , 282 , 283 as having a semi-oval or quarter-moon cross-sectional shape.
- the retention extensions 281 , 282 , 283 are configured and arranged to touchably engage the secondary element 6 within the housing 2 .
- the second retention extension 282 is illustrated in FIG. 3 radially extending toward the center of the media pack 3 overlapping with an outside edge 285 of a frame construction 402 of the secondary element 6 .
- the second retention extension 282 extends in overlapping engagement with the outside edge 285 of the secondary element 6 such that there is axial abutment between the retention extension 282 and a frame of the secondary element 6 . This ensures that the secondary element 6 is locked or secured within the secondary element chamber 22 and prevented from axially slipping within the housing 2 .
- the first and third extensions 281 , 283 likewise, touchably engage and axially abut the frame of the secondary element 6 to retain the secondary element 6 within the secondary element chamber 22 . As such, the secondary element 6 will be trapped between the stop surface 87 and the first, second, and third retention extensions 281 , 282 , and 283 .
- the retention extensions may be of other sizes or shapes, and the retention system 280 may include other numbers of retention extensions.
- the particular arrangement depicted is preferred in that it lends itself to convenient manufacturing techniques and is ornamental, eye-catching, and attractive.
- FIG. 10 depicts an exploded, perspective view of the secondary element 6 , shown in the air cleaner 1 of FIGS. 2 and 3.
- the secondary element 6 includes a frame construction 402 and a region of media 404 .
- the frame construction 402 is usable for holding and supporting the region of media 404 .
- the media 404 is for removing at least some particulates from a gas stream (that is, particulates having a smallest outermost dimension that is larger than a largest pore size of the media 404 ).
- the media 404 can be used to remove particulates from air being taken into an engine.
- the media 404 preferably is constructed and arranged to introduce little restriction into the air intake duct.
- the secondary element 6 including the media 404 in some arrangements, will have a restriction of no more than two inches of water, preferably no more than one inch of water.
- the region of media 404 within the periphery of the frame construction 402 in the embodiment depicted in FIG. 10, is nonpleated and noncylindrical. Further, in the particular FIG. 10 embodiment, the region of media 404 is nonwoven and comprises not more than a single layer.
- the particular type of media 404 depicted in FIG. 10 includes a region of depth media, such as fibrous media.
- the media 404 When media 404 of the type depicted in FIG. 10 is assembled in the frame construction 402 depicted in FIG. 10, the media 404 will include a filtering portion 406 and a skirted portion 408 as illustrated in FIG. 2.
- the filtering portion 406 will operate to remove contaminants and particulates having a size (i.e., smallest outermost dimension) greater than the pore size of the media 404 from an air or gas stream passing therethrough.
- the filtering portion 406 will remove about 50% of dust particles having an average particle size (smallest outermost dimension) of less than 1-10 microns passing therethrough.
- the skirted portion 408 preferably operates to cooperate with an annular surface of a duct, such as the secondary element chamber interior wall 269 to occupy or fill a volume between the wall 269 and the secondary element 6 and create a “sealing effect.”
- aling effect it is meant that high restriction is introduced in the volume between the periphery of the frame construction 402 and an inner wall portion 269 of the housing 2 ; while some air or gas may be allowed to pass through the region between an outer periphery of the frame construction 402 and the annular surface of the housing 2 , the air or gas that does pass through, for the most part, will pass through the media in the skirted portion 408 . This is described further below.
- the particular frame construction 402 depicted in FIG. 10 includes an outer periphery 410 .
- the outer periphery 410 defines a perimeter area 412 therewithin.
- the perimeter area 412 comprises the entire region within the outer periphery 410 .
- the outer periphery 410 may have a variety of shapes. In the particular embodiment shown in FIG. 10, the outer periphery 410 is circular. In the particular embodiment of FIG. 10, the perimeter area 412 would include everything within the circular periphery 410 and can be calculated by squaring the radius of the circular outer periphery 410 and multiplying it by pi ( ⁇ ).
- the filtering portion 406 occupies or fills the entire perimeter area 412 (FIG. 10).
- the skirted portion 408 extends outside of the outer periphery 412 and is not part of the perimeter area 410 .
- the skirted portion 408 extends both outside and radially projects from the outer periphery 412 .
- the media 404 FIG. 10
- the media 404 FIG. 10
- the frame construction 402 is a multi-piece construction.
- the frame construction 402 is a two-piece construction.
- the frame construction 402 includes first and second frame pieces 416 , 418 .
- the first and second frame pieces 416 , 418 preferably are constructed and arranged to hold the media 404 within the housing 2 , while providing sufficient structural integrity to prevent collapse under air pressure.
- the first and second frame pieces 416 , 418 include a locking arrangement 420 , constructed and arranged to permit the first and second pieces 416 , 418 to lock, or fit, or snap, or matably engage together.
- the locking construction or arrangement 420 holds the region of media 404 between the first and second frame pieces 416 , 418 to securely hold the media 404 in place and under sufficient tension to minimize the restriction through the media 404 .
- the locking arrangement 420 includes a bead and recess system. That is, preferably, at least one of the first and second frame pieces 416 , 418 has a projection, such as a bead, while the other of the first and second frame pieces 416 , 418 has a cooperating recess or indent for receiving the bead.
- the first frame piece 416 defines a recessed portion 422
- the second frame piece 418 defines a projection or bead member 424 for projecting or snapping therein.
- the frame construction 402 will include a handle system for permitting the convenient installation and removal of the secondary element 6 from the housing 2 .
- a handle system for permitting the convenient installation and removal of the secondary element 6 from the housing 2 .
- Many different types of handle systems may be implemented.
- FIG. 10 One particularly preferred embodiment of a handle system is illustrated in FIG. 10.
- the first frame piece 416 includes a first handle construction 440 .
- the first handle construction 440 includes a plurality of ribs 442 radially extending from the first region 444 of the first frame piece 416 .
- the ribs 442 intersect at a center frame member 446 .
- the ribs 442 and center frame member 446 provide structure for a user to grasp when handling the secondary element 6 , for example when changing out the secondary element 6 .
- the first handle construction 440 including the ribs 442 and center frame member 446 also provide support structure to the frame construction 402 .
- the frame construction 402 should have sufficient structural integrity to prevent collapse under air intake pressures, that can typically range from at least 25 in. of water, and can be up to 100 inches of water.
- the first handle construction 440 helps to maintain sufficient tension in the media 404 to minimize the restriction through the media 404 .
- the second frame piece 418 includes a second handle construction 450 .
- the second handle construction 450 includes a plurality of ribs 452 radially extending from a second region 454 of the first frame piece 418 .
- the ribs 452 intersect at a center frame member 456 .
- the ribs 452 and center frame member 456 provide structure for a user to grasp when handling the secondary element 6 .
- the second handle construction 450 including the ribs 452 and center frame member 456 also provide support structure to the frame construction 402 .
- the frame construction 402 should have sufficient structural integrity to prevent collapse under air intake pressures, that can typically range from at least 25 in. of water, and can be up to 100 inches of water.
- the second handle construction 450 helps to maintain sufficient tension in the media 404 to minimize the restriction through the media 404 .
- additional structure may be attached to the frame construction 402 to allow for the convenient installation and removal of the secondary element 6 from the housing 2 .
- both the first and second frame pieces 416 , 418 include handle constructions 440 , 450 , the secondary element 6 is reversible.
- reversible it is meant that the secondary element 6 may be installed in the housing 2 with either the first frame piece 416 or the second frame piece 418 in the most upstream position (alternatively stated, the first frame piece 416 or the second frame piece 418 may be installed in the most downstream position).
- the media construction 404 will deflect in the proper orientation and occupy to fill the space between the periphery of the frame construction 402 and the wall 269 , when the secondary element 6 is inserted.
- FIG. 3 Attention is directed to FIG. 3.
- the secondary element 6 is depicted installed in the housing 2 .
- the skirt 408 fills the volume between the inner wall 269 of the housing 2 and the frame construction 402 .
- the skirted portion 408 of the media 404 is preferably constructed and arranged to be sufficiently compressible to be compressed between the frame construction 402 and the inner wall 269 of the housing 2 .
- sealing effect 460 or media-stuffed volume or media-filled region, is formed for the secondary element 6 with the housing 2 .
- the sealing effect 460 is formed between the secondary element 6 and the inner wall 269 .
- the sealing effect 460 is formed by compressing the skirted portion 408 of the media 404 between and against the frame construction 402 and the inner wall 269 .
- the compression of the media 404 at the skirted portion 408 in preferred systems, will be preferably sufficient to form the sealing effect 460 under pressures of up to 100 in. of water, and light enough to permit convenient and easy change out by hand.
- the compression of the skirted portion 408 to form the media-occupied volume or region is at least 70%, preferably no greater than 90%, and typically between 75-85%.
- the sealing effect 460 can be created by applying typically under 5 pounds of force, and ranging between 1-20 pounds.
- the air cleaner assembly 1 includes the restriction indicator 5 for providing an indication to an user of the air cleaner assembly 1 of the restriction across the media pack 3 of the air cleaner assembly 1 .
- the restriction indicator 5 is designed to provide the user with an indication of when the media pack 3 needs to serviced or replaced.
- the restriction indicator 5 includes an outlet extension 800 , an indicator tube 801 , and an indicator 802 .
- the outlet extension 800 extends from the outlet exterior wall 18 of the housing 2 and defines an indicator chamber 803 .
- the indicator chamber 803 is in communication with the outlet chamber 23 such that air moves through the indicator chamber 803 .
- the outlet extension 800 is integral with the outlet exterior wall 18 of the housing 2 .
- the indicator tube 801 connects the outlet extension 800 with the indicator 802 .
- the indicator tube 801 is in communication with the outlet extension 800 such that air passes through the indicator tube 801 therethrough to the indicator 802 .
- the indicator tube 801 is connected to the outlet extension 800 and the indicator 802 by conventional securing means, such as screwing the indicator tube 801 onto the outlet extension 800 .
- the indicator 802 measures the air pressure across the outlet chamber 23 .
- the air pressure reaches a predetermined level, for example 25 inches of water, the indicator 802 provides an indication to the user of the air cleaner assembly 1 that the media pack 3 needs servicing or replacement.
- the air cleaner assembly 1 does not include a restriction indicator.
- the user services or replaces the media pack 3 after a predetermined number of hours of use, for example 150 hours, or by visual inspection of the media pack 3 .
- the media pack 3 may have color, such as blue, to help the user determine the level of occlusion in the media pack 3 .
- the media packs described herein are removable and replaceable from whatever system in which they are installed.
- the media pack will be installed in an air cleaner housing, such as the one shown in FIGS. 1 - 3 .
- the media in the filter construction 100 will become occluded, and the restriction in the media pack 3 will increase.
- the media pack 3 will be periodically replaced to maintain the appropriate removal of particulates from a fluid, without introducing too high of a restriction.
- the restriction indicator 5 will provide information to the user regarding the appropriate time to change out the media pack 3 .
- the user will need access to the media pack 3 .
- the media pack 3 is installed in an air cleaner housing such as the housing 2 shown in FIGS. 1 - 3 .
- the user will unlatch the cover 13 from the body member 12 , and remove the cover 13 from the body member 12 . This will expose an opening 80 (FIG. 9) defined by the body member 12 .
- the user will grasp the media pack 3 and break the radial seal 172 formed by the media pack 3 against the sidewall 16 of the housing 2 .
- the seal member 250 and the housing 2 will be designed such that the user will need to exert a force of no more than about 80 pounds, preferably no more than 50 pounds, and in some applications between 20 and 30 pounds to break the radial seal 172 and remove the media pack 3 .
- the user will then pull the media pack 3 through the opening 80 formed by the body member 12 .
- the old media pack 3 may then be disposed of.
- the media pack 3 will be constructed of non-metallic materials, such that it is readily incineratable.
- the media pack 3 will comprise at least 95 percent, and typically at least 98 percent nonmetallic materials.
- the secondary element 6 may be serviced. It is contemplated that the secondary element 6 may not need servicing every time the media pack 3 is serviced.
- the user removes the secondary element 6 from the housing 2 by breaking the sealing effect 460 formed by the media 404 . More specifically, the user grasps the handle construction 440 of the frame construction 402 and removes the secondary element 6 from the housing 2 . This may be done by grasping the ribs 442 and center framework 446 and axially pulling the element 6 from the housing 2 by sliding it along the interior wall 269 of the secondary element chamber 22 of the housing 2 . As the secondary element 6 is being slid along the wall 269 of the housing 2 , the skirted portion 408 of the media 404 wipes the wall 269 to help clean the housing 2 .
- the secondary element 6 is removed from the housing 2 , either the entire secondary element 6 can be disposed of and replaced with a new one, or alternatively, only the media 404 is disposed of while the frame construction 402 is reused.
- the secondary element 6 is constructed of substantially metal free materials such that it is readily incineratable.
- the secondary element 6 comprises at least 95%, and more preferably 98-100% nonmetallic materials. If the entire secondary element 6 is disposed of, the old secondary element 6 can be incinerated.
- the secondary element 6 can be disassembled and the media 404 removed.
- the old filter media 404 would be disposed of, such as by incineration.
- the frame construction 402 could be recycled, or alternatively, re-used. If re-used, a new region of filter media 404 would be secured to the frame construction 402 .
- the first and second frame pieces 416 , 418 are removed or unlocked or unsnapped from each other.
- a screwdriver or other suitable tool may be used to pry the first frame piece 416 from the second frame piece 418 .
- the secondary element 6 is then reassembled. This may be done by placing a new region of media over the end portion 462 of the second frame piece 418 .
- the skirted portion 408 of the media should be extending outwardly from the second frame piece 418 .
- the first frame piece 416 can then be aligned with the second frame piece 418 and snapped or locked to the second frame piece 418 .
- the new secondary element 6 can then be installed in the housing 2 . This may be done by grasping the frame construction, such as the ribs 442 (FIG. 10) of the handle construction 440 (FIG. 10) and inserting it into the housing 2 . The secondary element 6 is inserted until the frame construction 402 axially engages or abuts the stop surface 87 . The skirted portion 408 (FIG. 2) of the filter element becomes compressed between and against the frame construction 402 and the inner wall 269 of the housing 2 to occupy or fill the volume therebetween and create a media-filled region 460 and a sealing effect.
- the frame construction such as the ribs 442 (FIG. 10) of the handle construction 440 (FIG. 10)
- the secondary element 6 is inserted until the frame construction 402 axially engages or abuts the stop surface 87 .
- the skirted portion 408 (FIG. 2) of the filter element becomes compressed between and against the frame construction 402 and the inner wall 269 of the housing 2
- the media pack 3 may also then be replaced within the housing 2 .
- the user grasps the media pack 3 and inserts it through an opening in the housing 2 .
- the media pack 3 is inserted into the opening until the retention extensions 280 , 281 , 283 of the retention system 280 touchably engage the secondary element 6 and until the seal member 250 is sufficiently compressed against the annular wall 16 of the housing 2 to form radial seal 172 between and against the housing wall 16 and the tip portion 263 of the frame 205 .
- the end tip 86 of the seal member 250 will usually axially abut the stop surface 85 of the seat 84 , when properly installed.
- the cover 13 is then oriented over the exposed end of the media pack 3 to cover the opening 80 .
- the cover 13 is then latched to the body member 12 by the latches 42 , 43 .
- the housing 2 can be constructed of plastic, such as glass-filled nylon.
- the media 122 can comprise cellulose.
- cellulose media with the following properties: a basis weight of about 45-55 lbs./3000 ft 2 (84.7 g/m 2 ), for example, 48-54 lbs./3000 ft 2 ; a thickness of about 0.005-0.015 in, for example about 0.010 in.
- frazier permeability of about 20-25 ft/min, for example, about 22 ft/min (6.7 m/min); pore size of about 55-65 microns, for example, about 62 microns; wet tensile strength of at least about 7 lbs/in, for example, 8.5 lbs./in (3.9 kg/in); burst strength wet off of the machine of about 15-25 psi, for example, about 23 psi (159 kPa).
- the cellulose media can be treated with fine fiber, for example, fibers having a size (fiber diameter) of 5 microns or less, and in some instances, submicron.
- fine fiber for example, fibers having a size (fiber diameter) of 5 microns or less, and in some instances, submicron.
- a variety of methods can be utilized for application of the fine fiber to the media. Some such approaches are characterized, for example, in U.S. Pat. No. 5,423,892, column 32, at lines 48-60. More specifically, such methods are described in U.S. Pat. Nos. 3,878,014; 3,676,242; 3,841,953; and 3,849,241, incorporated herein by reference.
- Another alternative is a trade secret approach comprising a fine polymeric fiber web positioned over conventional media, practiced under trade secret by Donaldson Company under the designation ULTRA-WEB®.
- the frame 205 (FIG. 3) of the sealing system 4 will be constructed of a material that will provide structural integrity and is not subject to creep.
- the frame 205 will be constructed of a non-metallic material such that it is environmentally friendly and either recyclable or readily incineratable.
- the frame 205 can be constructed from most plastics, for example, glass reinforced plastic.
- One usable reinforced plastic is propylene or nylon. Of course, other suitable materials may be used.
- the compressible seal member 250 can be made from a variety of materials. There is no particular preference, provided that the seal member 250 forms a seal in the proper location under compression.
- One usable material will be a soft polymeric material, such as foamed urethane.
- One example usable material includes foamed polyurethane, processed to an end product having an “as molded” density of fourteen to twenty-two pounds per cubic foot.
- Foamed polyurethanes are available from a variety of sources, such as BASF Corporation of Wyandotte, Mich.
- One example of a foamed polyurethane comprises a material made with I35453R resin and I305OU isocyanate, which is sold exclusively to the assignee Donaldson by BASF Corporation.
- the materials should be mixed in a mix ratio of 100 parts I35453 resin to 36.2 parts I305OU isocyanate (by weight).
- the specific gravity of the resin is 1.04 (8.7 pounds/gallon), and for the isocyanate it is 1.20 (10 pounds/gallon).
- the materials are typically mixed with a high dynamic shear mixer.
- the component temperatures should be seventy to ninety-five degrees Fahrenheit.
- the mold temperatures should be 115-135° Fahrenheit.
- the resin material I35453R has the following description:
- the frame construction 402 (FIG. 10) of the secondary element 6 will be constructed of a material that will provide structural integrity and is not subject to creep. Further, the frame construction 402 can be constructed of a non-metallic material such that it is environmentally friendly and either recyclable or readily incineratable.
- the frame construction can be constructed from most plastics, for example, glass reinforced plastic. One usable reinforced plastic is propylene or nylon.
- the media 404 (FIG. 10) for the secondary element 6 will be a media that will introduce little restriction into the duct.
- the media can be a nonpleated, noncylindrical, nonwoven media.
- the media can be depth media, such as a fibrous media.
- fibrous media usable in the system described above is as follows:
- the first diameter D 1 of the first media chamber 20 of FIG. 9 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in one example would be approximately 4.1 inches (about 10 cm).
- the first axial length L 1 of the first media chamber 20 will be between 2 inches (about 5 cm) and 5 inches (about 13 cm), and in one example would be approximate 3.7 inches (about 9 cm).
- the second diameter D 2 of the sealing chamber 21 of FIG. 9 will be between 2 inches (about 5 cm) and 5 inches (about 13 cm), and in one example would be approximately 3.7 inches (about 9 cm).
- the second axial length L 2 of the sealing chamber 21 will be between 0.5 inches (about 1 cm) and 2 inches (about 5 cm), and in one example would be approximately 0.8 inches (2 cm).
- the third diameter D 3 of the secondary element chamber 22 of FIG. 9 will be between 1.5 inches (about 4 cm) and 4.5 inches (about 11 cm), and in one example would be approximately 2.7 inches (about 7 cm).
- the third axial length L 3 of the secondary element chamber 22 will be between 0.4 inches (1 cm) and 1.5 inches (about 4 cm), and in one example would be approximately 0.6 inches (1.5 cm).
- the fourth diameter D 4 of the outlet 23 of FIG. 9 will be between 1 inch and 3 inches, and in one example would be approximately 1.5 inches (about 4 cm).
- the fourth axial length L 4 of the outlet 23 will be between 1 inch (2.5 cm) and 4 inches (about 10 cm), and in one example would be approximately 2.1 inches (about 5 cm).
- the fifth diameter D 5 of the body chamber 30 of FIG. 7 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in one example would be approximately 4.3 inches (about 11 cm).
- the fifth axial length L 5 of the body chamber 30 will be between 0.2 inches (0.5 cm) and 1 inch (2.5 cm), and in one example would be approximately 0.3 inches (about 1 cm).
- the sixth diameter D 6 of the second media chamber 31 of FIG. 7 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in one example would be approximately 4.1 inches (about 10 cm).
- the sixth axial length L 6 of the second media chamber 31 will be between 1 inch (2.5 cm) and 4 inches (about 10 cm), and in one example would be approximately 2.2 inches (about 6 cm).
- the seventh axial length L 7 of the overall media pack chamber 67 of FIG. 3 will be between 5 inches (about 13 cm) and 10 inches (about 25 cm), and in one example would be approximately 7.1 inches (18 cm).
- the eighth axial length L 8 of the gap 106 of FIG. 3 will be between 0.1 inches (about 0.5 cm) and 0.5 inches (about 1 cm), and in one example would be approximately 0.2 inches (0.5 cm).
- the first distance K 1 of the support structure 35 of FIG. 7 will be between 0.5 inches (about 1 cm) and 1.5 inches (about 4 cm), and in one example would be approximately 0.8 inches (2 cm).
- the filter construction 100 of FIG. 3 will provide at least 250 sq. in and typically 400-500 sq. in. for example about 450-460 sq. in. of media surface area. It will occupy a volume of no greater than about 200 in 3 , and typically between 50-100 in 3 , and for example about 65-75 in 3 .
Abstract
An air cleaner includes a housing having first and second opposite ends. A media pack is preferably oriented within the interior volume of the housing. In preferred embodiments, the media pack will have a first and second opposite flow face and be constructed and arranged for air to flow into the media pack through the first flow face, and for air to exit the media pack through the second flow face. The air cleaner will include a seal member forming a seal between the media pack and the housing. In preferred constructions, a secondary filter element is oriented within the interior volume of the housing. In some preferred embodiments, the housing is constructed and arranged as a resonator. Certain embodiments include a seal construction that engages the secondary filter element. Methods of filtering systems, servicing filtration systems, and constructing filter arrangements and housings will use filter elements and constructions as characterized above.
Description
- This disclosure describes air cleaners for engines and methods. In particular, this disclosure describes an air cleaner having a straight-through flow, sealing system, resonator, and methods for servicing and use.
- Gas streams often carry particulate material therein. In many instances, it is desirable to remove some or all of the particulate material from a gas flow stream. For example, air intake streams to engines for motorized vehicles or other motorized equipment often include particulate material therein. The particulate material, should it reach the internal workings of the various mechanisms involved, can cause substantial damage thereto. It is therefore preferred, for such systems, to remove the particulate material from the gas flow upstream of the engine or other equipment involved. A variety of air filter or gas filter arrangements have been developed for particulate removal. In general, however, continued improvements are sought.
- This disclosure concerns, in one embodiment, an air cleaner including a housing having first and second opposite ends. Preferably, the housing defines an inlet adjacent to the first end and an outlet adjacent to the second end. A media pack is preferably oriented within the interior volume of the housing. In preferred embodiments, the media pack will have a first and second opposite flow face and be constructed and arranged for air to flow into the media pack through the first flow face, and for air to exit the media pack through the second flow face. The air cleaner will include a seal member forming a seal between the media pack and the housing. In preferred constructions, a secondary filter element is oriented within the interior volume of the housing.
- In some preferred embodiments, the housing is constructed and arranged as a resonator.
- Certain preferred embodiments will include seal constructions that engage the secondary filter element to help hold the secondary filter element axially within the housing.
- Methods of filtering systems, servicing filtration systems, and constructing filter arrangements and housings are described herein. Preferred methods will use filter elements and constructions as characterized above.
- FIG. 1 is a perspective view of one embodiment of an air cleaner, according to principles of this disclosure;
- FIG. 2 is an exploded, perspective view of the air cleaner of FIG. 1 and its internal components;
- FIG. 3 is a cross-sectional view of the air cleaner housing taken along the line3-3 of FIG. 1;
- FIG. 4 is a schematic view of one embodiment of a system in which air cleaners according to the present disclosure are used;
- FIG. 5 is an enlarged, fragmented, schematic cross-sectional view of one embodiment a compressible seal member utilized to form a seal between a media pack and the air cleaner housing of FIG. 1;
- FIG. 6 is an end elevational view of one embodiment of a cup of the air cleaner housing shown in FIG. 1;
- FIG. 7 is a cross-sectional view of the cup depicted in FIG. 6 taken along the line7-7 of FIG. 8;
- FIG. 8 is an opposite end elevational view of the cup depicted in FIG. 6;
- FIG. 9 is a cross-sectional view of one embodiment of a body member of the air cleaner housing depicted in FIG. 1 taken along the line9-9 of FIG. 2;
- FIG. 10 is an exploded, perspective view of one embodiment of a secondary filter element usable in the air cleaner depicted in FIG. 1, according to the principles of the present disclosure;
- FIG. 11 is a schematic, perspective view of a portion of filter media usable in the media pack shown in FIGS. 2 and 3; and
- FIG. 12 is a schematic, end view of the media pack depicted in FIGS. 2 and 3, according to principles of the present disclosure.
- A. Systems of Use, FIG. 4
- The filter constructions and arrangements described herein are usable in a variety of systems. One particular type of system is depicted schematically in FIG. 4 generally at700. In FIG. 4,
equipment 702, such as a vehicle, having anengine 703 with some defined rated air flow demand, for example at least 35 cfm, and typically 45-65 cfm is shown schematically. Theequipment 702 may comprise a lawn tractor, golf cart, power boat, or other powered equipment. Theengine 703 powers theequipment 702, through use of an air and fuel mixture. In FIG. 4, air flow is shown drawn into theengine 703 at anintake region 705. Anair cleaner 710 having afilter construction 712 and asecondary element 713 is upstream of theengine 703. Theair cleaner 710 can be constructed to have aresonator 706 integral therewith to reduce the sound pressure level exiting thesystem 700 upon which theair cleaner 710 is installed. - In general, in operation air is drawn in at
arrow 714 into theair cleaner 710 and through theprimary element 712 and thesecondary element 713. There, particles and contaminants are removed from the air. The cleaned air flows downstream atarrow 716 into theintake 705. From there, the air flows into theengine 703 for use in powering theequipment 702. - B. Overview of the Air Cleaner
- Attention is directed to FIGS.1-3. These Figs. illustrate an embodiment of an air cleaner, generally designated as reference no. 1. The air cleaner 1 is usable in engine air intake systems, such as
system 700, described above. - In FIG. 1, an
air cleaner housing 2 is depicted. Theair cleaner housing 2 holds or contains internal components for filtering or cleaning air that flows through thehousing 2. - FIG. 2 is an exploded, perspective view of an assembly of the air cleaner1. In the particular embodiment illustrated, the air cleaner 1 includes the
housing 2 and anindicator system 5. Thehousing 2 holds, or contains within it, amedia pack 3 and asecondary element 6. Themedia pack 3 has afilter construction 100 and asealing system 4. - When the particular air cleaner1 depicted in FIG. 2 is operably constructed and assembled together, the air cleaner 1 will have the cross-section as shown in FIG. 3. By the term “operably,” it is meant that during use in the system 700 (FIG. 4), when the air cleaner 1 is removing particulate matter from an air stream, the air cleaner 1 will be configured and arranged as illustrated in FIG. 3. FIG. 3 demonstrates the general, overall operation of the air cleaner 1: (a) fluid, such as air, enters the
housing 2 at an inlet orfirst end 10 in the direction ofarrow 306; (b) passes through themedia pack 3, where particulate matter is removed from the fluid; (c) passes through thesecondary element 6; and (d) exits thehousing 2 at an outlet orsecond end 11 in the direction ofarrow 307. In preferred embodiments, thehousing 2 is constructed and arranged to act as aresonator 14. As such, when air moves through thehousing 2, theresonator 14 will decrease the sound pressure level exiting the system 700 (FIG. 4). When theoptional indicator system 5, typically a conventional restriction indicator, is used with the air cleaner 1, theindicator system 5 will provide an indication of when themedia pack 3 is occluded and requires servicing. - As can be seen in FIG. 3, when media constructions such as
filter constructions 100 of the type shown are used in thehousing 2, thesealing system 4 is needed to ensure that air flows through thefilter construction 100, rather than in a path that bypasses thefilter construction 100. - When constructions of the type shown in FIG. 3 are used, the
media pack 3 will be removable and replaceable from thehousing 2. After a period of use, when themedia pack 3 is serviced, debris and contaminants may be knocked from themedia pack 3. Thesecondary element 6 operates to catch debris and contaminants and prevent these contaminants from being sucked into the engine. - Further details on the construction and methods of the air cleaner1 follow.
- C. The
Housing 2 - A variety of embodiments of housings for the air cleaner1 are possible. A
preferred housing construction 2 is illustrated in perspective in FIG. 1. An exploded view of thehousing 2 is shown in FIG. 2. - In the particular embodiment illustrated in FIG. 2, the
housing 2 preferably includes a body member orportion 12 and a cover orcup portion 13. Attention is directed to FIG. 9. FIG. 9 is a cross-sectional view of thebody 12. In general, thebody 12 includes a first mediachamber exterior wall 15, a sealingchamber exterior wall 16, a secondary elementexterior wall 17, and anoutlet exterior wall 18. - When the
housing 2 is constructed according to principles herein, the first mediachamber exterior wall 15 will define afirst media chamber 20. Thefirst media chamber 20 is configured for receiving, holding, and containing a portion of themedia pack 3. This can be seen in the cross-section of FIG. 3. The first mediachamber exterior wall 15 will have a cross-sectional configuration selected by the system designer, based on space considerations, manufacturing techniques, and other factors. In the particular embodiment illustrated, thefirst media chamber 20 is cylindrical, or has a slight frusto-conical shape, with a circular cross-section, having a first diameter D1 and a first axial length L1. It should be noted that the use of the term “cylindrical” herein denotes a general shape. After demolding, during manufacture, a draft angle may cause thehousing 2 to have a slight angle or frusto-conical shape rather than a cylindrical shape. - In reference again to FIG. 9, the sealing
chamber exterior wall 16 defines a sealingchamber 21. The sealingchamber 21 defines a sealingsurface 82. The sealingsurface 82 provides a rigid surface for receiving compression pressure of thesealing system 4. This will be described in further detail below, in conjunction with the description of thesealing system 4. In the embodiment illustrated, the sealingchamber 21 is cylindrical with a circular cross-section having a second diameter D2 and a second axial length L2. As such, the sealingsurface 82, in the particular embodiment shown, is an annular,radial sealing surface 82. The diameter D2 is smaller than the diameter D1 of thefirst media chamber 20. As a result, there is astep 83 between thefirst media chamber 20 and the sealingchamber 21. - The
body member 12 also defines afirst seat 84. Theseat 84 is preferably configured for acting as a stop for properly positioning and orienting themedia pack 3 within thebody member 12. In the particular arrangement shown in FIG. 9, theseat 84 includes asurface 85 angled relative to the sealingsurface 82. Thesurface 85 of theseat 84 can be angled between 60°-120°, typically 70-110°, and in the particular embodiment illustrated about 90°, relative to the sealingsurface 82. Thestop surface 85 will axially engage, or abut, an end axial surface 86 (FIG. 3) of thesealing system 4. - Adjacent to the
stop surface 85 is asecondary element chamber 22. Thesecondary element chamber 22 is defined by the secondary elementexterior wall 17. Thesecondary element chamber 22 has aninner wall 269, which corresponds to an opposite side from theexterior wall 17. As will be explained further below, theinner wall 269 acts as an engagement surface such that a portion of thesecondary filter element 6 can be compressed thereagainst. This will be discussed in further detail below, in connection with the discussion of thesecondary filter element 6. Thesecondary element chamber 22 also includes aseat 86 for helping the proper orientation and positioning of thesecondary filter element 6 in thebody member 12. In particular, the secondaryfilter element seat 86 has asurface 87 that will axially engage or abut an axial surface of thesecondary filter element 6. Thestop surface 87 is angled relative to theengagement surface 269, in order to provide the stopping or engagement purposes. Thesurface 87 can be angled relative to theengagement surface 269 in a range between about 60°-120°, typically 70°-110°, and in the particular embodiment illustrated, about 90°. - Still in reference to FIG. 9, in the particular embodiment shown, the
secondary element chamber 22 is cylindrical with a circular cross-section, which has a third diameter D3 and a third axial length L3. As can be seen in FIG. 9, D3 is smaller than the diameter of D2 (the sealing chamber 21) and D1 (the diameter of first media chamber 20). This construction allows for insertion and removal of thesecondary filter element 6 through anopening 80 defined by thebody member 12, through thefirst media chamber 20, through the sealingchamber 21, and into thesecondary element chamber 22. - Still in reference to FIG. 9, the
outlet exterior wall 18 is depicted as adjacent to thesecondary element chamber 22. Theoutlet exterior wall 18 defines anoutlet 23, through which air exits the air cleaner assembly 1. Theoutlet 23, in the embodiment illustrated, is angled relative to thestop surface 87 by an angle of between 70-110°, and in the one shown in the drawing, about 90°. Also, in the particular embodiment illustrated, theoutlet 23 is cylindrical with a fourth axial length L4 and a circular cross-section of a fourth diameter D4. - In the particular embodiment illustrated in FIGS. 2 and 9, the first media
chamber exterior wall 15 includes integral ridges orribs 24. Preferably, theribs 24 are continuous around the outside circumference of the first mediachamber exterior wall 15. In general, theribs 24 provide additional structural integrity or strength to theoverall housing 2. In the particular embodiment illustrated, theribs 24 are ornamental, eye-catching, and distinctive to Donaldson, the assignee. - Attention is directed to FIG. 7. FIG. 7 is a cross-sectional view of the
cup portion 13 of the housing 2 (FIG. 2). In general, the cover orcup 13 includes a bodychamber exterior wall 25, a second mediapack exterior wall 26, and a top wall, or inlet, 27. - Preferably, the body
chamber exterior wall 25 defines abody chamber 30 arranged and configured to receive the body portion 12 (FIG. 2) of the housing 2 (FIG. 2). During assembly, the first mediapack exterior wall 15 of thebody portion 12 is designed to fit within thebody chamber 30. In the particular embodiment illustrated, thebody chamber 30 is cylindrical and has a fifth diameter D5 and a fifth axial length L5. - Preferably, the second media
pack exterior wall 26 defines a secondmedia pack chamber 31 arranged and configured to receive a portion of the media pack 3 (FIG. 2). In the embodiment depicted, the secondmedia pack chamber 31 is cylindrical and has a sixth diameter D6 and a sixth axial length L6. - Preferably, the
top wall 27 secures the media pack 3 (FIG. 2) within the housing 2 (FIG. 2) and allows air to enter the air cleaner assembly 1 (FIG. 1) while preventing large objects, such as sticks, leaves, and butterflies, from entering thehousing 2. - In the particular embodiment illustrated in FIG. 7, the
cup portion 13 further includes asupport structure 35. Thesupport structure 35 provides support for holding the media pack 3 (FIG. 2) placed within the housing 2 (FIG. 2) and prevents axial slippage of themedia pack 3 during use. Referring to FIG. 3, typically, thesupport structure 35 is not in touchable engagement with themedia pack 3. Preferably, agap 106, having an eighth axial length of L8, exists between themedia pack 3 and thesupport structure 35. During use, thisgap 106 helps distribute theinlet air stream 306 throughout theface 105 of themedia pack 3. During use, forces exerted on the air cleaner assembly 1 may cause themedia pack 3 to vibrate loose. In other words, themedia pack 3 may become dislodged from its sealing engagement, described in detail below, with thehousing 2. In this event, thesupport structure 35 prevents themedia pack 3 from becoming completely dislodged and thereby ensures a sealing engagement between themedia pack 3 and thehousing 2. - In alternative embodiments, the
gap 106 may be partially filled with a ring or gasket (not shown) to ensure minimal axial slippage of themedia pack 3, thereby ensuring that themedia pack 3 remains in sealing engagement with thehousing 2. - The
support structure 35 also helps to maintain anair space 37 between thetop wall 27 of thecup portion 13 and themedia pack 3 when assembled. In addition, thesupport structure 35 partially creates anexpansion chamber 65 for sound, as will be discussed in more detail below. Thisair space 37 improves the air flow through themedia pack 3, as will be described in more detail below. - The
support structure 35 generally extends from thetop wall 27 of thecup 13 into the second media pack chamber 31 a first distance K1. Preferably, thesupport structure 35 comprises a plurality of fins orribs 36 as illustrated in FIGS. 7 and 8. FIG. 8 is an end elevational view of the inside of thecup portion 13. Thefins 36 extend from thetop wall 27 of thecup 13 and typically are integral with thetop wall 27. - Referring back to FIGS. 1 and 2, preferably, the
housing 2 includes a securingsystem 39 for securing thecup 13 to thebody 12. In typical applications, the securingsystem 39 includes first andsecond latches system 39 may include a twist lock mechanism as described in co-pending, commonly assigned, U.S. patent applications Ser. No. 08/928,684, filed Sep. 12, 1997, and Ser. No. 09/146,291, filed Sep. 3, 1998, entitled “Air Cleaner Assembly; and Method,” hereby incorporated by reference. - In the particular embodiment illustrated in FIG. 7, the
cup portion 13 includes first and second latch supports 40, 41. Referring back to FIG. 2, thelatches body portion 12 also includes first andsecond latch extensions latches second latch extensions cup 13 to thebody 12 of thehousing 2. - Preferably, the
body chamber 30 of thecup 13 is arranged and configured to receive the first andsecond latch extensions chamber exterior wall 25 includes first and secondlatch extension regions latch extension regions second latch extensions latch extension regions second latch extensions cup 13 is appropriately aligned with thebody 12 prior to securing thecup 13 to thebody 12. - Referring back to FIG. 1, the
housing 2 further includes an optionalradial alignment system 46. In the particular embodiment illustrated in FIGS. 1 and 2, the alignment system includes an alignment ridge, protrusion, or bump 48 on thebody 12 and an alignment region orchannel 47 in thebody chamber 30 of thecup 13. Thealignment channel 47 is arranged and configured to receive thealignment ridge 48. During assembly, thealignment ridge 48 and thealignment channel 47 ensure that the cup can be oriented only in one direction with respect to thebody member 12. This ensures proper air flow through the air cleaner assembly 1, as will be described in more detail below. In other embodiments, theridge 48 may be on thecup 13, while thechannel 47 is on thebody member 12. - Attention is directed to FIG. 6. FIG. 6 is an end elevational view of one embodiment of the
cup portion 13 of the air cleaner assembly 1 shown in FIG. 1. In the particular embodiment illustrated in FIG. 6, thetop wall 27 defines aninlet arrangement 27 a for intaking air flow into thehousing 2. In preferred embodiments, theinlet arrangement 27 a will include aradial diffuser 49 for distributing the air flow through the media pack 3 (FIG. 2). In the particular embodiment illustrated in FIG. 6, theradial diffuser 49 comprises a plurality ofslots 50. Theslots 50 allow a fluid, such as air, to enter the air cleaner assembly 1 (FIG. 1) while restricting large objects, such as sticks, from entering the air cleaner assembly 1. Preferably, theslots 50 are designed for efficient air flow through the air cleaner assembly 1. - In the particular embodiment illustrated in FIG. 6, the slots are diverging-converging openings or tear shaped. By the term “tear shaped,” it is meant that the
slots 50 have a wider opening at afirst end 51 than at asecond end 52. The wider opening at thefirst end 51 allows more air to enter the assembly 1 around the outer circumference of the assembly 1. The narrower opening at thesecond end 52 restricts the air entering the assembly 1 near the center of the assembly 1. Each of theslots 50 is tapered from the wider opening at thefirst end 51, down toward the opening at thesecond end 52. This particular arrangement improves air flow and filtration capacity since a larger surface area of media exists at the outer circumference of the media pack 3 (FIG. 2) than at the center of themedia pack 3. By directing a larger volume of air around the outer circumference of themedia pack 3, greater filtration capacity is achieved. - Still in reference to FIG. 6, preferably, the
slots 50 are placed in generally theupper half 90 of thetop wall 27 of thecup 13. By the term “upper half,” it is meant that when the air cleaner assembly 1 is installed in the system 700 (FIG. 4), thetop wall 27 will be arranged to be within a vertical plane such that thetop wall 27 will have an upper half with a higher vertical elevation than alower half 91 of thetop wall 27. In typical applications, the air cleaner assembly 1 is oriented such that theslots 50 align with an opening (not shown) in a shroud or hood of equipment for which the air cleaner assembly 1 is designed. For example, on garden tractors, the hood of the garden tractor contains an opening for air flow. The air cleaner assembly 1 is mounted within the hood such that theslots 50 of thecup 13 generally align with the opening in the hood of the garden tractor. This ensures maximum air flow through the air cleaner assembly 1. - In the particular embodiment illustrated, the
top wall 27 includes anarrow 55 and the word “top” 56 to ensure proper orientation by the user of the air cleaner assembly 1 with the openings in the hood of the garden tractor. In addition, preferably, thehousing 2 includes thealignment system 46 previously discussed to ensure proper orientation. In the particular embodiment illustrated in FIG. 6, theslots 50 are arranged in a semi-circular array, with each of the slots extending radially from acenter 77 of thetop wall 27 toward theouter periphery 78 of thetop wall 27. - In the particular embodiment illustrated, the
top wall 27 includes adrain hole 60 near the lower half of thetop wall 27 of thecup 13. Thedrain hole 60 allows any liquid, such as water or water condensation, that may enter the air cleaner assembly 1, to drain out of the air cleaner assembly 1 through thedrain hole 60. Thealignment system 46 helps to ensure that thedrain hole 60 is oriented at or near the bottom of the air cleaner 1. - Although the
particular body 12 andcup 13 depicted are preferred for thehousing 2, many different embodiments are possible. The embodiment depicted, however, is particularly convenient for manufacturing techniques, such as injection molding. Further, theparticular housing 2 depicted is preferred because it is attractive in appearance, eye-catching, and distinctive to Donaldson, the assignee. Further views of thehousing 2 are depicted in co-pending and commonly assigned U.S. patent application Ser. No. ______, filed the same date herewith, and entitled, “In-line Air Cleaner,” which application is incorporated by reference herein. - D. The
Resonator 14 - In certain preferred systems, the
housing 2 is constructed and arranged to act as aresonator 14. That is, in preferred constructions, thehousing 2 is constructed and arranged to reduce the sound pressure level exiting the system 700 (FIG. 4). When constructed according to the following principles, theresonator 14 will reduce the sound pressure level by at least 1 dB(A), typically between 1.5 and 3 dB(A), when compared to an air cleaner with an open end; that is, an air cleaner where an end of a media pack is not covered by a portion of a housing of the air cleaner. This sound pressure level decrease can be measured with equipment such as a Larson Davis Real Time Analyzer, with the microphone mounted about 30 inches above the seat of the equipment, such as a garden tractor. Alternatively, equipment such as an Aachen Head can be used, again, with the simulated head mounted about 30 inches above the seat of the equipment. - Attention is directed to FIG. 3. FIG. 3 is a cross-sectional view of the assembled air cleaner assembly1 of FIG. 1. Preferably, the length L7 of an
expansion chamber 65, which includes both the first and secondmedia pack chambers 20, 31 (FIGS. 7 and 9) of thebody 12 and thecup 13, respectively, and theinlet 27 are constructed and arranged to act as theresonator 14. L7 extends between theinlet wall 27 and thefirst seat surface 86. Preferably, the overall length L7 of theexpansion chamber 65 is equal to the speed of sound divided by 4 times the frequency desired to be removed by theresonator 14. This particular length L7 of theexpansion chamber 65 causes the sounds waves to bounce back and forth, canceling each other, according to sound pressure principles commonly known. The frequency desired to be removed by theresonator 14 is dependent on the particular source impedance of the downstream equipment. For example, a Yanmar, twin cylinder diesel engine operating at rated conditions and having a 20 horsepower rating, has a predominate source strength frequency at 500 hertz. Knowing this source strength frequency, the length L7 of theexpansion chamber 65 is determined. A ratio of the length L7 of theexpansion chamber 65 to the open area equivalent diameter of theinlet 27 is between about 4.5 and 5.0, for example about 4.7. A ratio of the length L7 of theexpansion chamber 65 to the largest outermost sectional dimension (in the particular illustrated embodiment, diameter) is at least 1.5, and typically between about 1.75 and 2.00, for example, about 1.8. - In addition, the
inlet arrangement 27 a is arranged and constructed to have an opening that has a smaller cross-sectional area than the opening of theoutlet chamber 23. The smaller cross-sectional area of theinlet 27 a acts to restrict the sound from exiting theinlet 27 a. Preferably, theinlet 27 a has a cross-sectional area that is at least 3 percent smaller than the cross-sectional area of theoutlet 23, and typically between 5 and 10 percent smaller. - The
expansion chamber 65 reduces, within the space constraints, the radiated sound of the predominate source strength frequency through theinlet 27 by destructive interference. Sound waves with frequencies above a few hundred Hertz are further attenuated by acoustic attenuation within themedia pack 3, according to sound absorption principles commonly known. The configuration thus provides effective broadband sound absorption and attenuation. - In the particular embodiment illustrated, the
expansion chamber 65 is cylindrical and has a diameter about at least 80 percent, and typically 100 to 250 percent larger than the largest cross-sectional dimension (in this case, diameter) of theoutlet 23. - Still in reference to FIG. 3, there is a
non-internal tube construction 93 within the interior of thehousing 2 between themedia pack 3 and theoutlet 23. By the term “non-internal tube construction”, it is meant that there are no internal tubular structures for sound attenuation mounted within thehousing 2. In other words, thehousing 2 is constructed and arranged to attenuate sound with theresonator 14 without any additional tubes located therewithin. In addition, theentire housing 2 includes anon-internal tube construction 94, in that there are no acoustic tubes located anywhere within the housing interior. While there is a negative cylinder at 95 for supporting thefins 36, thenegative cylinder 95 does not act as a acoustic tube, and is not within the definition of “non-internal tube construction.” - In the particular embodiment illustrated, the
resonator 14 is designed to reduce the sound pressure levels exiting the air cleaner assembly 1 without the use of baffles, absorptive packing material, sonic chokes, or other sound attenuating devices. The sound pressure level reduction is achieved by thehousing 2 consisting essentially of only the structure as described previously herein. - E.
The Media Pack 3 - Referring back to FIG. 2, the
filter construction 100 depicted is designed to remove particulates from a fluid, such as air, passing through thefilter construction 100, while thesealing system 4 is designed to seal themedia pack 3 against the sealingchamber exterior wall 16 of thehousing 2, as shown in FIG. 3. By the term “seal,” it is meant that thesealing system 4, under normal conditions, prevents unintended levels of fluid from passing through a region between themedia pack 3 and the sealingchamber exterior wall 16 of thehousing 2; i.e., thesealing system 4 inhibits fluid flow from avoiding passage through themedia pack 3. - In certain arrangements, the
media pack 3 will be configured for straight-through flow. By “straight-through flow,” it is meant that themedia pack 3 is configured in aconstruction 100 with a first flow face 105 (corresponding to an inlet end, in the illustrated embodiment) and an opposite, second flow face 110 (corresponding to an outlet end, in the illustrated embodiment), with fluid flow entering in onedirection 114 through thefirst flow face 105 and exiting in thesame direction 116 from thesecond flow face 110. When used with an inline-flow housing, such as thehousing 2 of FIG. 1, in general, the fluid will enter through the inlet of the housing in onedirection 306, enter thefilter construction 100 through thefirst flow face 105 in the same direction, exit thefilter construction 100 in the same direction from thesecond flow face 110, and exit the housing through thehousing outlet 11 also in thesame direction 307. - Although the
first flow face 105 is described above as corresponding to an inlet end, and thesecond flow face 110 is described above as corresponding to an outlet end, the inlet and outlet ends can be reversed. That is, thefirst flow face 105 depicted in FIG. 2 can correspond to an outlet end, while thesecond flow face 110 depicted in FIG. 2 can correspond to an inlet end. - In FIG. 2, the
first flow face 105 and thesecond flow face 110 are depicted as planar and as parallel. In other embodiments, thefirst flow face 105 and thesecond flow face 110 can be non-planar, for example, frusto-conical. Further, thefirst flow face 105 andsecond flow face 110 need not be parallel to each other. - Generally, the
filter construction 100 will be a wound construction. That is, theconstruction 100 will typically include a layer of filter media that is turned completely or repeatedly about a center point. Typically, the wound construction will be a coil, in that a layer of filter media will be rolled a series of turns around a center point. In arrangements where a wound, coiled construction is used, thefilter construction 100 will be a roll of filter media, typically permeable fluted filter media. - Attention is now directed to FIG. 11. FIG. 11 is schematic, perspective view demonstrating the principles of operation of certain media usable in the filter constructions herein. In FIG. 11, a fluted construction is generally designated at122. The
fluted construction 122 includes: alayer 123 of corrugations having a plurality offlutes 124 and aface sheet 132. The FIG. 11 embodiment shows two sections of theface sheet 132, at 132A (depicted on top of the corrugated layer 123) and at 132B (depicted below the corrugated layer 123). Typically, themedia construction 125 used in arrangements described herein will include thecorrugated layer 123 secured to thebottom face sheet 132B. When using thismedia construction 125 in a rolled construction, it typically will be wound around itself, such that thebottom face sheet 132B will cover the top of thecorrugated layer 123. Theface sheet 132 covering the top of the corrugated layer is depicted as 132A. It should be understood that theface sheet same sheet 132. - When using this type of
media construction 125, theflute chambers 124form alternating peaks 126 andtroughs 128. Thetroughs 128 andpeaks 126 divide the flutes into an upper row and lower row. In the particular configuration shown in FIG. 11, the upper flutes formflute chambers 136 closed at the downstream end, whileflute chambers 134, having their upstream end closed, form the lower row of flutes. Thefluted chambers 134 are closed by afirst end bead 138 that fills a portion of the upstream end of the flute between thefluting sheet 130 and thesecond facing sheet 132B. Similarly, asecond end bead 140 closes the downstream end of alternatingflutes 136. In some systems, both thefirst end bead 138 andsecond end bead 140 are straight along all portions of themedia construction 125, never deviating from a straight path. In some systems, thefirst end bead 138 is both straight and never deviates from a position at or near one of the ends of themedia construction 125, while thesecond end bead 140 is both straight and never deviates from a position at or near one of the ends of themedia construction 125. Theflutes 124 and endbeads media construction 125 that can be formed intofilter construction 100 and be structurally self-supporting without a housing. - When using media constructed in the form of
media construction 125, during use, unfiltered fluid, such as air, enters theflute chambers 136 as indicated by the shadedarrows 144. Theflute chambers 136 have their upstream ends 146 open. The unfiltered fluid flow is not permitted to pass through the downstream ends 148 of theflute chambers 136 because their downstream ends 148 are closed by thesecond end bead 140. Therefore, the fluid is forced to proceed through thefluting sheet 130 or facesheets 132. As the unfiltered fluid passes through thefluting sheet 130 or facesheets 132, the fluid is cleaned or filtered. The cleaned fluid is indicated by theunshaded arrow 150. The fluid then passes through the flute chambers 134 (which have their upstream ends 151 closed) to flow through the open downstream end 152 (FIG. 12) out thefluted construction 122. With the configuration shown, the unfiltered fluid can flow through thefluted sheet 130, the upper facingsheet 132A, or lower facingsheet 132B, and into aflute chamber 134. - Typically, the
media construction 125 will be prepared and then wound to form the rolled filter construction 100 (FIGS. 3 and 12) of filter media. When this type of media is selected for use, themedia construction 125 prepared includes the sheet ofcorrugations 123 secured with theend bead 138 to thebottom face sheet 132B (as shown in FIG. 11, but without thetop face sheet 132A). In these types of arrangements, themedia construction 125 will include a leading edge at one end and a trailing edge at the opposite end, with a top lateral edge and a bottom lateral edge extending between the leading and trailing edges. By the term “leading edge,” it is meant the edge that will be initially turned or rolled, such that it is at or adjacent to the center or core of the rolled construction. The “trailing edge” will be the edge on the outside of the rolled construction, upon completion of the turning or coiling process. - The leading edge and the trailing edge should be sealed between the
corrugated sheet 123 and thebottom face sheet 132B, before winding the sheet into a coil, in these types ofmedia constructions 125. While a number of ways are possible, in certain methods, the seal at the leading edge is formed as follows: (a) thecorrugated sheet 123 and thebottom face sheet 132B are cut or sliced along a line or path extending from the top lateral edge to the bottom lateral edge (or, from the bottom lateral edge to the top lateral edge) along aflute 124 forming a peak 126 at the highest point (or apex) of thepeak 126; and (b) sealant is applied between thebottom face sheet 132B and the sheet ofcorrugations 123 along the line or path of cut. The seal at the trailing edge can be formed analogously to the process of forming the seal at the leading edge. While a number of different types of sealant may be used for forming these seals, one usable material is a non-foamed sealant available from H. B. Fuller of St. Paul, Minn., identified under the designation HL0842. - When using the
media construction 125, it may be desired by the system designer to wind theconstruction 125 into a rolled construction of filter media, such as thefilter construction 100 of FIG. 12. FIG. 12 is a schematic, end view of themedia pack 3. A variety of ways can be used to coil or roll the media. Themedia construction 125 may be wound about a center mandrel or other element to provide a mounting member for winding. The center mandrel may be removed or left to plug to act as a core at the center of thecylindrical filter construction 100. It can be appreciated that non-round center winding members may be utilized for making other filtering construction shapes, such as filter constructions having an oblong, oval, rectangular, or racetrack-shaped profile, and can be usable in filtering systems herein. Various filter constructions with non-circular (as well as circular) cross-sections are described in co-pending, commonly assigned, U.S. patent application Ser. No. ______, entitled, “Filter Arrangement; Sealing System; and Methods,” filed the same date herewith, and herein incorporated by reference. Further view of various filter constructions that may be usable herein are depicted in copending and commonly assigned U.S. patent application Ser. No. ______, filed the same day herewith, and entitled, “Filter Element Having Sealing System,” herein incorporated by reference. - Still in reference to FIG. 11, the
media construction 125 can also be wound without a mandrel or center core. One method of forming a coreless rolled construction is as follows: (a) thetroughs 128 of the first few corrugations of thecorrugated sheet 123 spaced from the leading edge are scored from the top lateral edge to the bottom lateral edge (or from the bottom lateral edge to the top lateral edge); for example, the first four corrugations from the leading edge will have a score line cut along thetroughs 128; (b) thebead 140 of sealant is applied along the top of the sheet ofcorrugation 123 along the lateral edge opposite from the lateral edge havingend bead 138; (c) the leading edge is initially turned or rolled over against itself and then pinched together to be sealed with thesealant bead 140; and (d) the remainingcorrugated sheet 123 having thebottom face sheet 132B secured thereto is coiled or rolled or turned around the pinched leading edge. - In other methods, coreless constructions can be made from the
media construction 125 by automated processes, as described in U.S. Pat. Nos. 5,543,007 and 5,435,870, each incorporated by reference herein. In still other methods, the media construction can be rolled by hand. - When using rolled constructions, such as the
filter construction 100, the system designer will want to ensure that the outside periphery of theconstruction 100 is closed or locked in place to prevent thefilter construction 100 from unwinding. There are a variety of ways to accomplish this. In some applications, the outside periphery is wrapped with a periphery layer. The periphery layer can be a non-porous, adhesive material, such as plastic with an adhesive on one side. When this type of layer is utilized, the periphery layer prevents thefilter construction 100 from unwinding and prevents the fluid from passing through the outside periphery of thefilter construction 100, maintaining straight-through flow through thefilter construction 100. - In some applications, the
filter construction 100 is secured in its rolled construction by sealing the trailing edge of themedia construction 125 with an adhesive or sealant along a line 179 (FIG. 2) to secure the trailing edge to the outside surface of thefilter construction 100. For example, a bead of hot-melt may be applied along theline 179. - Attention is again directed to FIG. 12. In FIG. 12, the
second flow face 110 is shown including the open ends 152 and closed ends 148. Top and bottom plan views, as well as side elevational views of themedia pack 3 and thesealing system 4 usable in the systems and arrangements described herein are depicted in copending and commonly assigned U.S. patent application Ser. No. ______, filed the same day herewith, and entitled, “Filter Element Having Sealing System,” herein incorporated by reference. - F. The
Sealing System 4 - Turning back to FIG. 3, the
media pack 3 is shown installed in ahousing 2. In the arrangement shown, air flows into thehousing 2 at 306, through themedia pack 3, and out of thehousing 2 at 307. When media constructions such as themedia pack 3 of the type shown are used in a duct orhousing 2, sealingsystem 4 will be needed to ensure that air flows through themedia pack 3, rather than bypass it. - The
particular sealing system 4 depicted includes aframe construction 170 and aseal member 250. When this type ofsealing system 4 is used, theframe construction 170 provides a support structure or backing against which theseal member 250 can be compressed to form aradial seal 172 with thehousing 2. - Attention is further directed to FIGS. 2, 3 and12. FIG. 2 is a schematic, perspective view of the
sealing system 4; FIG. 3 is a schematic, cross-sectional view of themedia pack 3 installed in thehousing 2; and FIG. 12 is a schematic, end view of thesealing system 4 and themedia pack 3. - In general, when using
frame constructions 170 such as those described herein, theframe construction 170 will include aframe 205. Theframe 205 may be a variety of shapes. In the particular embodiment illustrated in FIG. 3, the shape of theframe 205 is generally circular. Theframe 205 depicted in FIG. 3 is convenient in that it is arranged and configured for attachment to the second flow face 110 (FIG. 2) of thefilter construction 100. - In the particular arrangement depicted, the
frame 205 has a band, skirt, or dependinglip 251 that is generally circular and has an inside diameter. Preferably, the inside diameter is approximately equal to the outside diameter of thefilter construction 100. The dependinglip 251 depends or extends down a first distance from a bottom 252 surface of cross braces 210 (FIG. 12). The dependinglip 251 is arranged and configured to extend radially around thesecond flow face 110 thefilter construction 100. In the particular embodiment depicted, the dependinglip 251 extends radially around thesecond flow face 110 of thefilter construction 100, such that the dependinglip 251 extends inboard the first distance of thesecond flow face 110 of thefilter construction 100, defining anoverlap region 255. - The
frame 205 is preferably secured to thefilter construction 100. A variety of ways to secure theframe 205 to thefilter construction 100 are possible. One particularly preferred way to secure theframe 205 to thefilter construction 100 is by use of an adhesive. In the particular embodiment depicted in FIG. 3, the adhesive is oriented in theoverlap region 255 between the dependinglip 251 and thefilter construction 100. - Preferably, the adhesive permanently affixes the
frame 205 to thefilter construction 100 while preventing the fluid from leaking out through theoverlap region 255 between thefilter construction 100 and theframe 205. In alternative embodiments, theframe 205 may be temporarily attached to thefilter construction 100. By the term “temporarily,” it is meant that theframe 205 may be removed from thefilter construction 100 without damaging either thesealing system 4 or thefilter construction 100. - Referring to FIG. 12, during use of
frames 205 of the type depicted herein, inward forces are exerted around the circumference of theframe 205. Cross braces 210 support theframe 205. By the term “support,” it is meant that the cross braces 210 prevent theframe 205 from radially collapsing under the forces exerted around the circumference of theframe 205. - Referring again to FIG. 3, the
particular frame construction 205 depicted preferably includes atip portion 263, or annular sealing support. In the one depicted in FIG. 3, thetip portion 263 is generally circular and is arranged and configured for insertion into thehousing 2. When circular, thetip portion 263 defines an inside diameter. Between thetip portion 263 and the dependinglip 251, theframe 205 includes astep 253. Thestep 253 provides a transition area between the larger inside diameter of the dependinglip 251 and the smaller inside diameter of thetip portion 263. - When constructed according to the arrangement shown in FIG. 3, the
tip portion 263 provides support for thecompressible seal member 250. Thecompressible seal member 250 is preferably constructed and arranged to be sufficiently compressible to be compressed between thetip portion 263 of theframe 205 and asidewall 260 of thehousing 2. When sufficiently compressed between thetip portion 263 and thesidewall 260, aradial seal 172 is formed between themedia pack 3 and thesidewall 260 of thehousing 2. - A variety of ways are possible to secure the
seal member 250 to thetip portion 263. One particularly convenient and preferred way is by molding theseal member 250 to engage, cover, or overlap both the outerradial side 271 of thetip portion 263 and the innerradial side 270 of thetip portion 263, including theend tip 180. One particular embodiment of this configuration is depicted in FIG. 3. Theseal member 250 completely covers thetip portion 263. - The
tip portion 263 of theframe 205 defines a wall or support structure between and against which theradial seal 172 may be formed by thecompressible seal member 250. The compression of thecompressible seal member 250 at thesealing system 4 is preferably sufficient to form a radial seal under insertion pressures of no greater than 80 pounds, typically, no greater than 50 pounds, for example, about 20-30 pounds, and light enough to permit convenient and easy change out by hand. Preferably, the amount of compression of thecompressible seal member 250 is at least fifteen percent, preferably no greater than forty percent, and typically between twenty and thirty-three percent. By the term “amount of compression,” it is meant the physical displacement of an outermost portion of theseal member 250 radially toward thetip portion 263 as a percentage of the outermost portion of theseal member 250 in a resting, undisturbed state and not installed within a duct or subject to other forces. - Attention is directed to FIG. 5. FIG. 5 is an enlarged schematic, fragmented view of a particular
preferred seal member 250 in an uncompressed state. In the preferred embodiment shown, theseal member 250 has a stepped cross-sectional configuration of decreasing outermost dimensions (diameter, when circular) from afirst end 264 to asecond end 265, to achieve desirable sealing. Preferred specifications for the profile of the particular arrangement shown in FIG. 5 are as follows: a polyurethane foam material having a plurality of (preferably at least three) progressively larger steps configured to interface with the sidewall 260 (FIG. 3) and provide a fluid-tight seal. - The
compressible seal member 250 defines a gradient of increasing internal diameters of surfaces for interfacing with thesidewall 260. Specifically, in the example shown in FIG. 5, thecompressible seal member 250 defines threesteps steps step second end 265 of thecompressible seal member 250. The smaller diameter at thesecond end 265 allows for easy insertion into a duct or housing, such as thehousing 2 of FIG. 3. The larger diameter at thefirst end 264 ensures a tight seal. - In general, for a properly functioning radially sealing structure, the
compressible seal member 250 needs to be compressed when the element is mounted in the housing 2 (FIG. 3). In many preferred constructions, it is compressed between about fifteen percent and forty percent (often about twenty to thirty-three percent) of its thickness, in the thickest portion, to provide for a strong robust seal, yet still be one that can result from hand installation of the element with forces on the order of 80 pounds or less, preferably 50 pounds or less, and generally 20-30 pounds. - Referring back to FIG. 3, in general, the
media pack 3 and sealingsystem 4 can be arranged and configured to be press-fit against thesidewall 260 of thehousing 2 or duct. In the specific embodiment shown in FIG. 3, thecompressible seal member 250 is compressed between thesidewall 260 and thetip portion 263 of theframe 205. After compression, thecompressible seal member 250 exerts a force against thesidewall 260 as thecompressible seal member 250 tries to expand outwardly to its natural state, forming theradial seal 172 between and against thetip portion 263 and thesidewall 260. - Referring back to FIG. 12, in the particular embodiment illustrated, the
media pack 3 also includes aretention system 280 for retaining the secondary element 6 (FIG. 3) within the secondary element chamber 22 (FIG. 3). Stated in other words, theretention system 280 prevents the secondary element from axially slipping out of thesecondary element chamber 22 within the housing 2 (FIG. 3). - In the particular embodiment illustrated in FIG. 12, the
retention system 280 includes first, second, andthird retention extensions retention extensions compressible seal member 250 of thesealing system 4. Typically, theretention extensions media pack 3 as illustrated. While a variety of configurations are contemplated, the particular embodiment illustrated shows theretention extensions - Referring to FIG. 3, the
retention extensions secondary element 6 within thehousing 2. Specifically, thesecond retention extension 282 is illustrated in FIG. 3 radially extending toward the center of themedia pack 3 overlapping with anoutside edge 285 of aframe construction 402 of thesecondary element 6. Thesecond retention extension 282 extends in overlapping engagement with theoutside edge 285 of thesecondary element 6 such that there is axial abutment between theretention extension 282 and a frame of thesecondary element 6. This ensures that thesecondary element 6 is locked or secured within thesecondary element chamber 22 and prevented from axially slipping within thehousing 2. The first andthird extensions secondary element 6 to retain thesecondary element 6 within thesecondary element chamber 22. As such, thesecondary element 6 will be trapped between thestop surface 87 and the first, second, andthird retention extensions - In alternative embodiments, the retention extensions may be of other sizes or shapes, and the
retention system 280 may include other numbers of retention extensions. The particular arrangement depicted is preferred in that it lends itself to convenient manufacturing techniques and is ornamental, eye-catching, and attractive. - G. The
Secondary Element 6 - Attention is directed to FIG. 10. FIG. 10 depicts an exploded, perspective view of the
secondary element 6, shown in the air cleaner 1 of FIGS. 2 and 3. - In general, the
secondary element 6 includes aframe construction 402 and a region ofmedia 404. In preferred constructions, theframe construction 402 is usable for holding and supporting the region ofmedia 404. Preferably, themedia 404 is for removing at least some particulates from a gas stream (that is, particulates having a smallest outermost dimension that is larger than a largest pore size of the media 404). For example, themedia 404 can be used to remove particulates from air being taken into an engine. - In preferred systems, the
media 404 preferably is constructed and arranged to introduce little restriction into the air intake duct. For example, thesecondary element 6 including themedia 404, in some arrangements, will have a restriction of no more than two inches of water, preferably no more than one inch of water. - The region of
media 404 within the periphery of theframe construction 402, in the embodiment depicted in FIG. 10, is nonpleated and noncylindrical. Further, in the particular FIG. 10 embodiment, the region ofmedia 404 is nonwoven and comprises not more than a single layer. The particular type ofmedia 404 depicted in FIG. 10 includes a region of depth media, such as fibrous media. - When
media 404 of the type depicted in FIG. 10 is assembled in theframe construction 402 depicted in FIG. 10, themedia 404 will include afiltering portion 406 and askirted portion 408 as illustrated in FIG. 2. Thefiltering portion 406 will operate to remove contaminants and particulates having a size (i.e., smallest outermost dimension) greater than the pore size of themedia 404 from an air or gas stream passing therethrough. For example, with certain types ofmedia 404 described herein, thefiltering portion 406 will remove about 50% of dust particles having an average particle size (smallest outermost dimension) of less than 1-10 microns passing therethrough. - The skirted
portion 408 preferably operates to cooperate with an annular surface of a duct, such as the secondary element chamberinterior wall 269 to occupy or fill a volume between thewall 269 and thesecondary element 6 and create a “sealing effect.” By the term “sealing effect,” it is meant that high restriction is introduced in the volume between the periphery of theframe construction 402 and aninner wall portion 269 of thehousing 2; while some air or gas may be allowed to pass through the region between an outer periphery of theframe construction 402 and the annular surface of thehousing 2, the air or gas that does pass through, for the most part, will pass through the media in the skirtedportion 408. This is described further below. - Still in reference to FIG. 10, the
particular frame construction 402 depicted in FIG. 10 includes anouter periphery 410. Theouter periphery 410 defines aperimeter area 412 therewithin. In other words, in the specific configuration depicted in FIG. 10, theperimeter area 412 comprises the entire region within theouter periphery 410. Theouter periphery 410 may have a variety of shapes. In the particular embodiment shown in FIG. 10, theouter periphery 410 is circular. In the particular embodiment of FIG. 10, theperimeter area 412 would include everything within thecircular periphery 410 and can be calculated by squaring the radius of the circularouter periphery 410 and multiplying it by pi (π). - When constructed in the way shown in FIG. 2, the
filtering portion 406 occupies or fills the entire perimeter area 412 (FIG. 10). When cleaning a gas stream passing therethrough, by occupying theentire perimeter area 412, there are no regions of unfiltered areas that the gas stream may escape through. As can also be seen in FIG. 2, preferably the skirtedportion 408 extends outside of theouter periphery 412 and is not part of theperimeter area 410. In the particular arrangement shown in FIG. 2, the skirtedportion 408 extends both outside and radially projects from theouter periphery 412. In FIG. 2, it can be seen that the media 404 (FIG. 10) includes an outermost edge or periphery at 414. Thisoutermost edge 414 is spaced from theouter periphery 412, when thesecondary element 6 is not installed in a duct or tubular construction. - In some preferred constructions, the
frame construction 402 is a multi-piece construction. In the particular arrangement depicted in FIG. 10, theframe construction 402 is a two-piece construction. In the particular FIG. 10 embodiment, theframe construction 402 includes first andsecond frame pieces second frame pieces media 404 within thehousing 2, while providing sufficient structural integrity to prevent collapse under air pressure. - When a
multi-piece frame construction 402 is used, there will include structure or a construction holding the multiple pieces together with themedia 404. In the particular illustrated arrangement, the first andsecond frame pieces locking arrangement 420, constructed and arranged to permit the first andsecond pieces arrangement 420 holds the region ofmedia 404 between the first andsecond frame pieces media 404 in place and under sufficient tension to minimize the restriction through themedia 404. - A variety of locking
arrangements 420 may be implemented. In the particular construction illustrated, the lockingarrangement 420 includes a bead and recess system. That is, preferably, at least one of the first andsecond frame pieces second frame pieces first frame piece 416 defines a recessedportion 422, while thesecond frame piece 418 defines a projection orbead member 424 for projecting or snapping therein. - In certain preferred arrangements, the
frame construction 402 will include a handle system for permitting the convenient installation and removal of thesecondary element 6 from thehousing 2. Many different types of handle systems may be implemented. One particularly preferred embodiment of a handle system is illustrated in FIG. 10. In the particular FIG. 10 embodiment, thefirst frame piece 416 includes afirst handle construction 440. While a variety of constructions are contemplated herein, in the embodiment shown in FIG. 10, thefirst handle construction 440 includes a plurality ofribs 442 radially extending from thefirst region 444 of thefirst frame piece 416. In the embodiment shown, theribs 442 intersect at acenter frame member 446. Theribs 442 andcenter frame member 446 provide structure for a user to grasp when handling thesecondary element 6, for example when changing out thesecondary element 6. - In certain preferred constructions, the
first handle construction 440 including theribs 442 andcenter frame member 446 also provide support structure to theframe construction 402. Again, theframe construction 402 should have sufficient structural integrity to prevent collapse under air intake pressures, that can typically range from at least 25 in. of water, and can be up to 100 inches of water. In addition, thefirst handle construction 440 helps to maintain sufficient tension in themedia 404 to minimize the restriction through themedia 404. - Likewise, the
second frame piece 418 includes asecond handle construction 450. While a variety of constructions are contemplated herein, in the embodiment shown in FIG. 10, thesecond handle construction 450 includes a plurality ofribs 452 radially extending from asecond region 454 of thefirst frame piece 418. In the embodiment shown, theribs 452 intersect at acenter frame member 456. Theribs 452 andcenter frame member 456 provide structure for a user to grasp when handling thesecondary element 6. - In certain preferred constructions, the
second handle construction 450 including theribs 452 andcenter frame member 456 also provide support structure to theframe construction 402. Again, theframe construction 402 should have sufficient structural integrity to prevent collapse under air intake pressures, that can typically range from at least 25 in. of water, and can be up to 100 inches of water. In addition, thesecond handle construction 450 helps to maintain sufficient tension in themedia 404 to minimize the restriction through themedia 404. - Alternatively, additional structure may be attached to the
frame construction 402 to allow for the convenient installation and removal of thesecondary element 6 from thehousing 2. Because both the first andsecond frame pieces handle constructions secondary element 6 is reversible. By the term “reversible,” it is meant that thesecondary element 6 may be installed in thehousing 2 with either thefirst frame piece 416 or thesecond frame piece 418 in the most upstream position (alternatively stated, thefirst frame piece 416 or thesecond frame piece 418 may be installed in the most downstream position). Themedia construction 404 will deflect in the proper orientation and occupy to fill the space between the periphery of theframe construction 402 and thewall 269, when thesecondary element 6 is inserted. - Attention is directed to FIG. 3. In FIG. 3, the
secondary element 6 is depicted installed in thehousing 2. Theskirt 408 fills the volume between theinner wall 269 of thehousing 2 and theframe construction 402. As can be seen in FIG. 3, the skirtedportion 408 of themedia 404 is preferably constructed and arranged to be sufficiently compressible to be compressed between theframe construction 402 and theinner wall 269 of thehousing 2. When sufficiently compressed between theframe construction 402 andinner wall 269, sealingeffect 460, or media-stuffed volume or media-filled region, is formed for thesecondary element 6 with thehousing 2. Specifically, the sealingeffect 460 is formed between thesecondary element 6 and theinner wall 269. In the particular embodiment shown in FIG. 3, the sealingeffect 460 is formed by compressing the skirtedportion 408 of themedia 404 between and against theframe construction 402 and theinner wall 269. - The compression of the
media 404 at the skirtedportion 408, in preferred systems, will be preferably sufficient to form the sealingeffect 460 under pressures of up to 100 in. of water, and light enough to permit convenient and easy change out by hand. Preferably, the compression of the skirtedportion 408 to form the media-occupied volume or region is at least 70%, preferably no greater than 90%, and typically between 75-85%. In preferred systems, the sealingeffect 460 can be created by applying typically under 5 pounds of force, and ranging between 1-20 pounds. - One usable secondary element is described in commonly assigned and co-pending U.S. patent application Ser. No. ______, entitled, “Filter Element and Methods,” filed on the same date herewith, and herein incorporated by reference.
-
H. Indicator System 5 - Referring back to FIG. 1, in the particular embodiment illustrated, the air cleaner assembly1 includes the
restriction indicator 5 for providing an indication to an user of the air cleaner assembly 1 of the restriction across themedia pack 3 of the air cleaner assembly 1. Therestriction indicator 5 is designed to provide the user with an indication of when themedia pack 3 needs to serviced or replaced. - Referring to FIG. 2, in general, the
restriction indicator 5 includes anoutlet extension 800, anindicator tube 801, and anindicator 802. Referring to FIG. 3, theoutlet extension 800 extends from theoutlet exterior wall 18 of thehousing 2 and defines anindicator chamber 803. Preferably, theindicator chamber 803 is in communication with theoutlet chamber 23 such that air moves through theindicator chamber 803. Typically, theoutlet extension 800 is integral with theoutlet exterior wall 18 of thehousing 2. - In the particular embodiment illustrated, the
indicator tube 801 connects theoutlet extension 800 with theindicator 802. Preferably, theindicator tube 801 is in communication with theoutlet extension 800 such that air passes through theindicator tube 801 therethrough to theindicator 802. Preferably, theindicator tube 801 is connected to theoutlet extension 800 and theindicator 802 by conventional securing means, such as screwing theindicator tube 801 onto theoutlet extension 800. - Preferably, the
indicator 802 measures the air pressure across theoutlet chamber 23. When the air pressure reaches a predetermined level, for example 25 inches of water, theindicator 802 provides an indication to the user of the air cleaner assembly 1 that themedia pack 3 needs servicing or replacement. - One such usable
restriction indicator device 5 is described in commonly assigned U.S. Pat. No. 3,443,365, herein incorporated by reference. - In alternative embodiments, the air cleaner assembly1 does not include a restriction indicator. In these embodiments, the user services or replaces the
media pack 3 after a predetermined number of hours of use, for example 150 hours, or by visual inspection of themedia pack 3. In other alternative embodiments, themedia pack 3 may have color, such as blue, to help the user determine the level of occlusion in themedia pack 3. - I. Change Out and Replacement
- In certain preferred applications, the media packs described herein are removable and replaceable from whatever system in which they are installed. For example, the media pack will be installed in an air cleaner housing, such as the one shown in FIGS.1-3. After a certain number of hours of use, the media in the
filter construction 100 will become occluded, and the restriction in themedia pack 3 will increase. In preferred applications, themedia pack 3 will be periodically replaced to maintain the appropriate removal of particulates from a fluid, without introducing too high of a restriction. - In applications where the
restriction indicator 5 is used, therestriction indicator 5 will provide information to the user regarding the appropriate time to change out themedia pack 3. - To service the air cleaner arrangements described herein, the user will need access to the
media pack 3. For example, if themedia pack 3 is installed in an air cleaner housing such as thehousing 2 shown in FIGS. 1-3, the user will unlatch thecover 13 from thebody member 12, and remove thecover 13 from thebody member 12. This will expose an opening 80 (FIG. 9) defined by thebody member 12. The user will grasp themedia pack 3 and break theradial seal 172 formed by themedia pack 3 against thesidewall 16 of thehousing 2. In certain systems, theseal member 250 and thehousing 2 will be designed such that the user will need to exert a force of no more than about 80 pounds, preferably no more than 50 pounds, and in some applications between 20 and 30 pounds to break theradial seal 172 and remove themedia pack 3. The user will then pull themedia pack 3 through theopening 80 formed by thebody member 12. Theold media pack 3 may then be disposed of. In certain preferred systems, themedia pack 3 will be constructed of non-metallic materials, such that it is readily incineratable. For example, in some preferred constructions, themedia pack 3 will comprise at least 95 percent, and typically at least 98 percent nonmetallic materials. - When the
media pack 3 is being serviced, sometimes debris and particulate materials can be knocked or jarred from themedia pack 3 and fall into thehousing 2. Thesecondary element 6 operates to catch this debris and contaminant and prevent these contaminants from being sucked into the engine. - After the
media pack 3 has been removed, thesecondary element 6 may be serviced. It is contemplated that thesecondary element 6 may not need servicing every time themedia pack 3 is serviced. When it is desired to service thesecondary element 6, the user removes thesecondary element 6 from thehousing 2 by breaking the sealingeffect 460 formed by themedia 404. More specifically, the user grasps thehandle construction 440 of theframe construction 402 and removes thesecondary element 6 from thehousing 2. This may be done by grasping theribs 442 andcenter framework 446 and axially pulling theelement 6 from thehousing 2 by sliding it along theinterior wall 269 of thesecondary element chamber 22 of thehousing 2. As thesecondary element 6 is being slid along thewall 269 of thehousing 2, the skirtedportion 408 of themedia 404 wipes thewall 269 to help clean thehousing 2. - After the
secondary element 6 is removed from thehousing 2, either the entiresecondary element 6 can be disposed of and replaced with a new one, or alternatively, only themedia 404 is disposed of while theframe construction 402 is reused. Preferably, thesecondary element 6 is constructed of substantially metal free materials such that it is readily incineratable. For example, preferably thesecondary element 6 comprises at least 95%, and more preferably 98-100% nonmetallic materials. If the entiresecondary element 6 is disposed of, the oldsecondary element 6 can be incinerated. - Alternatively, the
secondary element 6 can be disassembled and themedia 404 removed. Theold filter media 404 would be disposed of, such as by incineration. Theframe construction 402 could be recycled, or alternatively, re-used. If re-used, a new region offilter media 404 would be secured to theframe construction 402. For example, when disassembling thesecondary element 6, the first andsecond frame pieces first frame piece 416 from thesecond frame piece 418. By unlocking the first andsecond frame pieces old filter media 404, which may then be incinerated. Thesecondary element 6 is then reassembled. This may be done by placing a new region of media over theend portion 462 of thesecond frame piece 418. The skirtedportion 408 of the media should be extending outwardly from thesecond frame piece 418. Thefirst frame piece 416 can then be aligned with thesecond frame piece 418 and snapped or locked to thesecond frame piece 418. - The new
secondary element 6 can then be installed in thehousing 2. This may be done by grasping the frame construction, such as the ribs 442 (FIG. 10) of the handle construction 440 (FIG. 10) and inserting it into thehousing 2. Thesecondary element 6 is inserted until theframe construction 402 axially engages or abuts thestop surface 87. The skirted portion 408 (FIG. 2) of the filter element becomes compressed between and against theframe construction 402 and theinner wall 269 of thehousing 2 to occupy or fill the volume therebetween and create a media-filledregion 460 and a sealing effect. - After the
secondary element 6 is replaced, themedia pack 3 may also then be replaced within thehousing 2. - To install a
new media pack 3, the user grasps themedia pack 3 and inserts it through an opening in thehousing 2. Themedia pack 3 is inserted into the opening until theretention extensions retention system 280 touchably engage thesecondary element 6 and until theseal member 250 is sufficiently compressed against theannular wall 16 of thehousing 2 to formradial seal 172 between and against thehousing wall 16 and thetip portion 263 of theframe 205. Theend tip 86 of theseal member 250 will usually axially abut thestop surface 85 of theseat 84, when properly installed. Thecover 13 is then oriented over the exposed end of themedia pack 3 to cover theopening 80. Thecover 13 is then latched to thebody member 12 by thelatches - J. Example Materials
- In this section, examples are provided of usable materials. The particular choice for any given material will vary, depending on the filtering application. In other words, the particular material selected for the systems usable herein will be decided upon by the system designer based on the system requirements. A variety of materials are possible. The following section provides examples of materials that have been found to be suitable.
- The
housing 2 can be constructed of plastic, such as glass-filled nylon. - The
media 122 can comprise cellulose. One example of media usable in the system described above is as follows: cellulose media with the following properties: a basis weight of about 45-55 lbs./3000 ft2 (84.7 g/m2), for example, 48-54 lbs./3000 ft2; a thickness of about 0.005-0.015 in, for example about 0.010 in. (0.25 mm); frazier permeability of about 20-25 ft/min, for example, about 22 ft/min (6.7 m/min); pore size of about 55-65 microns, for example, about 62 microns; wet tensile strength of at least about 7 lbs/in, for example, 8.5 lbs./in (3.9 kg/in); burst strength wet off of the machine of about 15-25 psi, for example, about 23 psi (159 kPa). - The cellulose media can be treated with fine fiber, for example, fibers having a size (fiber diameter) of 5 microns or less, and in some instances, submicron. A variety of methods can be utilized for application of the fine fiber to the media. Some such approaches are characterized, for example, in U.S. Pat. No. 5,423,892, column 32, at lines 48-60. More specifically, such methods are described in U.S. Pat. Nos. 3,878,014; 3,676,242; 3,841,953; and 3,849,241, incorporated herein by reference. Another alternative is a trade secret approach comprising a fine polymeric fiber web positioned over conventional media, practiced under trade secret by Donaldson Company under the designation ULTRA-WEB®. With respect to the configurations of the filter element, the operation of the sealing system, and the construction and operation of the housing and resonator, there is no particular preference for: how the fine fibers are made; and, what particular method is used to apply the fine fibers. Enough fine fiber would be applied until the resulting media construction would have the following properties: initial efficiency of 99.5% average, with no individual test below 90%, tested according to SAE J726C, using SAE fine dust; and an overall efficiency of 99.98% average, according to SAE J726C.
- The frame205 (FIG. 3) of the
sealing system 4 will be constructed of a material that will provide structural integrity and is not subject to creep. Theframe 205 will be constructed of a non-metallic material such that it is environmentally friendly and either recyclable or readily incineratable. Theframe 205 can be constructed from most plastics, for example, glass reinforced plastic. One usable reinforced plastic is propylene or nylon. Of course, other suitable materials may be used. - The compressible seal member250 (FIG. 5) can be made from a variety of materials. There is no particular preference, provided that the
seal member 250 forms a seal in the proper location under compression. One usable material will be a soft polymeric material, such as foamed urethane. One example usable material includes foamed polyurethane, processed to an end product having an “as molded” density of fourteen to twenty-two pounds per cubic foot. Foamed polyurethanes are available from a variety of sources, such as BASF Corporation of Wyandotte, Mich. One example of a foamed polyurethane comprises a material made with I35453R resin and I305OU isocyanate, which is sold exclusively to the assignee Donaldson by BASF Corporation. - The materials should be mixed in a mix ratio of 100 parts I35453 resin to 36.2 parts I305OU isocyanate (by weight). The specific gravity of the resin is 1.04 (8.7 pounds/gallon), and for the isocyanate it is 1.20 (10 pounds/gallon). The materials are typically mixed with a high dynamic shear mixer. The component temperatures should be seventy to ninety-five degrees Fahrenheit. The mold temperatures should be 115-135° Fahrenheit.
- The resin material I35453R has the following description:
- (a) Average molecular weight
- 1) Base polyether polyol=500-15,000
- 2) Diols=60-10,000
- 3) Triols=500-15,000
- (b) Average functionality
- 1) total system=1.5-3.2
- (c) Hydroxyl number
- 1) total systems=100-300
- (d) Catalysts
- 1) amine=Air Products 0.1-3.0 PPH
- 2) tin=Witco 0.01-0.5 PPH
- (e) Surfactants
- 1) total system= 0.1-2.0 PPH
- (f) Water
- 1) total system=0.03-3.0 PPH
- (g) Pigments/dyes
- 1) total system=1-5% carbon black
- (h) Blowing Agent
- 1) 0.1-6.0% HFC 134A.
- The I3050U isocyanate description is as follows:
- (a) NCO content—22.4-23.4 wt %
- (b) Viscosity, cps at 25° C.=600-800
- (c) Density=1.21 g/cm3 at 25° C.
- (d) Initial boiling pt.—190° C. at 5 mm Hg
- (e) Vapor pressure=0.0002 Hg at 25° C.
- (f) Appearance—colorless liquid
- (g) Flash point (Densky-Martins closed cup)=200° C.
- The frame construction402 (FIG. 10) of the
secondary element 6 will be constructed of a material that will provide structural integrity and is not subject to creep. Further, theframe construction 402 can be constructed of a non-metallic material such that it is environmentally friendly and either recyclable or readily incineratable. The frame construction can be constructed from most plastics, for example, glass reinforced plastic. One usable reinforced plastic is propylene or nylon. - The media404 (FIG. 10) for the
secondary element 6 will be a media that will introduce little restriction into the duct. The media can be a nonpleated, noncylindrical, nonwoven media. In particular, the media can be depth media, such as a fibrous media. One example of fibrous media usable in the system described above is as follows: - 1 layer of 4.0-4.8 oz/yd2 (136-163 g/m2) polyester fiber depth media (mixed fibers); 0.55-0.70″ (14-18 mm) thickness freestate (as measured under 0.002 psi compression); average fiber diameter about 21.0 micron (mass weighted average) or about 16.3 micron (length weighted average); permeability (minimum) 500 ft/min (152 m/min.); free state solidity about 0.6-1.0%, typically about 0.7%.
- K. Example Construction
- In this section, examples are provided of a set of operating specifications. These are intended as an example. A wide variety of alternate sizes can be used.
- The first diameter D1 of the
first media chamber 20 of FIG. 9 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in one example would be approximately 4.1 inches (about 10 cm). The first axial length L1 of thefirst media chamber 20 will be between 2 inches (about 5 cm) and 5 inches (about 13 cm), and in one example would be approximate 3.7 inches (about 9 cm). - The second diameter D2 of the sealing
chamber 21 of FIG. 9 will be between 2 inches (about 5 cm) and 5 inches (about 13 cm), and in one example would be approximately 3.7 inches (about 9 cm). The second axial length L2 of the sealingchamber 21 will be between 0.5 inches (about 1 cm) and 2 inches (about 5 cm), and in one example would be approximately 0.8 inches (2 cm). - The third diameter D3 of the
secondary element chamber 22 of FIG. 9 will be between 1.5 inches (about 4 cm) and 4.5 inches (about 11 cm), and in one example would be approximately 2.7 inches (about 7 cm). The third axial length L3 of thesecondary element chamber 22 will be between 0.4 inches (1 cm) and 1.5 inches (about 4 cm), and in one example would be approximately 0.6 inches (1.5 cm). - The fourth diameter D4 of the
outlet 23 of FIG. 9 will be between 1 inch and 3 inches, and in one example would be approximately 1.5 inches (about 4 cm). The fourth axial length L4 of theoutlet 23 will be between 1 inch (2.5 cm) and 4 inches (about 10 cm), and in one example would be approximately 2.1 inches (about 5 cm). - The fifth diameter D5 of the
body chamber 30 of FIG. 7 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in one example would be approximately 4.3 inches (about 11 cm). The fifth axial length L5 of thebody chamber 30 will be between 0.2 inches (0.5 cm) and 1 inch (2.5 cm), and in one example would be approximately 0.3 inches (about 1 cm). - The sixth diameter D6 of the
second media chamber 31 of FIG. 7 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in one example would be approximately 4.1 inches (about 10 cm). The sixth axial length L6 of thesecond media chamber 31 will be between 1 inch (2.5 cm) and 4 inches (about 10 cm), and in one example would be approximately 2.2 inches (about 6 cm). - The seventh axial length L7 of the overall
media pack chamber 67 of FIG. 3 will be between 5 inches (about 13 cm) and 10 inches (about 25 cm), and in one example would be approximately 7.1 inches (18 cm). - The eighth axial length L8 of the
gap 106 of FIG. 3 will be between 0.1 inches (about 0.5 cm) and 0.5 inches (about 1 cm), and in one example would be approximately 0.2 inches (0.5 cm). - The first distance K1 of the
support structure 35 of FIG. 7 will be between 0.5 inches (about 1 cm) and 1.5 inches (about 4 cm), and in one example would be approximately 0.8 inches (2 cm). - The
filter construction 100 of FIG. 3 will provide at least 250 sq. in and typically 400-500 sq. in. for example about 450-460 sq. in. of media surface area. It will occupy a volume of no greater than about 200 in3, and typically between 50-100 in3, and for example about 65-75 in3. - The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
Claims (20)
1. An air cleaner arrangement comprising:
(a) a housing having first and second opposite ends and defining an interior volume; said housing defining an inlet adjacent to said first end and an outlet adjacent to said second end;
(b) a media pack oriented within said interior volume of said housing;
(i) said media pack having a first flow face and an opposite second flow face; said first flow face being adjacent to said first end, and said second flow face being adjacent to said second end;
(A) said media pack being constructed and arranged for air to flow into said media pack through said first flow face, and for air to exit said media pack through said second flow face;
(c) a seal member forming a seal between said media pack and said housing; and
(d) a secondary filter element oriented within said interior volume of said housing.
2. An air cleaner arrangement according to wherein:
claim 1
(a) said secondary filter element is oriented between said seal member and said outlet.
3. An air cleaner according to wherein:
claim 1
(a) said housing includes a cup and a body member; one of said cup and said body member having an alignment protrusion, and one of said cup and said body member having a channel in receipt of said protrusion.
4. An air cleaner according to further including:
claim 3
(a) at least one latch member for selectively securing together said cup and said body member.
5. An air cleaner according to wherein:
claim 1
(a) said media pack comprises a plurality of flutes; each of said flutes having an upstream portion adjacent to said first flow face and a downstream portion adjacent to said second flow face;
(i) selected ones of said flutes being open at said upstream portion and closed at said downstream portion; and selected ones of said flutes being closed at said upstream portion and open at said downstream portion.
6. An air cleaner according to wherein:
claim 1
(a) said seal member is supported by an extension of a frame arrangement;
(i) said extension projecting axially from one of said first and second flow faces;
(ii) said seal member forming a radial seal between and against said extension and said housing.
7. An air cleaner according to wherein:
claim 6
(a) said housing includes an internal annular sealing surface;
(b) said seal member is circumscribed by said sealing surface; said radial seal being formed by compression of said seal member between and against said sealing surface and said extension of said frame arrangement.
8. An air cleaner according to wherein:
claim 7
(a) said housing includes a first seat for engaging said seal member;
(i) said first seat being angled relative to said annular sealing surface.
9. An air cleaner according to wherein:
claim 8
(a) said extension includes an end tip; an outer radial surface, and an opposite inner radial surface; and
(b) said seal member includes a first portion being oriented against at least said outer radial surface of said extension.
10. An air cleaner according to wherein:
claim 9
(a) said seal member includes a second portion oriented against said end tip; and a third portion oriented against said inner radial surface.
11. An air cleaner according to wherein:
claim 10
(a) said second portion of said seal member is oriented between said end tip and said first seat.
12. An air cleaner according to wherein:
claim 11
(a) said third portion of said seal member includes a plurality of projections extending therefrom;
(i) said projections engaging said secondary filter element.
13. An air cleaner according to wherein:
claim 12
(a) said housing includes a second seat for engaging said secondary filter element;
(i) said secondary filter element being between and against said second seat and said projections.
14. An air cleaner comprising:
(a) a housing having an inlet, an outlet, and a wall extending between said inlet and said outlet; said inlet and outlet being at opposite ends of said housing; said wall defining a housing interior portion;
(i) said housing having an annular seat constructed and arranged to support a filter element;
(ii) said inlet comprising a first open area defined by said housing;
(iii) said outlet comprising a second open area defined by said housing;
(A) said first open area being about 5-10 percent smaller than said second open area;
(iv) said wall being cylindrical and having a diameter about 100-250 percent larger than a largest cross-sectional dimension of said outlet;
(v) said wall having a length extending between said inlet and said annular seat; a ratio of said wall length to said diameter of said wall being at least about 1.5;
(b) a filter element oriented within said housing interior portion against said annular seat;
(c) a seal member forming a seal between said filter element and said housing; and
(d) a non-internal tube construction within said housing interior portion between said filter element and said outlet.
15. An air cleaner according to wherein:
claim 14
(a) said filter element comprises a cylindrical construction with a first flow face, and an opposite second flow face; said filter element being constructed and arranged to permit the flow of air into the filter element through the first flow face and exit the filter element through the second flow face;
(i) said filter element having a plurality of flutes; each of said flutes having an upstream portion adjacent to said first flow face and a downstream portion adjacent to said second flow face;
(ii) selected ones of said flutes being open at said upstream portion and closed at said downstream portion; and selected ones of said flutes being closed at said upstream portion and open at said downstream portion; and
(b) said seal member is supported by an extension of a frame arrangement;
(i) said extension projecting axially from one of said first and second flow faces;
(ii) said seal member forming a radial seal between and against said extension and said wall.
16. An air cleaner according to further including:
claim 15
(a) a secondary filter element oriented in said housing interior between said seal member and said outlet;
(i) said secondary filter element including a region of filter media and a frame construction holding said region of filter media;
(A) said region of filter media having a skirted portion; said skirted portion being positioned between said wall and said frame construction.
17. An air cleaner according to wherein:
claim 16
(a) said housing includes a cover and a body member; said cover defining said housing inlet;
(i) said inlet comprises a plurality of slots defined by said cover;
(A) each of said slots having first and second ends; each of said first ends being adjacent to an outer periphery of said cover; each of said second ends being adjacent to a center of said cover;
(B) each of said slots being tapered in width from said first end to said second end.
18. An air cleaner arrangement comprising:
(a) a housing having first and second opposite ends and defining an interior volume; said housing defining an inlet adjacent to said first end and an outlet adjacent to said second end;
(b) a primary filter element oriented within said interior volume of said housing;
(c) a seal member forming a seal between said primary filter element and said housing;
(d) a secondary filter element oriented within said interior volume of said housing;
(i) said secondary filter element being oriented between said seal member and said outlet; and
(ii) said seal member engaging a portion of said secondary filter element.
19. An air cleaner arrangement according to wherein:
claim 18
(a) said secondary filter element includes a frame construction;
(b) said seal member comprises a circular gasket having opposite outer and inner radial sides;
(i) said seal member having a plurality of projections extending from said inner radial side;
(ii) said projections axially abutting said frame construction.
20. An air cleaner arrangement according to wherein:
claim 19
(a) said housing defines a first seat constructed and arranged to support said seal member; and a second seat constructed and arranged to support said secondary filter element;
(i) said secondary filter element being between and against said second seat and said projections.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/771,779 US20010003893A1 (en) | 1999-02-26 | 2001-01-29 | Air cleaner, filter element, and methods |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/258,412 US6179890B1 (en) | 1999-02-26 | 1999-02-26 | Air cleaner having sealing arrangement between media arrangement and housing |
US09/771,779 US20010003893A1 (en) | 1999-02-26 | 2001-01-29 | Air cleaner, filter element, and methods |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/258,412 Continuation US6179890B1 (en) | 1999-02-26 | 1999-02-26 | Air cleaner having sealing arrangement between media arrangement and housing |
Publications (1)
Publication Number | Publication Date |
---|---|
US20010003893A1 true US20010003893A1 (en) | 2001-06-21 |
Family
ID=22980440
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US09/258,412 Expired - Lifetime US6179890B1 (en) | 1999-02-26 | 1999-02-26 | Air cleaner having sealing arrangement between media arrangement and housing |
US09/771,779 Abandoned US20010003893A1 (en) | 1999-02-26 | 2001-01-29 | Air cleaner, filter element, and methods |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/258,412 Expired - Lifetime US6179890B1 (en) | 1999-02-26 | 1999-02-26 | Air cleaner having sealing arrangement between media arrangement and housing |
Country Status (3)
Country | Link |
---|---|
US (2) | US6179890B1 (en) |
AU (1) | AU3705300A (en) |
WO (1) | WO2000050152A1 (en) |
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AU3705300A (en) | 2000-09-14 |
WO2000050152A1 (en) | 2000-08-31 |
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