WO2008045325A2

WO2008045325A2 - Air cleaner assembly, air cleaner filter cartridge, and method of servicing an air cleaner assembly

Info

Publication number: WO2008045325A2
Application number: PCT/US2007/021401
Authority: WO
Inventors: Michel Baseotto; E. Moreau; Paul R. Coulonvaux; Robert Wood
Original assignee: Donaldson Company, Inc.
Priority date: 2006-10-06
Filing date: 2007-10-08
Publication date: 2008-04-17
Also published as: WO2008045325A3

Abstract

An air cleaner assembly, an air filter cartridge, and a method of servicing an air cleaner assembly are described. The air cleaner assembly can be provided for receipt of an air filter cartridge that can be characterized as a V-shaped air filter cartridge containing fluted filter media. The air filter cartridge can be replaceable within the air cleaner assembly.

Description

AIR CLEANER ASSEMBLY, AIR CLEANER FILTER CARTRIDGE, AND METHOD OF SERVICING AN AIR CLEANER ASSEMBLY

This application is being filed on 08 October 2007, as a PCT International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Michael Baseotto, E. Moreau, and Paul R. Coulonvaux, all citizens of Belgium, applicants for the designation of the US only, and claims priority to U.S. Provisional Patent Application Serial No. 60/849,907, filed October 6, 2006.

Field of the Invention

The present invention relates to air cleaners for use, for example, for cleaning engine combustion air for vehicles and other equipment.

Background

Gas streams often carry particulate material therein. In many instances it is desirable to remove some or all of the particulate material from the gas flow stream. For example, air intake streams to engines for motorized vehicles or power generation equipment often include particulate material therein. The particulate material, should it reach the internal workings of the mechanisms involved, can cause substantial damage. 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 cleaner arrangements have been developed for particulate removal.

Summary of the Disclosure

An air cleaner assembly, an air filter cartridge, and a method of servicing an air cleaner assembly are described. The air cleaner assembly can be provided for receipt of an air filter cartridge that can be characterized as a V-shaped air filter cartridge containing fluted filter media. The air filter cartridge can be replaceable within the air cleaner assembly. Brief Description of the Drawings

Figure 1 is a perspective view of an air cleaner assembly according to the principles of the present invention.

Figure 2 is a perspective, exploded view of the air cleaner assembly according to Figure 1.

Figure 3 is a perspective view showing the insertion of an air filter cartridge into an air cleaner housing.

Figure 4 is a perspective view showing the insertion of an air filter cartridge into an air cleaner housing. Figure 5 is a perspective view showing the insertion of an air filter cartridge into an air cleaner housing.

Figure 6 is a sectional view of the air cleaner assembly according to Figure 1 taken along lines 6-6.

Figure 7 is a perspective view of the air cleaner according to Figure 1 with the water separator removed and showing the operation of the locking mechanism.

Figure 8 is a perspective view of the air cleaner according to Figure 1 with the water separator removed and showing the operation of the locking mechanism. Figure 9 is a perspective view showing operation of the locking knob.

Figure 10 is a perspective view showing operation of the locking knob.

Figure 11 is a fragmentary, schematic, perspective view of an exemplary z-filter media useable in arrangements according to the present disclosure.

Figure 12 is an enlarged schematic, cross-sectional view of a portion of the media depicted in Figure 11.

Figure 13 is a schematic view of various corrugated media definitions.

Detailed Description

Referring to Figures 1 and 2, an air cleaner assembly is shown at reference number 10. The air cleaner assembly 10 includes an air cleaner housing 12 and an air filter cartridge 14. The air cleaner assembly 10 can additionally include a water separator 16.

The air cleaner assembly 10 includes an unfiltered air inlet 18 and a filtered air outlet 20. In general, air enters the air cleaner assembly 10 via the unfiltered air inlet 18 and exits through the filtered air outlet 20. As air enters the unfiltered air inlet 18, the air passes through the water separator 16 for the removal of liquid water that may be present in the air entering the air cleaner assembly 10. The air passing through the water separator 16 can then pass through the air filter cartridge 14 for the removal of particulates, and then out the filtered air outlet 20. The air filter cartridge 14 is constructed so that it is replaceable from within the air cleaner housing 12. In general, it is expected that after a certain period of use, the air filter cartridge 14 will have achieved its useful life and should be replaced. The air filter cartridge 14 can then be removed from the air cleaner housing 12 and discarded, and replaced with a new air filter cartridge. The air cleaner housing 12 includes an air filter cartridge receiving area 13 where the air filter cartridge 14 fits within the air cleaner housing 12.

The air filter cartridge 14 includes a guide member arrangement 24 provided on a first side 26 of the air filter cartridge 14, and a guide member arrangement 24 (see Figure 6) provided on a second side 28 of the air filter cartridge 14. The guide member arrangements 24 are provided for engaging the guide member receiving surface 30 on the first side 32 of the air cleaner housing 12 and on the second side 34 of the air cleaner housing 12. The guide member arrangements 24 include lower projections 38 and upper projections 40. The guide member receiving surface 30 can be provided as a groove 36 that receives the lower projection 38 and the upper projection 40 on the guide member arrangements 24.

Accordingly, the air filter cartridge 14 can be inserted into the air cleaner housing 12 so that the lower projections 38 and the upper projections 40 are received within the groove 36. Once the lower projections 38 engage the groove lower end 42 of the groove 36, the air filter cartridge 14 can then be moved toward the filtered air outlet 20 so that the air filter cartridge 14 is in a sealing arrangement with respect to the air cleaner housing 12. The lower projections 38 can move into the lower sealing grooves 44, and the upper projections 40 can move into the upper sealing grooves 46. The movement of the air filter cartridge 14 as it is introduced into the air cleaner housing 12 can be seen in the context of Figures 3-5. In Figure 3, the air filter cartridge 14 is shown where the lower projection 38 is sliding through the groove 36, and the upper projection 40 is about to engage the groove 36. In Figure 4, the air filter cartridge 14 is received within the air cleaner housing 12 so that the lower projection 38 has engaged the groove lower end 42. At this point, the air filter cartridge 14 can be pushed toward the filtered air outlet 20 so that the air filter cartridge 14 is provided within the air cleaner housing 12 as shown in Figure 5. As the air filter cartridge 14 moves toward the air outlet 20, the lower projections 38 move into the lower sealing grooves 44, and the upper projections 40 move into the upper sealing grooves 46. When it is desirable to replace the air filter cartridge 14, the air filter cartridge 14 can reverse the steps and disengage from the air cleaner housing 12.

Now referring to Figure 6, a sectional view of the air filter cartridge 14 is shown. The air filter cartridge 14 includes a first separation filter member 50 and a second separation filter member 52. The first separation filter member 50 and the second separation filter member 52 can be arranged at an angle relative to each other so that the arrangement can be generally characterized as having a v-shape. The air cleaner cartridge 14 can be referred to as a v cartridge because of the angular relationship between the first separation filter member 50 and the second separation filter member 52. The first separation filter member 50 includes a first upstream end cap 54 and a first downstream end cap 56. The second separation filter member 52 includes a second upstream end cap 58 and a second downstream end cap 60. The first upstream end cap 54 and the second upstream end cap 58 can be constructed so that they are attached forming an upstream end cap 62. The upstream end cap 62 can be configured to allow the air filter cartridge 14 to fit around the lock post 100 of the air cleaner housing 12. In addition, the upstream end cap 62 prevents flow of unfiltered air from bypassing the first separation filter member 50 or the second separation filter member 52. The first downstream end cap 56 and the second downstream end cap 60 can collectively be referred to as the downstream end cap 61. Referring to Figures 2 and 6, the air filter cartridge 14 includes a header 67 extending from the upstream end cap 62. If desired, the header 67 can attach to the upstream end cap 62. The first separation filter member 50 includes a first air inlet face 64 and first air outlet face 66. The second separation filter member 52 includes a second air inlet face 68 and a second air outlet face 70. Unfiltered air flows through the first separation filter member 50 or the second separation filter member 52 by entering the first air inlet 64 or the second air inlet 68. Filtered air exits the first separation filter member 50 and the second separation filter member 52 via the first air outlet face 66 or the second air outlet face 70. Accordingly, the unfiltered air can generally be found at unfiltered air region 72 and filtered air can generally be found at filtered air region 74 within the housing 12. The air filter cartridge 14 additionally includes an outlet wall 76 and a seal arrangement 78. The outlet wall 76 can be seen in Figures 2 and 6, and stops the movement of the air filter cartridge 14 when it is moved toward the filtered air outlet 20. The seal arrangement 78 includes a support member 80 and a compressible sealing material 82. The support member 80 can be provided as a relatively rigid structure and formed as part of the outlet wall 76 and the downstream end cap 61. In general, the support member 80 should be sufficiently strong to maintain a seal. The compressible sealing material 82 can be formed as a separate preformed piece and adhered to the support member 80 by, for example, adhesive. Alternatively, the compressible sealing material 82 can be molded onto the support member 80. This type of seal arrangement is described, for example, in U.S. Patent Number 6,190,432, U.S. Patent Number 6,350,291, U.S. Patent Number 6,610,117, and U.S. Patent Number 6,783,565, incorporated herein by reference.

The compressible sealing material 82 includes a sealing surface 83. The sealing surface 83 is constructed to engage a radial seal surface 89 extending from the housing 12 at the outlet 20. The radial seal surface 89 can be provided as part of duct work 91 extending at the outlet periphery 85.

As shown in Figures 1 , 2, and 6, the air filter cartridge 14 includes a top cover 84 and a bottom cover 86. The top cover 84 and the bottom cover 86 attach to the upstream end cap 62 and the downstream end cap 61 thereby enclosing the first separation filter member 50 and the second separation filter member 52. The top cover 84 and the bottom cover 86 additionally attach to the outlet wall 76 and the support member 80 to provide a filtered air region 74 when the air filter cartridge 14 is installed in the air cleaner housing 12. Now referring to Figures 1, 2, and 6, the air cleaner housing 12 includes side walls 90 and 92, bottom wall 94, and access cover 96 as shown, for example, in Figures 3-5, the access cover 96 can be provided so that it rotates about a hinge 98. The air cleaner housing 12 includes a lock post 100 extending from the bottom wall 94, and a lock assembly 102 extending from the access cover 96. The lock assembly 102 engages the lock post 100 and the air cleaner housing 12 to lock the access cover 96 and the air filter cartridge 14 in place.

The lock assembly 102 includes a knob 104 located on the exterior side 106 of the access cover 96. A shaft 108 extends from the knob 104 and holds a key 110 in place. The shaft 108 can include threads 112 for receipt of a washer 114 and a nut 116 that holds the key 110 in place. The key 110 includes upper engagement members 120 and 122 and lower engagement members 124 and 126.

Now referring to Figure 5, as the access cover 96 is lowered, the lock assembly 102 engages the header opening 130 so that the lock assembly 102 passes through the header opening 130. Once the access cover 96 is closed, the lock assembly 102 is provided in the position shown in Figure 7. By turning the knob 104, the lower engagement members 124 and 126 engage the openings 132 and 134 in the block post 100. Simultaneously, the upper engagement members 120 and 122 engage the header locking surface 136. The lock assembly 102 is in a locking position in engagement with the lock post 100 and the header 67 in Figure 8. Once the lock assembly 102 is in a locking position in engagement with the lock post 100 and the header 67, the air filter cartridge 14 is locked in position within the air cleaner housing 12. As a result, vibrations and other movement of the air cleaner assembly 10 should not cause the air filter cartridge 14 to fall out of the sealing engagement with the air cleaner housing 12.

As shown in Figures 7 and 8, the header 67 extends to a depth 69 so that there remains a clearance 71 between the bottom surface 73 of the header 67, and the top surface 75 of the lock post 100. As a result of the clearance 71, the lock post 100 does not interfere with the installation of the air filter cartridge 14. Now referring to Figures 9 and 10, as the knob 104 turns, a latch mechanism 140 can be provided that includes ears 142 on each side that engage protrusions 144 and cause the knob to lock in place. In order to unlock the knob, the latch mechanism 140 can be pulled up so that the ears 142 are no longer held in place by the protrusions 144. The protrusions 144 can be provided as part of a ring member 150 that attaches the lock assembly 102 to the axis cover 96 as shown in Figure 2.

Now referring to Figures 1, 2, and 6, the air cleaner housing 12 can include a water separator 16. It should be understood that the water separator is optional and can be included or omitted, as desired. In general, because of various design criteria for motor vehicles, the air cleaner assembly 10 is often located in an environment where water has a tendency to enter into the air cleaner. One area of concern is when the air intake for the air cleaner is near a wheel of the vehicle. In that case, the wheel can have a tendency to kick up water into the air intake.

Furthermore, during periods of rain, water can have a tendency to enter into the air intake, and water can have a detrimental effect on the filtration media. Accordingly, there can be a desire to remove liquid water from the air intake.

The air cleaner housing 12 is shown having a water separator 16 located in the unfiltered air inlet 18. Various designs for water separators are presently available, and the various designs can be used in place of the particular water separator shown. The bottom wall 94 of the air cleaner housing 12 can include a drain 160 for providing for the removal of water that collects as a result of operation of the water separator 16. The first separation filter member 50 and the second separation filter member 52 can be provided as fluted filter media. Fluted filter media can be used to provide fluid filter constructions in a variety of manners. One well known manner is as a z-filter construction. The term "z-filter construction" as used herein, is meant to refer to a filter construction in which individual ones of corrugated, folded or otherwise formed filter flutes are used to define longitudinal filter flutes for fluid flow through the media; the fluid flowing along the flutes between opposite inlet and outlet flow ends (or flow faces) of the media. Some examples of z-filter media are provided in U.S. patents 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469; 6,190,432; 6,350,296; 6,179,890; 6,235,195; Des. 399,944; Des. 428,128; Des. 396,098; Des. 398,046; and, Des. 437,401 ; each of these fifteen cited references being incorporated herein by reference.

One type of z-filter media, utilizes two specific media components joined together, to form the media construction. The two components are: (1) a fluted (typically corrugated) media sheet; and, (2) a facing media sheet. The facing media sheet is typically non-corrugated, however it can be corrugated, for example perpendicularly to the flute direction as described in U.S. provisional 60/543,804, filed February 11, 2004, incorporated herein by reference. Now referring to Figure 6, flutes are represented by the lines 161. It should be understood that the flutes are not intended to be drawn to scale. The flutes are shown extending from the first air inlet face 64 to the first air outlet face 66, and from the second air inlet face 68 to the second air outlet face 70. As represented in Figure 6, the flutes can extend between the air inlet flow face and the air outlet flow face at an angle of 90° or less than 90° (from perpendicular to the face). For many prior art the media filters, the flutes have a tendency to extend between an air inlet flow face and an air outlet flow face at angle of about 90°. The angle of the flutes relative to the air inlet flow face or the air outlet flow face can be varied depending upon the desired flow pattern within the air cleaner housing, and depending upon the convenience of manufacturing a filter media having a particular flute angle. An exemplary range of angles that can be selected includes the range of about 30° to about 80° relative to one or both of the air inlet flow face or the air outlet flow face.

In certain z-filter arrangements, the fluted (typically corrugated) media sheet and the facing media sheet, together, can be used to define media having parallel inlet and outlet flutes. In some instances, the fluted sheet and non- fluted sheet are secured together and are then coiled to form a z-filter media construction. Such arrangements are described, for example, in U.S. 6,235,195 and 6,179,890, each of which is incorporated herein by reference. In certain other arrangements, some non-coiled sections of fluted media secured to flat media, are stacked on one another, to create a filter construction. An example of this is described in Fig. 11 of 5,820,646, incorporated herein by reference. In general, the stacked arrangements can be advantageously utilized to form the separation filter member. In addition, coiled arrangements can be utilized.

Typically, coiling of the fluted sheet/facing sheet combination around itself, to create a coiled media pack, is conducted with the facing sheet directed outwardly. Some techniques for coiling are described in U.S. provisional application 60/467,521, filed May 2, 2003 and PCT Application US 04/07927, filed March 17, 2004, each of which is incorporated herein by reference. The resulting coiled arrangement generally has, as the outer surface of the media pack, a portion of the facing sheet, as a result.

The term "corrugated" used herein to refer to structure in media, is meant to refer to a flute structure resulting from passing the media between two corrugation rollers, i.e., into a nip or bite between two rollers, each of which has surface features appropriate to cause a corrugation affect in the resulting media. The term "corrugation" is not meant to refer to flutes that are formed by techniques not involving passage of media into a bite between corrugation rollers. However, the term "corrugated" is meant to apply even if the media is further modified or deformed after corrugation, for example by the folding techniques described in PCT WO 04/007054, published January 22, 2004, incorporated herein by reference.

Corrugated media is a specific form of fluted media. Fluted media is media which has individual flutes (for example formed by corrugating or folding) extending thereacross. Serviceable filter element or filter cartridge configurations utilizing z- filter media are sometimes referred to as "straight through flow configurations" or by variants thereof. In general, in this context what is meant is that the serviceable filter elements generally have an inlet flow end (or face) and an opposite exit flow end (or face), with flow entering and exiting the filter cartridge in generally the same straight through direction. (The term "straight through flow configuration" disregards, for this definition, air flow that passes out of the media pack through the outermost wrap of facing media.) The term "serviceable" in this context is meant to refer to a media containing filter cartridge that is periodically removed and replaced from a corresponding air cleaner. In some instances, each of the inlet flow end and outlet flow end will be generally flat or planar, with the two parallel to one another. However, variations from this, for example non-planar faces, are possible in some applications.

A straight through flow configuration is, for example, in contrast to serviceable filter cartridges such as cylindrical pleated filter cartridges of the type shown in U.S. Patent No. 6,039,778, in which the flow generally makes a substantial turn as its passes through the serviceable cartridge. That is, in a 6,039,778 filter, the flow enters the cylindrical filter cartridge through a cylindrical side, and then turns to exit through an end face (in forward-flow systems). In a typical reverse-flow system, the flow enters the serviceable cylindrical cartridge through an end face and then turns to exit through a side of the cylindrical filter cartridge. An example of such a reverse-flow system is shown in U.S. Patent No. 5,613,992, incorporated by reference herein. The term "z-filter media construction" and variants thereof as used herein, without more, is meant to refer to any or all of: a web of corrugated or otherwise fluted media secured to (facing) media with appropriate sealing to inhibit air flow from one flow face to another without filtering passage through the filter media; and/or, such a media coiled or otherwise constructed or formed into a three dimensional network of flutes; and/or, a filter construction including such media. In many arrangements, the z-filter media construction is configured for the formation of a network of inlet and outlet flutes, inlet flutes being open at a region adjacent an inlet face and being closed at a region adjacent an outlet face; and, outlet flutes being closed adjacent an inlet face and being open adjacent an outlet face. However, alternative z-filter media arrangements are possible, see for example US

2006/0091084 Al , published May 4, 2006 to Baldwin filters, also comprising flutes extending between opposite flow faces, with a seal arrangement to prevent flow of unfiltered air through the media pack.

In Figure 11 herein, an example type of media 200 useable as z-filter media is shown. The media 200 is formed from a fluted (in the example corrugated) sheet 203 and a facing sheet 204.

In general, the (fluted corrugated) sheet 202, Fig. 11 is of a type generally characterized herein as having a regular, curved, wave pattern of flutes or corrugations 207. The term "wave pattern" in this context, is meant to refer to a flute or corrugated pattern of alternating troughs 207b and ridges 207a. The term "regular" in this context is meant to refer to the fact that the pairs of troughs and ridges (207b, 207a) alternate with generally the same repeating corrugation (or flute) shape and size. (Also, typically in a regular configuration each trough 207b is substantially an inverse of each ridge 207a.) The term "regular" is thus meant to indicate that the corrugation (or flute) pattern comprises troughs and ridges with each pair (comprising an adjacent trough and ridge) repeating, without substantial modification in size and shape of the corrugations along at least 70% of the length of the flutes. The term "substantial" in this context, refers to a modification resulting from a change in the process or form used to create the corrugated or fluted sheet, as opposed to minor variations from the fact that the media sheet 203 is flexible. With respect to the characterization of a repeating pattern, it is not meant that in any given filter construction, an equal number of ridges and troughs is necessarily present. The media 200 could be terminated, for example, between a pair comprising a ridge and a trough, or partially along a pair comprising a ridge and a trough. (For example, in Fig. 11 the media 200 depicted in fragmentary has eight complete ridges 207a and seven complete troughs 207b.) Also, the opposite flute ends (ends of the troughs and ridges) may vary from one another. Such variations in ends are disregarded in these definitions, unless specifically stated. That is, variations in the ends of flutes are intended to be covered by the above definitions.

In the context of the characterization of a "curved" wave pattern of corrugations, the term "curved" is meant to refer to a corrugation pattern that is not the result of a folded or creased shape provided to the media, but rather the apex 207a of each ridge and the bottom 207b of each trough is formed along a radiused curve. Although alternatives are possible, a typical radius for such z-filter media would be at least 0.25 mm and typically would be not more than 3 mm. (Media that is not curved, by the above definition, can also be useable.)

An additional characteristic of the particular regular, curved, wave pattern depicted in Fig. 11, for the corrugated sheet 203, is that at approximately a midpoint 230 between each trough and each adjacent ridge, along most of the length of the flutes 207, is located a transition region where the curvature inverts. For example, viewing back side or face 203a, Fig. 1, trough 207b is a concave region, and ridge 207a is a convex region. Of course when viewed toward front side or face 203b, trough 207b of side 203a forms a ridge; and, ridge 207a of face 203a, forms a trough. (In some instances, region 230 can be a straight segment, instead of a point, with curvature inverting at ends of the segment 230.)

A characteristic of the particular regular, curved, wave pattern corrugated sheet 203 shown in Fig. 11, is that the individual corrugations are generally straight. By "straight" in this context, it is meant that through at least 70% (typically at least 80%) of the length between edges 208 and 209, the ridges 207a and troughs 207b do not change substantially in cross-section. The term "straight" in reference to corrugation pattern shown in Fig. 1 1, in part distinguishes the pattern from the tapered flutes of corrugated media described in Fig. 1 of WO 97/40918 and PCT Publication WO 03/47722, published June 12, 2003, incorporated herein by reference. The tapered flutes of Fig. 1 of WO 97/40918, for example, would be a curved wave pattern, but not a "regular" pattern, or a pattern of straight flutes, as the terms are used herein.

Referring to the present Fig. 11 and as referenced above, the media 200 has first and second opposite edges 208 and 209. For the example shown, when the media 200 is coiled and formed into a media pack, in general edge 209 will form an inlet end for the media pack and edge 208 an outlet end, although an opposite orientation is possible in some applications.

In the example shown, adjacent edge 208 is provided sealant, in this instance in the form of a sealant bead 210, sealing the corrugated (fluted) sheet 203 and the facing sheet 204 together. Bead 210 will sometimes be referred to as a "single facer" bead, since it is a bead between the corrugated sheet 203 and facing sheet 204, which forms the single facer or media strip 201. Sealant bead 210 seals closed individual flutes 211 adjacent edge 208, to passage of air therefrom.

In the example shown, adjacent edge 209 is provided sealant, in this instance in the form of a seal bead 214. Seal bead 214 generally closes flutes 215 to passage of unfiltered fluid therein, adjacent edge 209. Bead 214 would typically be applied as the media 200 is coiled about itself, with the corrugated sheet 203 directed to the inside. Thus, bead 214 will form a seal between a back side 217 of facing sheet 204, and side 218 of the corrugated sheet 203. The bead 214 will sometimes be referred to as a "winding bead" since it is typically applied, as the strip 200 is coiled into a coiled media pack. If the media 200 is cut in strips and stacked, instead of coiled, bead 214 would be a "stacking bead."

Referring to Fig. 11, once the media 200 is incorporated into a media pack, for example by coiling or stacking, it can be operated as follows. First, air in the direction of arrows 212, would enter open flutes 21 1 adjacent end 209. Due to the closure at end 208, by bead 210, the air would pass through the media shown by arrows 213. It could then exit the media pack, by passage through open ends 215a of the flutes 215, adjacent end 208 of the media pack. Of course operation could be conducted with air flow in the opposite direction. In more general terms, z-filter media comprises fluted filter media secured to facing filter media, and configured in a media pack of flutes extending between first and second opposite flow faces. A sealant or seal arrangement is provided within the media pack, to ensure that air entering flutes at a first upstream edge cannot exit the media pack from a downstream edge, without filtering passage through the media. Alternately stated, a z-filter media is closed to passage of unfiltered air therethrough, between the inlet face and the outlet flow face, typically by a sealant arrangement or other arrangement.

For the particular arrangement shown herein in Fig. 1 1 , the parallel corrugations 207a, 207b are generally straight completely across the media, from edge 208 to edge 209. Straight flutes or corrugations can be deformed or folded at selected locations, especially at ends. Modifications at flute ends for closure are generally disregarded in the above definitions of "regular," "curved" and "wave pattern." Z-filter constructions which do not utilize straight, regular curved wave pattern corrugation (flute) shapes are known. For example in Yamada et al. U.S. 5,562,825 corrugation patterns which utilize somewhat semicircular (in cross section) inlet flutes adjacent narrow V-shaped (with curved sides) exit flutes are shown (see Figs. 1 and 3, of 5,562,825). In Matsumoto, et al. U.S. 5,049,326 circular (in cross-section) or tubular flutes defined by one sheet having half tubes attached to another sheet having half tubes, with flat regions between the resulting parallel, straight, flutes are shown, see Fig. 2 of Matsumoto '326. In Ishii, et al. U.S. 4,925,561 (Fig. 1) flutes folded to have a rectangular cross section are shown, in which the flutes taper along their lengths. In WO 97/40918 (FIG. 1), flutes or parallel corrugations which have a curved, wave patterns (from adjacent curved convex and concave troughs) but which taper along their lengths (and thus are not straight) are shown. Also, in WO 97/40918 flutes which have curved wave patterns, but with different sized ridges and troughs, are shown.

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

In the corrugation or fluting process, an inelastic deformation is caused to the media. This prevents the media from returning to its original shape. However, once the tension is released the flutes or corrugations will tend to spring back, recovering only a portion of the stretch and bending that has occurred. The facing sheet is sometimes tacked to the fluted sheet, to inhibit this spring back in the fluted (or corrugated) sheet. Also, typically, the media contains a resin. During the corrugation process, the media can be heated to above the glass transition point of the resin. When the resin then cools, it will help to maintain the fluted shapes.

The media of the corrugated sheet 203, facing sheet 204 or both, can be provided with a fine fiber material on one or both sides thereof, for example in accord with U.S. 6,673,136, incorporated herein by reference.

An issue with respect to z-filter constructions relates to closing of the individual flute ends. Typically a sealant or adhesive is provided, to accomplish the closure. As is apparent from the discussion above, in typical z-filter media, especially that which uses straight flutes as opposed to tapered flutes, large sealant surface areas (and volume) at both the upstream end and the downstream end are needed. High quality seals at these locations are critical to proper operation of the media structure that results. The high sealant volume and area creates issues with respect to this.

Still referring to Fig. 1 1 , at 220 tack beads are shown positioned between the corrugated sheet 203 and facing sheet 204, securing the two together. The tack beads 220 can be for example, discontinuous lines of adhesive. The tack beads can also be points in which the media sheets are welded together.

From the above, it will be apparent that the example corrugated sheet 203 depicted is typically not secured continuously to the facing sheet, along the troughs or ridges where the two adjoin. Thus, air can flow between adjacent inlet flutes, and alternately between the adjacent outlet flutes, without passage through the media. However air which has entered in inlet flute cannot exit from an outlet flute, without passing through at least one sheet of media, with filtering. Attention is now directed to Figure 12, in which a z- filter media construction 240 utilizing a fluted (in this instance regular, curved, wave pattern corrugated) sheet 243, and a non-corrugated flat, facing, sheet 244, is depicted. The distance Dl, between points 250 and 251, defines the extension of flat media 44 in region 52 underneath a given corrugated flute 253. The length D2 of the arcuate media for the corrugated flute 253, over the same distance Dl is of course larger than Dl, due to the shape of the corrugated flute 253. For a typical regular shaped media used in fluted filter applications, the linear length D2 of the media 253 between points 250 and 251 will generally be at least 1.2 times Dl . Typically, D2 would be within a range of 1.2 - 2.0, inclusive. One particularly convenient arrangement for air filters has a configuration in which D2 is about 1.25 - 1.35 x Dl. Such media has, for example, been used commercially in Donaldson Powercore™ Z- filter arrangements. Herein the ratio D2/D1 will sometimes be characterized as the flute/flat ratio or media draw for the corrugated media. In the corrugated cardboard industry, various standard flutes have been defined. For example the standard E flute, standard X flute, standard B flute, standard C flute and standard A flute. Figure 3, attached, in combination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure, has used variations of the standard A and standard B flutes, in a variety of z-filter arrangements. These flutes are also defined in Table A and Fig. 13.

TABLE A

(Flute definitions for Fig. 3)

DCI A Flute: Flute/flat = 1.52: 1 ; The Radii (R) are as follows:

RlOOO = .0675 inch (1.715 mm); RlOOl = .0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch (1.730 mm);

DCI B Flute: Flute/flat = 1.32:1; The Radii (R) are as follows:

R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm); R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm);

Std. E Flute: Flute/flat = 1.24: 1 ; The Radii (R) are as follows:

R1008 = .0200 inch (.508 mm); R1009 = .0300 inch (.762 mm); RlOlO - .0100 inch (.254 mm); RlOl 1 = .0400 inch (1.016 mm);

Std. X Flute: Flute/flat = 1.29:1; The Radii (R) are as follows:

R1012 = .0250 inch (.635 mm); R1013 = .0150 inch (.381 mm);

Std. B Flute: Flute/flat = 1.29: 1 ; The Radii (R) are as follows:

R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874 mm); R1016 - .0310 inch (.7874 mm);

Std. C Flute: Flute/flat - 1.46: 1 ; The Radii (R) are as follows:

R1017 = .0720 inch (1.829 mm); R1018 = .0620 inch (1.575 mm);

Std. A Flute: Flute/flat = 1.53:1; The Radii (R) are as follows:

R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575 mm).

Of course other, standard, flute definitions from the corrugated box industry are known.

In general, standard flute configurations from the corrugated box industry can be used to define corrugation shapes or approximate corrugation shapes for corrugated media.

Claims

WE CLAIM:

1. An air cleaner assembly comprising:

(a) an air cleaner housing comprising:

(i) an unfiltered air inlet, a filtered air outlet containing a radial seal surface, a pair of side walls, a bottom wall, and an access cover containing a lock assembly;

(ii) an air filter cartridge receiving area that can be accessed through the access cover; and

(iii) a lock post extending from the housing bottom wall and into the air filter cartridge receiving area and constructed for engaging the lock assembly on the access cover for holding the access cover in place; and

(b) an air filter cartridge constructed for receipt within the filter cartridge receiving area, the air filter cartridge comprising:

(i) a first separation filter member having an inlet flow face and an outlet flow face, and extending from an upstream end cap to a downstream end cap;

(ii) a second separation filter member having an air inlet face and an air outlet face, and extending from an upstream end cap to a downstream end cap;

(iii) a top cover and a bottom cover extending from the first separation filter member and the second separation filter member, enclosing the first separation filter member and the second separation filter member and forming a filtered air internal area;

(iv) a header constructed to engage the lock assembly on the access cover when the air filter cartridge is installed within the air filter cartridge receiving area;

(v) a seal arrangement for engaging the housing radial seal surface; and

(vi) the first separation filter member and the second separation filter member each comprising a media pack comprising a plurality of flutes extending between the inlet flow face and the outlet flow face, the media pack being closed to passage of unfiltered air therethrough, between the inlet face and the outlet face.

2. An air cleaner assembly according to claim 1 , further comprising a water separator within the unfiltered air inlet.

3. An air filter assembly according to claim 2, wherein the unfiltered air inlet comprises a water drain.

4. An air cleaner assembly according to claim 1, wherein the lock assembly is constructed to engage the lock post and the header to hold the air filter cartridge in place within the filter cartridge receiving area.

5. An air cleaner assembly according to claim 1, wherein the first separation filter member and the second separation filter member are constructed to provide a V-shape.

6. An air cleaner assembly according to claim 1, wherein the first separation filter member and the second separation filter member each comprise a plurality of flutes extending at an angle of less than 90° from the inlet flow face and the outlet flow face.

7. An air cleaner assembly according to claim 1, wherein the first separation filter member and the second separation filter member each comprise flutes extending at an angle of about 30° to about 80° relative to the air inlet face and the air outlet face.

8. An air cleaner assembly according to claim 1 , wherein the air cleaner housing comprises grooves along the pair of sidewalls, and the air filter cartridge comprises projections constructed to engage the grooves on the sidewalls.

9. An air cleaner assembly according to claim 7, wherein the projections comprise lower projections and upper projections.

10. An air cleaner assembly according to claim 9, wherein the grooves are constructed to guide the air filter cartridge into a sealing arrangement with the air cleaner housing.

11. An air filter cartridge comprising:

(a) an air filter cartridge constructed for receipt within the filter cartridge receiving area, the air filter cartridge comprising:

(iv) a seal arrangement; and

(v) the first separation filter member and the second separation filter member each comprising a media pack comprising a plurality of flutes extending between the inlet flow face and the outlet flow face, the media pack being closed to passage of unfiltered air therethrough, between the inlet face and the outlet face.

12. An air filter cartridge according to claim 11, wherein the first separation filter member and the second separation filter member are constructed to provide a V-shape.

13. An air filter cartridge according to claim 11, wherein the first separation filter member and the second separation filter member each comprise a plurality of flutes extending at an angle of less than 90° from the inlet flow face and the outlet flow face.

14. An air filter cartridge according to claim 1 1 , wherein the first separation filter member and the second separation filter member each comprise flutes extending at an angle of about 30° to about 80° relative to the air inlet face and the air outlet face.

15. An air filter cartridge according to claim 11 , wherein the air filter cartridge comprises a first side and a second side, and the first and the second sides comprise projections constructive for engaging a groove on an air cleaner housing.

16. An filter cartridge according to claim 15, wherein the projections comprise lower projections and upper projections.

17. An filter cartridge according to claim 11, further comprising a header extending from an upstream end cap, wherein the header is available for locking the air filter cartridge within an air cleaner housing.

18. An filter cartridge according to claim 17, wherein the header has an opening for receipt of a lock assembly.

19. A method for servicing an air cleaner assembly, the method comprising:

(a) removing the air filter cartridge from the air cleaner housing according to claim 1, and introducing a new air filter cartridge into the air cleaner housing.