Air cleaner assembly

Abstract

A filter cartridge configured to be removably positioned within an interior opening of a housing, wherein the filter cartridge includes a media pack including an inlet end, an outlet end, and an outer surface having an outer peripheral shape, and at least one of: (a) a frame member at least partially surrounding the media pack, the frame member including a frame wall having a shape different than the outer peripheral shape of the media pack; and (b) a shell at least partially surrounding the media pack, the shell including a shell wall having a shape different than the outer peripheral shape of the media pack, and a seal member extending at least partially around the inlet end of the media pack, wherein the seal member includes a pinch seal portion spaced apart from the outer surface of the media pack.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 358,932, filed July 6, 2016, the entire contents of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0003] The present invention relates to filter arrangements typically used to filter air, such as internal combustion engine intake air, and more particularly to filter assemblies including multiple components arranged in a housing to provide desired filtration capabilities. BACKGROUND

[0004] Air streams can carry contaminant material, such as dust and other particulates. For example, air streams provided to engines of construction equipment, motor vehicles, power generation equipment, combustion furnaces, and the like can carry particulate contaminants that can damage and / or adversely affect the performance of such equipment. In many cases, some or all of the incoming contaminant material must and / or should be filtered from the air stream. A large number of air filter arrangements have been developed for removing contaminants, which are typically specifically designed to fit within a particular space within or proximate to the equipment. However, there is an ongoing need to improve the effectiveness and efficiency of air filtration equipment. SUMMARY

[0005] In one aspect of the application, a filter cartridge is provided that is configured to be removably positioned within an interior opening of a housing. The filter cartridge includes a media pack including an inlet end, an outlet end, and an outer surface having an outer peripheral shape, and at least one of: (a) a frame member at least partially surrounding the media pack, the frame member including a frame wall having a shape that is different than the media pack outer peripheral shape, and (b) a shell at least partially surrounding the media pack, the shell including a shell wall having a shape that is different than the media pack outer peripheral shape. The cartridge further includes a seal member extending at least partially around the inlet end of the media pack, wherein the seal member includes a pinch seal portion spaced apart from the outer surface of the media pack. The filter cartridge can be used in combination with a housing, wherein the housing includes an inlet end, an outlet end, and an interior opening defined between the inlet end and the outlet end by a housing wall having an inner peripheral shape. At least one of the shell wall and the frame wall can have an outer shape that substantially matches the housing wall inner peripheral shape. If a frame member is provided, it can include an interior opening at least partially defined by an upper lip that extends inwardly at its upper edge from the frame wall across a gap at at least one location, the gap being between the frame wall and the outer surface of the media pack when the media pack is at least partially positioned in the interior opening of the frame member. The frame member can further include a handle and / or at least one notch extending along at least a portion of the frame wall height and / or at least one tab or foot extending from a bottom edge of the frame wall.

[0006] In another aspect of the application, an air cleaner assembly is provided that includes a housing having an inlet end, an outlet end, and an interior opening defined between the inlet end and the outlet end by a housing wall having an inner surface; a filter cartridge removably positioned within the interior opening of the housing. The filter cartridge includes a media pack having an inlet end, an opposite outlet end, and an outer surface; and a seal member secured to the inlet end of the media pack, wherein the seal member includes a pinch seal portion spaced apart from the outer surface of the media pack, and wherein the seal portion is positionable within the channel of the housing when the filter cartridge is positioned within the interior opening of the housing. The assembly further includes a pre-cleaner assembly positionable between the filter cartridge and the inlet end of the housing, the pre-cleaner including a base member having a lower edge and an access cover removably attached to the inlet end of the housing, wherein the pre-cleaner assembly is sealable within the air cleaner assembly by pressing the lower edge of the base member against a top surface of the seal member and pressing a gasket of the access cover against the inlet end of the housing.

[0007] In another aspect of the application, an air cleaner assembly is provided that includes a housing having an inlet end, an outlet end, and an interior opening between the inlet end and the outlet end, and a pre-cleaner assembly at the inlet end of the housing. The pre-cleaner assembly includes a pre-cleaner body, an access cover removably attached to the inlet end of the housing, and a plurality of contaminant separator tubes extending in a flow tube arrangement from the access cover in a first direction, where the flow tube arrangement includes a plurality of pairs of tubes arranged in rows spaced apart from one another along a length of the access cover, where the tubes of each row are offset from each adjacent row. The access cover is removably mountable on the housing over the inlet end and with the contaminant separator tubes projecting toward the outlet end of the housing. Further, the contaminant separator tubes can include ejection slots positioned between their inlet ends and outlet ends, where each of the ejection slots is rotationally positioned for directional movement of contaminants from the pre-cleaner assembly. In one configuration, a first plurality of the contaminant separator tubes are rotationally positioned with their ejection slots facing in a first direction, and a second plurality of the contaminant separator tubes are rotationally positioned with their ejection slots facing in a second direction different from the first direction. BRIEF DESCRIPTION OF DRAWINGS

[0008] The application will be further explained with reference to the drawings, wherein like structures are referred to by like numerals, and wherein:

[0009] Figure 1 is a perspective view of an exemplary media type that can be used in the air cleaner assembly of the present application;

[0010] Figure 2 is a perspective view of a portion of the media type shown in Figure 1 is an enlarged sectional view of a portion of the media type shown in

[0011] Figure 3 is a perspective view of a wound filter arrangement that can be used in a filter cartridge according to the present application, which can include Figure 1 media of the type shown in

[0012] Figure 4 is a perspective view of an air cleaner assembly according to the present application, the view generally facing toward the inlet end of the air cleaner assembly;

[0013] Figure 5 is Figure 4 another perspective view of the air cleaner assembly of

[0014] Figure 6 is Figure 4 an exploded perspective view of the air cleaner assembly of

[0015] Figure 7 isFigure 4 perspective view of an air cleaner assembly of the present invention;

[0016] Figure 8 is Figure 4 an exploded perspective view of a pre-cleaner of an air cleaner assembly of the present invention;

[0017] Figure 9 is Figure 4 a perspective cross-sectional view of an air cleaner assembly of the present invention, including a pre-cleaner;

[0018] Figure 10 is Figure 4 a cross-sectional view of an air cleaner assembly of the present invention, the perspective cross-sectional view of which is shown in Figure 9 ;

[0019] Figure 11 is Figure 10 an enlarged cross-sectional view of a portion of the air cleaner shown in

[0020] Figure 12 is a perspective view of an exemplary filter cartridge of the present invention for use in an air cleaner assembly;

[0021] Figure 13 is Figure 12 an exploded perspective view of the filter cartridge shown in

[0022] Figure 14 is Figure 12 a perspective view of a filter seal member of the filter cartridge of Figure 13 ;

[0023] Figure 15 is a perspective view of another exemplary filter cartridge of the present invention for use in an air cleaner assembly;

[0024] Figure 16 is Figure 15 an exploded perspective view of the filter cartridge shown in

[0025] Figure 17 is Figure 15 a perspective view of a filter seal member of the filter cartridge of Figure 16 ;

[0026] Figure 18 is a perspective view of a safety filter element for use in an air cleaner assembly of the present invention;

[0027] Figure 19 is an enlarged perspective view of a latch of an access cover in a locked configuration relative to an air cleaner housing;

[0028] Figure 20 is a perspective view of a filter cartridge of the present invention, shown in Figure 19Another perspective view of the latch of the service cover positioned relative to the air cleaner shown at different angles;

[0029] Figure 21 is a perspective view of a latch according to the present invention Figures 19-20 is a perspective view of a latch of the type shown in

[0030] Figure 22 is a perspective view of a latch of the type shown in Figures 19-21 is a bottom perspective view of the latch shown in

[0031] Figure 23 is a perspective view of a latch of the type shown in Figures 19-22 is a side view of the latch shown in

[0032] Figure 24 is an exploded perspective view of an exemplary embodiment of an air cleaner assembly of the present invention; and

[0033] Figure 25 is a perspective view of a filter cartridge used in an air cleaner assembly of the type shown in Figure 24 DETAILED DESCRIPTION

[0034] Reference is now made to the drawings wherein like numerals refer to like parts, first referring to Figures 1-2 illustrates an exemplary configuration of fluted filter media that can be used in filter system embodiments of the present invention. In particular, fluted filter media (also referred to as media having media ridges) can be used to provide fluid filter configurations in a variety of ways. One well-known way is characterized herein as a z-filter configuration. As used herein, the term "z-filter configuration" refers to a type of filter configuration in which individual filter flutes in a corrugated, pleated, or otherwise formed filter fluting are used to define sets of longitudinal (typically parallel) inlet and outlet filter flutes for fluid flow through the media; fluid flows along the length of the flutes between opposite inflow (or inflow faces) and outflow (or outflow faces) of the media. Some examples of z-filter media are provided in U.S. Patent Nos. 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; D399,944; D428,128; D396,098; D398,046; and D437,401, each of which is incorporated herein by reference.

[0035] ​One type of z-filter media utilizes two specific media components that are joined together to form a media construction. The two components include a fluted (typically corrugated) media sheet and a face media sheet. The face media sheet is typically non-corrugated, however it can be corrugated (e.g., perpendicular to the fluting direction) as described in U.S. Provisional Application No. 60 / 543,804, filed February 11, 2004, and published as PCT WO 05 / 077487 on August 25, 2005, which is incorporated herein by reference.

[0036] The fluted media sheet and the face media sheet are used together to define media having parallel inlet flutes and outlet flutes. In some examples, the fluted sheet and the face sheet are secured together and then wound into a media strip to form a z-filter media construction. Such arrangements are described, for example, in U.S. Patent Nos. 6,235,195 and 6,179,890, each of which is incorporated herein by reference. In certain other arrangements, some un-wound sections or strips of fluted (typically corrugated) media secured to a face media are layered on top of one another to form a filter construction.

[0037] Corrugated media is a specific form of fluted media in which the fluted media has a single flute or ridge extending thereon (e.g., formed by corrugation forming or folding). As used herein, the term "corrugated" refers to structures in the media such as media having flute structures that result from passing the media between two corrugation rollers (i.e., into a nip or gap between the two rollers, each of the two rollers having appropriate surface features to form corrugations in the resulting media).

[0038] Maintainable filter element or filter cartridge configurations that employ z-filter media are sometimes referred to as "straight flow configurations" or variations thereof. Generally, a maintainable filter element or filter cartridge has an inflow end (or face) and an opposing outflow end (or face), with flow into and out of the filter cartridge being in generally the same straight-through direction. In this context, the term "maintainable" refers to media that includes a filter cartridge that can be periodically removed and replaced from a corresponding fluid (e.g., air) filter.

[0039] Figure 1An exemplary media 1 that can be used in a z-filter media configuration of the filter system of the present application is shown. The term "z-filter media configuration" generally refers to a web of corrugated or other form fluted media secured to a face media with appropriate seals to define inlet and outlet flutes, and / or to a media pack that is configured or formed into a three-dimensional web of inlet and outlet flutes; and / or to a filter cartridge or configuration that includes such a media pack. The media 1 is formed from a fluted or ridged sheet 3 and a face sheet 4. Configurations such as the media 1 are referred to herein as single-sided layer strips or single-sided strips.

[0040] Generally, the type of corrugated fluted or ridged sheet 3 is characterized herein as having regular, curved, wavelike patterns of flutes, ridges or corrugations 7 arranged in a pattern of alternating troughs 7b and ridges 7a, with each trough 7b being essentially an inverted ridge of each ridge 7a. Generally, the corrugation pattern is not provided by the fold or crease shape imparted to the media, but rather the apex of each ridge 7a and the bottom of each trough 7b can be formed along radiused curves. Exemplary radii for such z-filter media would be between 0.25 mm and 3 mm.

[0041] With continued reference to Figure 1 , the media 1 has a first edge 8 and an opposite second edge 9. When the media 1 is formed into a media pack, the second edge 9 generally provides the inlet end or face of the media pack, and the first edge 8 will provide the outlet end or face, although the opposite orientation is possible. A bead of sealant 10 can be provided adjacent the first edge 8 for sealing the corrugated sheet 3 and the face sheet 4 together. Such a bead of sealant 10 will seal closed the individual flutes 11 adjacent the first edge 8 for air passage.

[0042] Another bead of sealant 14 can be provided adjacent the second edge 9 for generally closing the flutes 15 for unfiltered media passage. The bead 14 will be in place when the media 1 is configured into a media pack. If the media pack is made from a stack of strips, for one example, the bead 14 will form a seal between the back face 17 of the face sheet 4 and the face 18 of the next adjacent corrugated sheet 3.

[0043] After the filter media 1 is incorporated into a media pack, for example, by stacking or winding, it can be used as follows. First, air in the direction of arrow 12 can enter the open flutes 11 adjacent the second edge 9. Since the first edge 8 is closed by the bead 10, the air can pass through the filter media 1, such as in the direction shown by arrow 13. The air can then exit the media or media pack through the open end 15a of the flutes 15 adjacent the first edge 8 of the media pack. Operation can also be performed with air flow in the opposite direction.

[0044] For Figure 1In the exemplary arrangement shown in the figures, the corrugations 7a, 7b extend generally straight along the medium from the first edge 8 to the second edge 9. The straight corrugations, ridges or waves can be deformed or folded at selected locations, such as at the ends. In the above definitions of "regular", "curved" and "wavy pattern", the modifications made at the ends of the corrugations for closure are generally ignored.

[0045] Z-filter configurations that do not employ straight, regular curved wavy pattern corrugation shapes can also be used in the assemblies of the present invention. For several examples, U.S. Patent No. 5,562,825 (Yamada et al.) provides a corrugation pattern that employs somewhat semi-circular (cross-section) inlet channels adjacent to narrow V-shaped (with curved sides) outlet corrugations; U.S. Patent No. 5,049,326 (Matsumoto et al.) provides circular (cross-section) or tubular channels defined by one sheet having half-tubes (attached to another sheet having half-tubes) with flat areas between the resulting parallel straight channels; U.S. Patent No. 4,925,561 (Ishii et al.) provides channels that are folded with rectangular cross-sections and tapered along their length; WO 97 / 40918 provides channels or parallel corrugations with a curved wavy pattern (from adjacent curved convex and concave valleys) but tapered along their length; WO 97 / 40918 provides channels with a curved wavy pattern but with different sized ridges and valleys. Each of the references is incorporated herein by reference in its entirety. In addition, channels that are modified in shape to include various ridges can be employed in the assemblies of the present invention.

[0046] In general, the filter medium used is a relatively flexible material, such as a nonwoven fibrous material (of cellulose fibers and / or synthetic fibers) that can include resin, sometimes treated with additional materials. Thus, it can generally be adapted or configured into different corrugated patterns without unacceptable damage to the medium. In addition, it is readily wound or otherwise configured for use without unacceptable damage to the medium. The medium generally has properties such that it will maintain the required corrugated configuration during use.

[0047] In a corrugated process, the media can be formed non-elastically such that it is able to prevent recovery to its original shape. However, once the tension is released, the corrugations or waves can still tend to spring back slightly, recovering only a portion of the stretching and bending that has occurred. Therefore, a surface media sheet is sometimes affixed to the fluted media sheet to prevent such spring back of the corrugated sheet, such as at the location designated by reference numeral. The media of the corrugated (fluted) sheet 3 and / or the surface sheet 4 can also be provided with a fine fiber material on one or both of its faces, for example as described in U.S. Patent No. 6,673,136, which is incorporated herein by reference. In some examples, when such a fine fiber material is used, it can be desirable to provide the fine fiber on the upstream side of the material and inside the flutes. When this occurs, airflow will typically enter the edge including the affixed beads.

[0048] Figure 2 An exemplary configuration of a z-filter media construction 40 is shown, which includes a regular, curved, wave pattern corrugated sheet 43 and a non-corrugated flat sheet 44. The distance Dl between points 50 and 51 defines the extent of the flat media 44 in the area 52 beneath a given corrugated flute 53. Due to the shape of the corrugated flute 53, the length D2 of the arc of media of the corrugated flute 30 above the same distance Dl is greater than Dl. For an exemplary regular shape media used in fluted filter applications, the linear length D2 of the media 53 between points 50 and 51 can be at least 1.2 times Dl, such as in the range of 1.2 to 2.0 times Dl. In a particular exemplary air filter configuration, D2 is about 1.25 to 1.35 times Dl. Such media has been used commercially in z-filter arrangements, such as for example those sold under the trade name "Powercore" by Donaldson. Another media variation including fluted media with surface media affixed thereto can be used in arrangements according to the present disclosure, such as described in U.S. Patent Publication No. 2014 / 0208705, owned by Baldwin Filters, Inc. and published July 31, 2014, the disclosure of which is incorporated herein by reference.

[0049] Wound media or media pack arrangements can have various outer perimeter shapes, such as circular, oblong, and oval, some of which oval shapes have opposite curved ends attached by a pair of opposite sides that are also curved. In other oval shapes, sometimes referred to as racetrack shapes, the opposite sides between the opposite curved ends are generally straight. Racetrack shapes are described, for example, in PCT WO 04 / 007054 and PCT application US04 / 07927 published as WO 04 / 082795, each of which is incorporated herein by reference.

[0050] Figure 3An exemplary wound media pack (also referred to as a wound media) 130 is shown constructed from a single strip of single facer media that is wound. The particular wound media pack depicted is an oval media pack 130a, which can more specifically be referred to as a racetrack media pack 131. The tail end 131x of the media is shown as being external to the media pack 130. A bead of hot melt sealant or sealant can be positioned along this tail end to ensure sealing. In the media pack 130, the opposite flow (end) faces are designated 132, 133. The filter arrangements of the present disclosure can use additional media types in which the media is stacked or wound to include an arrangement of opposite inflow and outflow ends or faces, such as described in U.S. Patent Application Serial No. 62 / 077,749, filed November 10, 2014, and owned by, for example, the assignee of the present disclosure.

[0051] Many of the techniques characterized herein will be used in conjunction with media that is oriented to filter between opposite flow ends of a filter cartridge, such as media having flute or pleat tips that extend in a direction between the opposite ends. However, the techniques characterized herein with respect to seal arrangements can be applied to other filter cartridges having opposite flow ends in which media is positioned for filtering fluid flow between the ends, even if the media does not include flute or pleat tips that extend in a direction between the ends. For example, the media can be depth media, can pleat in an alternative direction, or can be a non-pleated material.

[0052] Figures 4-20 An exemplary embodiment of an air cleaner assembly according to the present disclosure is shown that can include a filter cartridge having media and / or media packs as previously described with respect to Figures 1-3 Figure 4 and Figure 5 , different views of an exemplary air cleaner assembly 400 according to the present disclosure are shown that generally includes a housing 401 with a removable access cover 403 for accessing an interior region of the housing, such as to place and remove a filter cartridge. The air cleaner assembly 400 also includes an outlet 405 arranged to have filtered air exit. The outlet 405 can be made separate from and attached to the housing 401, or can be integrally constructed as part of the housing 401. The outlet 405 can be provided as a separate component in an assembly that can desirably allow selection of different outlet configurations. The housing 401 also includes an air inlet end 402 through which air to be filtered enters the air cleaner assembly 400.

[0053] ​The housing 401 can be constructed using a variety of materials or combinations of materials and using a large number of different construction techniques. In one exemplary embodiment, the housing 401 is a molded plastic component that can include optional rib members extending from its outer surface to provide structural strength to the housing 401 and / or for aesthetic purposes. Thus, when optional ribs are provided, they can have a variety of configurations to meet the desired rib function, including different shapes, sizes, and numbers.

[0054] The particular air cleaner assembly 400 shown is a two-stage air cleaner assembly that includes a pre-cleaner 410 adjacent the inlet end thereof. Figure 4 The general position and configuration of the pre-cleaner 410 is shown, while the components making up the pre-cleaner 410 are better shown and will be described in further detail below, for example, in Figure 6 and Figure 8 The pre-cleaner 410 is generally used to clean selected materials or contaminants entrained in the air stream before the air reaches the filter element provided in the air cleaner assembly 400. Such pre-cleaning can substantially remove liquid particles, such as rain or splashed water, and / or various dust or other particles, such as larger particles. In the illustrated example, the pre-cleaner 410 includes an access cover 403 that can be attached to the housing 401. In embodiments of the present application, it is contemplated that the air cleaner assembly 400 can not include a pre-cleaner. In such cases, the access cover would be attached directly to the housing 401 and used to directly access the interior region of the housing 401 and any components contained therein.

[0055] In the illustrated embodiment, the access cover 403 is attachable to and removable from the housing 401 by a plurality of connectors or latches 419 that are attached to the access cover 403 in a removable manner by connection and disconnection. In the illustrated embodiment, two pairs of latches 419 are positioned symmetrically on opposite edges of the access cover 403. However, it should be understood that different numbers and / or locations of latches 419 can be used, such as two latches on each edge of the access cover 403, different numbers of latches on opposite edges of the access cover 403, or latches positioned at different locations around the perimeter of the access cover 403. It should also be understood that alternative connector arrangements can be used in place of or in addition to the latches 419, including, for example, bolts or other fasteners.

[0056] The housing 401 also includes a mounting pad arrangement by which the air cleaner assembly 400 can be secured to equipment for use. Figure 4 and Figure 5The exemplary mounting pad shown includes a plurality of mounting feet or pads 414 extending from the outer surface of housing 401. In this exemplary embodiment, the mounting feet 414 are configured to engage connectors, such as screws or other extension members that engage the center hole of the foot. Although this embodiment provides four mounting feet or pads 414 on each side of housing 401, different numbers of feet or pads may also be provided.

[0057] As in Figure 5 Most notably, housing 401 also includes a utility port 423 adjacent to outlet 405. Utility port 423 can be used for limit indicators or other devices. Furthermore, an air flow sensor (MAFS) arrangement can optionally be installed at outlet 405 or in other pipes further downstream.

[0058] Continue to refer to Figure 4 and Figure 5 When the filter is positioned in this orientation, housing 401 also includes a discharge or outlet port 426 in its lower end or bottom region. The positioning of port 426 facilitates the removal of particles and / or water (i.e., contaminants) collected by the pre-filter from housing 401, and thus may be referred to as a discharge port. In one embodiment of the invention, this port 426 is oriented in a portion of housing 401 such that it points downwards in use. In many applications, outlet port 426 is pointed downwards in such a way that gravity can facilitate the discharge of material from pre-filter 410. However, if it is desired to install the air filter assembly 400 in a different manner than shown, such as along one side, a mounting structure may be provided on that side, or port 426 may be positioned at a different location relative to the housing body or on a portion of an access cover. In any of these arrangements, port 426 may have a discharge valve assembly disposed therein, or it may be attached to a purging conduit to facilitate the removal of material from pre-filter 410.

[0059] Now for reference Figure 6 An exploded perspective view of an exemplary embodiment of an air filter assembly 400 of the present invention is shown. This air filter assembly generally includes a housing 401, a pre-filter 410, a filter element 430, and an optional safety filter 435, wherein these components and their relationships to each other will be further described below. Figure 6 In this exploded view, each of these components is shown as a separate figure in the accompanying drawings, and is also described above and / or below.

[0060] Refer to the above text Figure 4 and Figure 5 The overall components shown illustrate one exemplary embodiment of housing 401; however, housing 401 is also shown in more detail. Figure 7In this figure, the corresponding air filter assembly 400 is not shown. As shown, housing 401 includes an inlet 402 at the opposite end of outlet 405, through which system components can be inserted for mounting the air filter assembly 400. Housing 401 also includes an internal lip 406 extending around its periphery and spaced from the inlet 402, and at least one protrusion 407 extending inwardly from the wall of housing 401. Furthermore, housing 401 includes at least one retaining member 408 located outside the outer wall of housing and adjacent to the inlet 402 for engaging a latching mechanism 419 of access cover 403. The internal lip 406 is positioned to provide one side of a channel or recess 481, which is also defined by the inner wall of housing 401 and a bottom channel surface extending between the internal lip 406 and the inner wall of housing 401. The channel 481 generally extends around the periphery of housing 401, as will be described in further detail below.

[0061] Figure 6 The pre-filter 410 shown is also illustrated in its exploded configuration. Figure 8 The pre-filter 410 includes an access cover 403 that engages with the base member 412 (and can also be attached to the housing 401 via a latch). In embodiments of the air filter assembly 400, the access cover 403 can engage the base member 412 via an attachment configuration such as a snap-fit ​​arrangement to secure the two components to each other as a single unit, which can then be attached to the housing 401 via a latch 419. In this embodiment, the access cover 403 of the pre-filter 410 can also be detached from the base member 412 for example, to facilitate cleaning. However, in another embodiment of the pre-filter 410, the access cover 403 is permanently attached to the base member 412 or molded as a single unit provided as a single piece to the air filter assembly 400. In any case, the pre-filter 410 typically removes a portion of the material before dust or other particulate material (e.g., liquid particulate material) entering the air filter through the airflow inlet can reach the internally positioned filter element 430. The pre-filter 410 thus helps extend the life of the components without maintenance and protects the filter element from damage.

[0062] In one example embodiment, the base member 412 of the prefilter 410 is secured to the access cover 403 by engaging at least one tab member 420 extending from the edge of the access cover 403 with an engagement member 422 located externally to the base member 412. Alternatively, tab members and other features can extend from the base member 412 while engagement members extend from the access cover 403. In the illustrated embodiment, the tab members 420 each include a hole 424 sized and shaped to accept at least a portion of a corresponding engagement member 422 by simply pushing the access cover 403 and base member 412 toward one another and sliding the tab members 420 over the top of the corresponding engagement members 422 until the holes 424 engage the engagement members 422. However, it is contemplated that a wide variety of different configurations and features can be used to secure the components of the prefilter 410 to one another.

[0063] Figures 9-11 Various views of the prefilter 410 as it is assembled and positioned within the housing 401 are provided. The access cover 403 includes a perimeter mounting flange 450 that aligns with the end of the housing 401 during installation. A sealing member or gasket 452, which can be, for example, an O-ring seal, can be positioned between the access cover 403 and the housing 401.

[0064] The access cover 403 also includes a plurality of inlet tubes or contaminant separator tubes 460 extending from the interior surface of the cover 403 toward the interior region of the housing 401. The tubes 460 can be sized to protrude at least 40 mm or more than 60 mm from the interior surface of the access cover 403 and into the housing body, although greater or lesser lengths are also contemplated. The tubes 460 can be pre-formed and crimped into holes of the cover 403 during assembly, or can be attached in other ways, such as by adhesive. In general, each separator tube 460 includes an upstream inlet end 462 into which unfiltered air of the air cleaner assembly 400 will flow. Each tube 460 can include a vane arrangement located at or adjacent to the inlet end 462 and configured for inducing and directing cyclonic airflow of the inlet air. The tubes 460 also include an opposite end 463 spaced apart from the inlet end 462. Each separator tube 460 also includes a side slot 464 between the ends 462 and 463 through which contaminants (dust, particulate contaminants, or water) isolated by the contaminant separator arrangement can exit to be exhausted through the housing contaminant exhaust port 426 described above with reference to Figure 4 and Figure 5 the housing contaminant exhaust port 426.

[0065] While a wide variety of arrangements of the tubes 460 are contemplated, the example embodiment includes tubes 460 arranged in rows, each row including two tubes along the length of the access cover 403, with each row of tubes 460 at least slightly offset from each adjacent row of tubes 460 (see, e.g., FIG. 4). Figure 8). As shown in this exemplary embodiment of service cover 403, each row of tubes 460 is offset so that the centerline of each of the tubes in a row is approximately centered in the space between two tubes in an adjacent row; however, greater or lesser amounts of offset are also contemplated. Some or all of tubes 460 can also include a vane arrangement for directing airflow in a desired manner. The vane arrangement can vary greatly depending on the desired airflow, and it is contemplated that tubes 460 of a single service cover 403 can have different vane arrangements.

[0066] With reference to an exemplary vane arrangement, it will be appreciated that each tube 460 can operate by centrifugal separation of contaminants performed internally. To this end, air entering inlet end 462 of tube 460 can be directed generally in a cyclonic pattern by the vanes. Side slot 464 of each tube 460 can be an arcuate opening in a side wall portion adjacent to and spaced apart from end 463 of each tube 460. The size and shape of side slot 464 is generally selected to provide maximum operating efficiency. End 463 of each tube 460 can be understood to be a cyclonic outlet, and the vortex material generally exits in a direction at a right angle to the center of the associated slot.

[0067] To effectively separate contaminants in the contaminated air entering air cleaner assembly 400 in the orientation shown, tubes 460, with their associated slots 464, are positioned to direct contaminants generally toward the outer wall so that the contaminants ultimately move downward toward discharge port 426 when installed. To this end, it is contemplated that the orientation of tubes 460 on one side of service cover 403 is different than the orientation of tubes 460 on the other side of service cover 403 (e.g., the tubes closer to the left side are oriented differently than the tubes closer to the right side). In one example, for the tubes 460 on the right side, each outlet slot 464 can be directed away from port 426, with the tubes 460 on the left side oriented (centered) with their outlet slots 464 pointing in the opposite or downward direction (i.e., toward port 426). However, if air cleaner assembly 400 is oriented differently (e.g., 90 degrees from the orientation shown), outlet slots 464 of tubes 460 can instead all be directed toward the middle of service cover 403. Figure 8

[0068] Base member 412 of pre-cleaner 410 also includes a base plate 467 (generally indicated in Figure 8 ) having a plurality of outlet tubes 468 extending therefrom. Outlet tubes 468 are positioned relative to base plate 467 so that, when base member 412 and service cover 403 are assembled to make pre-cleaner 410, each of outlet tubes 468 extends into one of inlet tubes 460. Outlet tubes 468 can be molded or otherwise integrally formed with base member 412, or can be separately manufactured and then attached to base plate 467.

[0069] Reference is now made to Figure 12 and Figure 13 ​FIG. 4 shows an exploded view of an air cleaner assembly 400, showing an exemplary embodiment of a filter cartridge 430 of the air cleaner assembly 400, Figure 14 An enlarged view of a frame member 470 of the filter cartridge 430 is also shown. The filter cartridge 430 can be considered a primary or main filter cartridge, used to selectively separate a desired amount of particulate or contaminant material from the system that was not filtered out by the pre-cleaner 410. The filter cartridge 430 is generally a serviceable or removable component, such that it can be periodically removed and replaced as desired or as needed during the service life of the air cleaner 400. In particular, when the cartridge 430 becomes clogged or otherwise needs to be replaced, the service cover 403 is removed from the housing 401, the pre-cleaner 410 (if used) is removed, and the clogged filter cartridge 430 is removed. After such removal, a new filter cartridge 430 can be placed in the housing 401, or the removed filter cartridge 430 can be refurbished and then replaced in its previous position in the housing 401. The pre-cleaner 410 and / or cover 403 can then be repositioned and secured to the housing 401, such that the air cleaner assembly 400 is again ready for use.

[0070] As Figure 13 shown in the exploded view of FIG. 4, the filter cartridge 430 generally includes a media pack 431, an outer shell 480, a frame member 470, and a sealing member 474, where the sealing member is generally made of a relatively flexible material and can be referred to herein as a "flexible sealing member." When assembled, a lower portion of the media pack 431 is positioned within an interior opening of the outer shell 480, with a top portion of the media pack extending above a top surface of the outer shell 480. This top portion of the media pack 431 will then be positioned within an interior opening of the frame member 470, after which the flexible sealing member 474 is formed to fill the space between the frame member 470 and the outer surface of the media pack 431 and to connect the frame member 470 to the outer shell 480 and media pack 431, as described below. It should be noted that while the illustrated configuration in this figure shows the filter cartridge 430 including both a frame member 470 and an outer shell 480, it is contemplated that particular embodiments of filter cartridges of the present invention can provide only one of these two components 470, 480, and the following description contemplates all such configurations.

[0071] The media pack 431 includes a filtration medium, which can be any of a variety of types, such as the fluted filtration medium described above. In exemplary embodiments, the filtration medium is provided in the form of an elongated sheet of filtration medium, which is wrapped or wound to provide the predetermined size oval or racetrack outer shape of the media pack 431, as shown in Figure 13 The amount of filtration medium in a particular media pack is designed and selected to provide certain filtration characteristics during the filtration process. For example, the filtration medium can be tightly packed to achieve a greater density in certain applications, but can be more loosely wound in other applications.

[0072] Referring again to Figure 12 and Figure 13 The filter cartridge 430 shown includes an optional outer shell 480. Such a shell 480 encloses the media pack 431 and protects the media during handling and use. The shell 480 may, for example, comprise a pre-formed molded plastic piece into which the media pack 431 is positioned during assembly of the filter cartridge 430. As shown, the outer surface of the shell 480 can have a shape that generally matches the outer shape of the frame member 470 (e.g., a racetrack oval), or can have a different shape.

[0073] The exemplary filter cartridge 430 shown is considered a "straight flow" arrangement in that it includes a first, inflow face or end 432 and an opposite, outflow face or end 433, thereby filtering air flow that generally passes through the filter cartridge 430 from the inlet end 432 to the outlet end 433. More generally, the primary filter cartridge 430 includes a permeable filter media through which air is filtered as it passes. In a typical application, the filter media will be configured in a media pack that performs air filtration as air flows from an inlet end of the media pack to an opposite outlet end of the media pack in a flow direction. Thus, generally, the filter cartridge 430 can be a straight flow configuration in that air enters from one end and exits from the other end without significant redirection within the media pack.

[0074] The frame member 470 includes a frame wall 471 that has an outer shape that generally matches the inner perimeter shape of the housing wall of the housing into which the frame member will be positioned. In this particular embodiment, the outer shape of the frame wall 471 is a generally elongated octagonal shape, but it should be understood that the outer shape can be any desired polygonal shape that matches the inner shape of the housing wall. The frame member 470 also includes an inner opening 472 thereof at the top edge that is defined by an upper lip 473 that extends inwardly from the frame wall 471 at at least one location to fill at least one gap space between the frame wall and the outer surface of the media pack when the media pack is positioned in the frame member 470. That is, because the shape of the frame wall 471 (e.g., elongated octagonal) differs from the outer shape of the media pack 431 (e.g., racetrack oval), there will be a gap between these elements in areas where the shapes diverge from one another (e.g., the areas where the angled corners of the frame wall 471 are spaced apart from the curved outer surface of the filter cartridge 430). In this embodiment, the overhang 479 of the upper lip 473 from the frame wall 471 will fill this gap to approximate the inner oblong or racetrack oval shape of the inner opening 472 of the filter seal member along the top edge of the filter seal member.

[0075] In other embodiments of the application, the frame wall 471 is shaped the same or nearly the same as the outer shape of the media pack 431. Because there will not be the same gap as described above, the frame member will not have an upper lip extending inward from the frame wall to fill such a gap space.

[0076] The frame member 470 also includes a plurality of feet or extension members 441 extending from the bottom edge of the frame wall 471. Each of the feet 441 extends from the bottom edge of the frame wall 471 and has a distal end that rests on a flange 442 extending around at least a portion of the top edge of the housing 480, where the length of the feet 441 corresponds to the distance the bottom edge of the frame wall 471 will be spaced apart from the flange 442. The size, shape, and number of the feet can vary greatly and are generally selected to provide sufficient space between them through which the desired amount of sealing material can flow during the manufacture and assembly of the flexible seal member 474. Another consideration with respect to the size, shape, and number of the feet is the need to provide sufficient structural integrity to the system during and after manufacture.

[0077] In an exemplary configuration, the number of feet selected will provide sufficient structural integrity to hold the frame wall 471 at the desired distance from the flange 442 during the formation of the flexible seal member 474, while allowing sufficient material to flow and form the flexible seal member 474. In one embodiment, at least two feet 441 are positioned along the straight edges of the frame wall 471 and at least one foot 441 is positioned along each of the angled edges of the frame wall 471. Additionally, the feet or extension members 441 can have a length that is capable of providing a gap of greater than 2 mm between the flange 442, or the gap can be less than 2 mm. In any case, the size of the feet or extension members 441 should allow sufficient material to flow during the manufacturing process, while ensuring that the frame member 470 is captured by the sealing material.

[0078] Still referring to Figures 12-14 The filter cartridge 430 shown includes an optional handle 475 having ends extending from opposite sides of the frame wall 471 and oriented adjacent to the cartridge inlet end 432 and projecting therefrom in a direction away from the outlet end 433. This positioning and orientation of the handle 475 facilitates grasping by an operator to manage the maintenance of the filter cartridge 430. The particular handle 475 of this embodiment includes a central handle bridge structure defining a space through which a person's fingers can extend during grasping of the handle member 475. A variety of shapes, sizes, and features can be used for the optional handle 475. Additionally, one or more optional additional support members 443 can be spaced apart from the handle 475 and extend across the opening in the frame wall 471 in substantially the same direction as the handle 475.

[0079] The exemplary filter element 430 has a non-circular cross-sectional shape as described above, but may also have alternative shapes. In many applications of the present invention, the filter element will have a cross-sectional shape having a long cross-sectional axis in a plane perpendicular to the airflow and a short axis perpendicular to the long axis and located along the midpoint of the layer axis, wherein the ratio of the length of the long axis to the length of the short axis (at a position halfway along the length of the long axis) is at least 1.4. While alternative options are possible, such ratios will generally be used in the arrangements according to the invention because they involve air filters with an overall profile having a relatively small ratio of cross-sectional dimensions to opposite cross-sectional dimensions. In an exemplary embodiment, the media package has an extension of at least 100 mm between the flow ends, and may be at least 250 mm long.

[0080] The flexible peripheral sealing member 474 of the filter element 430 extends generally around the periphery of the housing 480 adjacent to the frame member 470. When the filter element 430 is positioned within the housing, as described above, the sealing member 474 is configured and positioned to function as a clamping seal. This clamping seal extends around the periphery of the filter element 430 at a location such that it can be clamped between the two housing components under sealing pressure during use. The illustrated sealing member 474 is sometimes referred to in the industry as an “axial” clamping seal because it is configured to apply sealing pressure between the two housing components in the axial direction (i.e., in the direction of extension of the axis extending through the medium from its inlet end to its outlet end). However, other types of sealing arrangements can be used according to the selected principles of the invention.

[0081] More specifically, the sealing member 474 is configured such that the channel 476 (see, for example, see...) Figure 12 A channel 476 is positioned between a portion of the sealing member 474 and the housing 480, wherein the channel 476 is positioned to mate with the inner lip 406 of the housing 401. The channel 476 may be located between the housing 480 and an axially oriented portion 477 of the sealing member 474. The size and shape of this portion 477 of the sealing member 474 are configured to provide a leak-proof seal through the inner surface of the housing 401 when the air filter assembly 400 is in operation. To facilitate this, the sealing member 474 may be of a type of elastic material typically used for such sealing purposes. An exemplary material that can be used to prepare the flexible sealing member is polyurethane molded to an appropriate hardness, such as molded to a Shore A hardness not greater than 22. The flexible sealing member 474 may be molded in place while the media package 431 is positioned inside the housing 480 and the frame member 470 is positioned in its desired configuration. Thus, the sealing member 474 will be embedded in the frame wall 471 of the frame member 470.

[0082] For details, please refer to the following: Figure 13The sealing member 474 includes a transition region 478 that includes a portion of its inner surface that takes the shape of the media pack 431 and a portion that takes the shape of the frame member 470 and / or the housing 480. Such regions provide the sealing member 474 with a transition from one shape to another.

[0083] The axially directed portion 477 of the sealing member 474 can have a profile around portions of its perimeter to selectively engage other portions of the housing 401. In particular, the axially directed portion 477 can have a profile around its perimeter with "steps" that can be recessed and / or protruding relative to the regions between the steps, and that can also be more protruding toward the outlet 433 of the filter cartridge 430 than the remainder of the sealing member 474. Such stepped portions can vary greatly, with example configurations of the steps described in WO 2014 / 210541, which is incorporated herein by reference in its entirety. In example embodiments of the present application, the same amount of material is used around the sealing member for each portion thereof, such that in regions where the stepped portion is thicker, the axial dimension is shorter. For such example embodiments, the opposite is also true, in that in regions where the stepped portion is thinner, the axial dimension of the stepped portion is longer.

[0084] To accommodate the steps of the sealing member 474, the channel or pocket 481 (see Figure 11 ) between the housing 401 and the lip 406 can have portions that are deeper or shallower than other regions. Further, with reference to the above, the housing 401 includes an inner lip 406 that extends around the perimeter and is spaced apart from the inlet 402, and at least one protrusion 407 that extends inwardly from a wall of the housing 401. For this configuration, the protrusions 407 of the housing 401 can be arranged in various positions around the inner perimeter of the housing 401, and are generally positioned at least partially within the pocket or channel 481. The protrusions 407 each have a particular dimension, shape, and position to align with a corresponding feature or configuration of the sealing member 474, such as a stepped or profiled region of the sealing member 474. It is contemplated that one or more protrusions 407 extend from opposite sides of the housing in a symmetrical configuration (such that a corresponding filter cartridge with symmetrical protrusions / recesses can be inserted in either of two orientations to seat within the channel 481), or in an asymmetrical configuration (such that a corresponding filter cartridge with asymmetrical protrusions / recesses can only be inserted in one orientation to seat within the channel 481).

[0085] With continued reference to Figure 11The service cover 403 is configured such that when it is secured to the housing 401, the pre-filter 410 will be pressed toward the filter cartridge 430. In this manner, if the components within the housing 401 have not been seated in their final position, the pressure of the pre-filter arrangement will "push" the components toward the outlet 405 and into the seated position. For example, this movement can ensure that the passage 475 of the flexible seal member 474 is properly seated through the interior lip 406 of the housing 401. Furthermore, when the components are positioned in their desired locations, the bottom edge 481 of the base member 412 will press against the flexible seal member 474. When so positioned, the pre-filter 410 will be effectively "isolated" as a component that is individually isolated from contaminants at one end of the pre-filter and at the bottom edge 481 of the base member via the seal 452 within the area of the seal member 474.

[0086] Referring now to Figure 15 and Figure 16 , an exemplary embodiment of a filter cartridge 730 is shown that is similar to the filter cartridge 430 discussed above, Figure 17 An enlarged view of the frame member 770 of the filter cartridge 730 is also shown. Accordingly, similar applications and structures described above with respect to the filter cartridge 430 can also apply to the filter cartridge 730.

[0087] As shown in the exploded view of Figure 16 , the filter cartridge 730 generally includes a media pack 731, a shell 780, a frame member 770, and a flexible seal member 774. When assembled, a lower portion of the media pack 731 is positioned within an interior opening of the shell 780, with a top portion of the media pack extending above a top surface of the shell 780. This top portion of the media pack 731 will then be positioned within an interior opening of the frame member 770, after which the flexible seal member 774 is formed to fill the space between the frame member 770 and the outer surface of the media pack 731 and to connect the frame member 770 to the shell 780 and the media pack 731, as described below. It should be noted that although the illustrated configuration shown in this figure includes both a frame member 770 and a shell 780, it is contemplated that particular embodiments of filter cartridges of the present invention provide only one of these two components 770, 780, and the following description contemplates all of these configurations.

[0088] Referring again to Figure 15 and Figure 16The filter cartridge 730 shown includes an optional outer shell 780. Such outer shell 780 encloses the media pack 731 and protects the media during handling and use. The outer shell 780 can for example comprise a preformed molded plastic piece into which the media pack 731 is positioned during assembly of the filter cartridge 730. As shown, the outer surface of the outer shell 780 can have a shape that generally matches the outer shape of the frame member 770, or can have a different shape.

[0089] The frame member 770 includes a frame wall 771 that has an outer shape that generally matches the inner perimeter shape of the housing wall into which it will be positioned. In this particular embodiment, the outer shape of the frame wall 771 is a generally elongated octagonal shape. The frame member 770 also includes an inner opening 772 at the top edge thereof that is defined by an upper lip 773 that extends inwardly from the frame wall 771 at at least one location to fill at least one gap space between the frame wall and the outer surface of the media pack when the media pack is positioned in the frame member 770. In this embodiment, the overhang 779 of the upper lip 773 from the frame wall 771 will fill this gap to approximate the inner oblong or racetrack oval shape of the inner opening 772 of the filter seal member along the top edge of the filter seal member.

[0090] The frame wall 771 of the frame member 770 can be a solid structure around its perimeter, or can also include notches or slots 741 at one or more locations around its perimeter. The size, shape and number of notches or slots 741 can vary widely, such as in the range between 1 mm and 20 mm. The size and shape of the slots or notches 741 are selected or designed depending on their location relative to the media pack to control the amount of sealing material of the flexible seal member 774 that can flow during manufacture and assembly of the filter cartridge 730. In one exemplary embodiment, at least one notch is positioned along the straight edges of the frame wall 771, and at least one notch 741 is positioned along each of the angled edges of the frame wall 771.

[0091] It should be appreciated that the size, shape and arrangement of the slots or notches 741 can include all slots 741 having the same configuration as each other, can include all slots having different configurations, or can include some slots having the same configuration and other slots having different configurations, particularly for the frame wall. For example, the slots 741 disposed in the curved sections of the frame member 770 can be larger or more numerous than the slots disposed on the straight edges of the frame member 770. It is also contemplated that the spaces between adjacent slots 741 around the perimeter of the frame member 770 can be the same or different, depending on the desired material flow facilitated by these slots.

[0092] Still referring to Figures 15-17The filter cartridge 730 shown includes optional handles 775 having ends extending from opposite sides of the frame wall 771. A variety of shapes, sizes, and features can be used for the optional handles 775. In addition, one or more optional additional support members 743 can be spaced apart from the handles 775 and extend across the opening in the frame wall 771 in substantially the same direction as the handles 775.

[0093] The filter cartridge 730 also includes a flexible perimeter seal member 774 extending substantially around the perimeter of the housing 780 adjacent the frame member 770. The filter cartridge 730 also includes a flexible perimeter seal member 774 extending substantially around the perimeter of the housing 780 adjacent the frame member 770. When the filter cartridge 730 is positioned within the housing, as described above, the seal member 774 is configured and positioned to act as a pinch seal. Such pinch seals extend around the perimeter of the filter cartridge 730 at a location such that it can be pinched between two housing components under seal pressure during use. The seal member 774 shown is sometimes referred to in the industry as an "axial" pinch seal because it is configured for a seal pressure between two housing components to be applied in an axial direction, i.e., in the direction of extension of the axis through the media from its inlet end to its outlet end. However, other types of seal arrangements can be used in accordance with selected principles of the present disclosure.

[0094] More particularly, the seal member 774 is configured such that a channel is provided between a portion of the seal member 774 and the housing 780, with the channel positioned to mate with a portion of the housing into which it will be inserted. The flexible seal member 774 can be molded in place with the media pack 731 positioned inside the housing 780 and the frame member 770 positioned in its desired configuration. Thus, the seal member 774 will be embedded in the frame wall 771 of the frame member 770.

[0095] Referring again to the air cleaner assembly 400 shown and described in, for example, Figure 4 and Figure 5 it should be noted that for the desired sealing and arrangement of components within the housing 401, the inner lip 406 is positioned a distance from the inlet end 402 of the housing 401 such that the particular components will be securely positioned and engaged with one another, and there is no undesirable space between the components. That is, for the air cleaner assembly 400 shown and described with reference to, for example, Figure 6 the service cover 403 is part of the pre-cleaner 410, and thus the inner lip 406 is recessed far enough to accommodate the structure and operation of the pre-cleaner 410. In general, the inner lip 406 will not be recessed any deeper than is necessary to accommodate different housings and inlet features and their operation. While this is not a requirement for air cleaner assembly operation, it is advantageous for the size and weight of the air cleaner housing 401 to not exceed that which is necessary.

[0096] Referring again to Figure 6 , the example air cleaner assembly 400 includes an optional secondary or safety filter 435, which is also shown in Figure 18 . The safety filter 435 can generally be positioned between the primary filter cartridge 430 and the outlet 405 of the housing 401. In a typical arrangement, the safety filter 435 is removably positioned within the air cleaner assembly 400, and is typically also considered a serviceable component that can be removed and replaced as desired and / or as needed. However, since the safety filter does not typically accumulate a large amount of dirt in use, it is not generally replaced very frequently, and instead is a useful option to provide additional dust protection for internal components, such as when the primary filter cartridge 430 is removed from the housing 401.

[0097] An example embodiment of the safety filter 435 includes an outer frame 436 that generally matches the size and shape of the interior region of the housing 401 proximate the outlet 405, preferably without gaps. In this way, the safety filter 435 can be pressed into the housing with a friction fit against the walls of the housing 401 so that no air can reach the outlet 405 without first passing through the safety filter 435. The safety filter 435 also includes an upper face 439 from which at least one handle 437 extends. Each handle 437 provides a convenient way for a user to disassemble the safety filter 435, as each handle preferably includes a hole or other feature that facilitates engagement with one or more fingers to pull the safety filter 435 from the housing 401. Each handle 437 also assists in seating and positioning the filter cartridge 430 when it is inserted into the housing 401.

[0098] The safety filter 435 can also include a plurality of louvered grates 438 in at least a portion of the upper face 439, where such louvered grates 438 have slots between them through which air can pass into the filter 435 and contact the filter media (not shown). The filter media of such a safety filter can be pleated media, where the pleats extend along the long dimension of the outer frame 436. The outer frame 436 can include pleat spacing to help maintain the spacing integrity of adjacent pleats.

[0099] As noted above, the service cover 403 is secured to the housing 401 via at least one latch 419, where in multiple figures the latches 419 are shown attached to the securing members 408 that extend from the outer surface of the housing 401. Such attachment of the latches 419 to the housing 401 is shown in the enlarged view of Figures 19-20 , where a single latch 419 is shown as a separate component from the service cover 403 in Figures 21-23 .

[0100] The latches 419 include a latch body 490 and a plurality (e.g., two) U-shaped wire members 492 engaged within the latch body 490. The latch body 490 includes a plurality of contours for engaging surfaces and features of the access cover 403 and the housing 401, such as a channel 494 with a lower lip 495. The channel 494 is configured to receive the edge of the access cover 403 as well as the securing member 408 of the housing 401 to secure these components to one another. In particular, the lip 495 can be positioned below the securing member 408 and the upper region of the channel 494 will be adjacent to the upper surface of the access cover 403. The latch body 490 also includes a lower concave region in which a series of ribs 496 are spaced apart from one another. These ribs 496 can be molded into the latch body 490 or can be separately manufactured and then secured to the latch body 490. Each of the ribs 496 includes a hole that can engage a straight portion of one of the U-shaped wire members 492. As shown, one of the straight portions of each of the wire members 492 is rotationally positioned within the hole of the rib 496, while the other straight portions of each of the wire members 492 are attached to pivot / rotate with the access cover 403.

[0101] To secure the access cover 403 to the housing 401, as the access cover 403 is pressed toward the inlet end 402 of the housing 401, the latches 419 are rotated away from the access cover 403. When the cover 403 is properly positioned, the lip 495 of the channel 494 of each latch 419 is moved to engage one of the securing members 408 and is rotated about the U-shaped wire member 492 by the securing member 408 and the edge of the access cover 403 positioned within the channel 494. The upper surface 497 is then pressed toward the top surface of the access cover until the latches 419 "snap" into engagement with the access cover 403.

[0102] The filter cartridges of the present disclosure can be configured to be positioned in the housing in one or more rotational orientations. For the type of cartridge shown, where the cartridge has a long cross-sectional inlet and a short cross-sectional inlet, the cartridge can be configured to be properly positioned in only one rotational orientation, or can be configured to be properly positioned in two rotational orientations. An indexing arrangement can be used between the cartridge and the housing to accommodate either rotational orientation or both rotational orientations as desired.

[0103] Reference is now made to Figure 24 and Figure 25FIG. 6 shows an exploded perspective view of another exemplary embodiment of an air cleaner assembly 600 of the present disclosure, which differs in shape from other air cleaner assemblies described herein, but includes a number of features that are the same or similar to other embodiments. The air cleaner assembly 600 generally includes a housing 601, a pre-cleaner 610, a filter cartridge 630, and an optional safety filter 635. As shown, at least a portion of some of these components generally have an octagonal outer shape, with each of the eight sides being approximately the same length, which provides certain options for mating components to one another that would otherwise not be available. For example, the filter cartridge 630 can have a number of orientations in which it can be mated into the housing 601, as described further below.

[0104] The exemplary housing 601 includes an inlet 602 at an opposite end from the outlet 605, where elements of the system can be inserted into the inlet 601 for assembly of the air cleaner assembly 600. The housing 601 can also include an internal lip (not shown) extending around the perimeter and spaced apart from the inlet 602. Further, the housing 601 includes at least one securing member 608 located on the exterior of the housing outer wall and adjacent to the inlet 602 for engaging the latch mechanism 619 of the pre-cleaner 610. The internal lip of the housing 601 is positioned to provide one side of a channel or pocket, where the channel is also defined by the inner wall of the housing 601 and a bottom channel surface extending between the internal lip and the inner wall of the housing 601. The channel extends generally around the perimeter of the housing 601 to provide a seal with features of the filter cartridge, as described below.

[0105] The pre-cleaner 610 can include a service cover that is capable of engaging a base member (and attachment to the housing 601 via a latch), or the pre-cleaner 610 can be a single piece component that also generally includes a latch. That is, in certain embodiments of the air cleaner assembly 600, the pre-cleaner can include a service cover that engages a base member via an attachment configuration such as a snap-fit arrangement to secure the two components to one another as a single unit, which can then be attached to the housing 601 via the latch 619. In such embodiments, the service cover would be separable from the base member to facilitate cleaning, for example. However, in another embodiment of the pre-cleaner 610, the service cover can be made as a single piece that is provided to the air cleaner assembly 600 as a single unit. In any case, the pre-cleaner 610 generally removes a portion of dust or other particulate material (e.g., liquid particulate material) that enters the air cleaner through the airflow inlet before it can reach the internally located filter cartridge 630.

[0106] The prefilter 610 also includes a plurality of inlet tubes or contaminant separator tubes 660 extending from the interior surface of the cover toward the interior region of the housing 601. The tubes 660 can be preformed and crimped into the holes of the cover during assembly, or can be attached in other ways, such as by adhesive. In general, each separator tube 660 includes an upstream inlet end into which air entering the air cleaner assembly 600 (to be filtered) will flow. Each tube 660 can include a vane arrangement at or adjacent the inlet end, and is configured for inducing (directing) a cyclonic airflow of the inlet air. As with other embodiments described herein, the tubes 660 can also include a side slot between the tube ends through which contaminant (dirt, particulate contaminants, or water) separated by the contaminant separator arrangement can flow out to ultimately be expelled through the housing contaminant expulsion port.

[0107] While a variety of arrangements of the tubes 660 are contemplated, the exemplary embodiment includes tubes 660 arranged in two intersecting or overlapping "rings" 662, 664, each of the two rings including two tubes at the top and bottom of the ring and one tube at either side of the ring. The two bottom tubes of the first ring 662 are also the two tubes that make up the two top tubes of the second ring 664. As shown in this exemplary embodiment, the tubes 660 are preferably arranged so that a desired pattern is achieved for the flow of air out of the tubes. Some or all of the tubes 660 can also include a vane arrangement for directing airflow in a desired manner. The vane arrangement can vary greatly depending on the desired airflow, and it is contemplated that the tubes 660 of a single prefilter 610 can have different vane arrangements.

[0108] With more particular reference to Figure 25 The filter cartridge 630 can be considered a primary or preliminary filter cartridge for selectively separating a desired amount of particulate or contaminant material that was not filtered out of the system by the prefilter 610. The filter cartridge 630 is generally a working or removable component that can be periodically removed and replaced as needed during the useful life of the air cleaner assembly 600. The filter cartridge 630 includes a filter or filter media 631 that can be any of a variety of types, such as the fluted filter media described above. The exemplary filter cartridge 630 is considered a "straight flow" arrangement in that it includes a first, flow-in face or end 632 and an opposite, flow-out face or end 633, thereby filtering airflow that generally passes through the filter cartridge 630 from the inlet end 632 to the outlet end 633.

[0109] The filter cartridge 630 can also include a filter seal member (not shown) having an interior opening defined by an upper lip at its top edge, the upper lip extending inwardly from the frame wall in at least one location to fill at least one gap space between the frame wall and the outer surface of the media pack when positioned in the filter seal member. That is, because the shape of the frame wall (e.g., octagonal) is different than the outer shape of the filter cartridge 630 (e.g., circular), there will be a gap between these elements in areas where the shapes diverge from one another (e.g., the areas where the angled corners of the frame wall are spaced apart from the curved outer surface of the filter cartridge 630). In this embodiment, the overhang of the upper lip from the frame wall will fill this gap to approximate the interior octagonal shape of the filter seal member along its top edge.

[0110] The filter cartridge 630 also includes a flexible perimeter seal member 674 extending generally around the perimeter of the top of the filter cartridge 630. The seal member 674 also includes an axially directed portion 677 sized and shaped to provide a leak resistant seal against the interior surface of the housing 601 when the air cleaner assembly 600 is in operation. To facilitate this, the seal member 674 can be of a resilient material type typically used for such sealing purposes. The flexible seal member 674 can be molded in place while the media 631 is positioned inside the outer shell of the filter cartridge 630 such that the seal member 674 will be embedded in the frame wall of the filter seal member, as described above. When the cartridge 730 is positioned within the housing, its seal member 674 can provide a pinch seal type arrangement, as described above for other configurations of the cartridge.

[0111] The axially directed portion 677 of the seal member 674 can have a profile around portions of its perimeter to selectively engage other portions of the housing 601. In embodiments of the filter cartridge 630 where all sides of the seal member 674 are the same length, the filter cartridge 630 can "walk" or rotate to any of eight different orientations within the housing 601. However, the axially directed portion 677 on one or more sides can include a profile or overhang that makes the shape different from the other sides. In such embodiments, the interior region of the housing 601 can be designed such that only a particular orientation of the filter cartridge 630 will provide for the proper seating of the seal member within the housing 601.

[0112] According to the present application, another exemplary air cleaner assembly is contemplated that does not include a pre-cleaner requiring a contaminant discharge port, so the air cleaner body can include a side airflow inlet rather than an end inlet. The outlet arrangement of such an embodiment can be made as a separate component from the rest of the body and then secured thereto, or it can be integrally molded with the rest of the body. In such an arrangement, the service cover would not be secured to the pre-cleaner base member or the body, but can instead be mounted directly to the housing. This service cover can be used to secure the filter element within the housing.

[0113] The application now being described will be more fully understood from the following description of several embodiments thereof, taken in conjunction with the accompanying drawings. The entire disclosure of any patent or patent application identified herein is hereby incorporated by reference. The detailed description and examples given herein are only for the clear understanding of the application. They should not be considered necessary limitations on the scope of the application. It will be apparent to one of ordinary skill in the art that many modifications, additions and substitutions can be made to the embodiments described without departing from the scope of the application. Accordingly, the scope of the application should not be limited by the descriptions of the embodiments set forth above but should be defined by the appended claims and their equivalents.

Claims

1. A filter cartridge configured to be removably positioned in an interior opening of a housing, wherein the filter cartridge comprises: a media pack comprising an inlet end, an outlet end, and an outer surface having an outer peripheral shape; at least one of: (a) a frame member at least partially surrounding the media pack, the frame member comprising a frame wall having a shape different than the outer peripheral shape of the media pack; and (b) a shell at least partially surrounding the media pack, the shell comprising a shell wall having a shape different than the outer peripheral shape of the media pack; and a seal at least partially extending around the inlet end of the media pack, wherein the seal connects the media pack to at least one of the frame member and the shell; wherein the seal comprises a sealing portion spaced apart from the outer surface of the media pack by a channel, wherein the outer peripheral shape of the media pack comprises at least one curved portion, and wherein the shape of at least one of the frame wall and the shell wall comprises a polygonal shape; the filter cartridge in combination with the housing, the housing comprising an inlet end, an outlet end, and an interior opening defined between the inlet end and the outlet end by a housing wall having an inner peripheral shape; wherein the housing further comprises an interior lip extending around a periphery and spaced apart from the inlet end, and at least one protrusion extending inwardly from the wall of the housing, wherein the interior lip is positioned to provide one side of a channel or pocket (481), wherein the channel or pocket (481) is further defined by an inner wall of the housing and a bottom channel surface extending between the interior lip and the inner wall of the housing, wherein the channel or pocket (481) extends around the periphery of the housing; wherein the housing wall is present in the channel when the filter cartridge is in an installed condition.

2. The filter cartridge of claim 1, comprising the shell, wherein the shell wall has an outer shape that generally matches the inner peripheral shape of the housing wall.

3. The filter cartridge of claim 1, comprising the frame member, wherein the frame wall has an outer shape that generally matches the inner peripheral shape of the housing wall.

4. The filter cartridge of claim 1, comprising both the frame member and the shell.

5. The filter cartridge of claim 1, wherein the seal is flexible.

6. The filter cartridge of claim 1, comprising at least the frame member, wherein the frame member further comprises an interior opening at least partially defined by an upper lip extending inwardly from the frame wall at its upper edge across a gap at at least one location, the gap being between the frame wall and the outer surface of the media pack when the media pack is at least partially positioned in the interior opening of the frame member.

7. The filter cartridge of claim 1, comprising at least the frame member, wherein the frame wall further comprises a handle extending across the interior opening of the frame member.

8. The filter cartridge of claim 1, comprising at least the frame member, wherein the frame wall comprises at least one notch extending along at least a portion of a height of the frame wall.

9. The filter cartridge of claim 8, wherein the frame wall comprises a plurality of notches, each of the notches extending along at least a portion of a height of the frame wall. ​ 10. The filter cartridge of claim 8, wherein the frame member includes at least one curved portion and at least one straight portion, and wherein the notch located on the at least one curved portion includes a size that is different than the size of the notch located on the at least one straight portion.

11. The filter cartridge of claim 1, including at least the frame member, wherein the frame member further includes a bottom perimeter edge and at least one extension member extending from the bottom perimeter edge.

12. The filter cartridge of claim 11, further including a housing, wherein the housing further includes a flange extending around at least a portion of a top edge of the housing.

13. The filter cartridge of claim 12, wherein each extension member includes a length and a distal end, the distal end being positioned to contact the flange of the housing such that the length of the extension member corresponds to a distance that the bottom perimeter edge of the frame wall is spaced apart from the flange of the housing.

14. The filter cartridge of claim 11, wherein the at least one extension member includes a plurality of extension members spaced apart from each other around the bottom perimeter edge of the frame wall.

15. The filter cartridge of claim 14, wherein the plurality of extension members are spaced apart from each other at the same distance around the bottom perimeter edge of the frame wall.

16. The filter cartridge of claim 14, wherein the plurality of extension members are not spaced apart from each other at the same distance around the bottom perimeter edge of the frame wall.

17. A filter cartridge configured to be removably positioned in an interior opening of a housing, wherein the filter cartridge comprises: a media pack including an inlet end, an outlet end, and an outer surface having an outer peripheral shape; at least one of: a) a frame member at least partially surrounding the media pack, the frame member including a frame wall having a shape that is different than the outer peripheral shape of the media pack; and b) a housing at least partially surrounding the media pack, the housing including a housing wall having a shape that is different than the outer peripheral shape of the media pack; and a seal member at least partially extending around the inlet end of the media pack, wherein the seal member includes a pinch seal portion spaced apart from the outer surface of the media pack, wherein the seal member connects the media pack to at least one of the frame member and the housing; wherein the seal member includes an axially directed portion sized and shaped to provide a leak-tight seal with an inner surface of the housing, wherein the axially directed portion has a stepped profile around a periphery thereof defining a stepped region, the stepped region defined by a recess or a protrusion.

18. The filter cartridge of claim 17, wherein the shape of the housing is oblong.

19. The filter cartridge of claim 17 or 18, wherein the frame wall includes a shape that is different than the shape of the housing wall.

20. The filter cartridge of claim 17 or 18, further comprising a handle extending across opposite sides of the frame wall.

21. The filter cartridge of claim 17 or 18, wherein the outer peripheral shape of the media pack includes at least one curved portion.

22. The filter cartridge of claim 20, wherein the handle is oriented proximate the inlet end and extends in a direction away from the outlet end. ​

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