Self-cleaning air filtration device and method

Abstract

An air filtering device includes: an air flow head assembly including a fan assembly and a blade assembly; a filter assembly; and a separator chamber housing, wherein the filter assembly is disposed inside the separator chamber housing. The separator chamber housing has a chamber inlet at a first axial side of the separator chamber housing and a clean air outlet at a second axial side of the separator chamber housing opposite to the first axial side. The filter assembly has a first axial end adjacent to the chamber inlet and a second axial end adjacent to the clean air outlet. The separator chamber housing includes at least one debris discharge chute extension configured to discharge debris from the interior space of the separator chamber housing. The filter assembly includes a debris catch tray disposed at the second axial end, the debris catch tray having a debris discharge chute aligned with the at least one debris discharge chute extension.

Description

Technical Field

[0001] The present disclosure relates to an improved air filtration device and air filtration method for efficiently removing heavier-than-air particulate debris from debris-laden air to provide a clean air flow to equipment using the air filtration device and method. Background Art

[0002] Air pre-cleaners and air filtration methods are known that centrifugally separate debris heavier than the air from air using filters used in internal combustion engines, ventilation systems, and other devices that draw in debris-laden air. Such air pre-cleaners include powered air pre-cleaners and air filtration methods that employ a motor-driven fan to draw debris-laden air into the air pre-cleaner, as well as air pre-cleaners and air filtration methods that rely solely on vacuum applied to the air pre-cleaner and air filtration method by a device supplied with clean air (e.g., an internal combustion engine) to draw debris-laden air into the air pre-cleaner. Examples of the assignee's prior air pre-cleaners and air filtration methods are shown in the following U.S. patents, all of which are incorporated herein by reference in their entirety:

[0003] U.S. Patent No. 5,656,050;

[0004] U.S. Patent No. 5,766,315;

[0005] U.S. Patent No. 6,319,304;

[0006] U.S. Patent No. 6,338,745;

[0007] U.S. Patent No. 6,406,506;

[0008] U.S. Patent No. 6,425,943;

[0009] U.S. Patent No. 6,878,189;

[0010] U.S. Patent No. 7,056,368; and

[0011] U.S. Patent No. 7,452,409.

[0012] Current engine and HVAC air filtration systems suffer from numerous design and performance issues. For example, current systems are based on designs that create significant air intake restriction, resulting in shortened air filter life and negatively impacted engine performance and fuel economy. Furthermore, current systems operate under vacuum, which prematurely shortens filter life due to the high initial air intake restriction, necessitating more frequent filter maintenance. Current air filtration systems often include air pre-cleaners that trap airborne debris within the system, requiring manual removal of the trapped debris. Other current technologies use dump valves, which allow the weight of trapped debris to overcome the vacuum created within the air pre-cleaner / filtration system and physically fall out of the air filtration system; however, these dump valves often clog when moisture or mixed debris is present in the airstream. Current systems can use vacuum equipment to remove separated airborne debris from the air filtration system, but this requires additional components to capture and remove the removed debris. Such systems also tend to clog when moisture or mixed debris is present in the airstream.

[0013] In addition, the physical size and weight of current technology air filtration systems used to produce a given air flow to downstream equipment can create installation and maintainability problems. Due to variations in construction and performance requirements, known air filtration systems may require custom manufacturing of the pre-cleaner, air filtration system, and / or its mounting components. This customization limits the range of applications for known air filtration systems and adversely affects manufacturing time and cost. Examples of such variations between applications requiring individual customization include: the separate components required for pre-filtration and disposal of debris that is centrifugally separated from the pre-filtration equipment and must be exhausted to the atmosphere; the location and direction of air flow through the filter; the location of the clean air outlet for providing clean air from the air filtration system to the engine or equipment using the air filtration system; the physical size and style of the filter; the location of available support structure for mounting the air filtration system and its components; and the specific clean air flow rate required to ensure performance of the downstream system. In the case of powered air pre-cleaners and air filtration systems, it has been found that the life of the motor of the motor-driven fan is shortened by the reduced air flow used to cool the motor when the motor is in the airflow path on the clean side of the filter. This is because when the filter is loaded, the air flow is reduced, and the residual heat on the motor shortens its life. Furthermore, it has been found that debris accumulated in the separator chamber during filter servicing can easily enter the clean air outlet, which can lead to shortened engine life or debris entering the HVAC and ventilation systems, respectively.

[0014] Therefore, there is a need for an improved air pre-cleaner filtering device and method that overcomes these shortcomings and limitations of known air pre-cleaner filtering devices. More specifically, there is a need for an improved air pre-cleaner filtering device that is physically compact, thereby permitting its use in limited space applications, and is versatile for a range of applications where different mounting configurations and clean air flow rate requirements exist, thereby eliminating the expense and inefficiency of custom-manufactured air pre-cleaner filtering systems. There is also a need for a method of air filtration in a compact, single-block powered air pre-cleaner filtering device that can properly cool the fan motor as part of its design, thereby ensuring extended motor life. Relatedly, there is a need for an improved air pre-cleaner filtering device that operates at full efficiency regardless of the air flow requirements of the equipment on which the system is installed, while ensuring that the exhaust slot / port does not become clogged during operation. There is also a need for a disposable air filter cartridge to provide a barrier to keep separated debris out of the clean side outlet during filter servicing and to direct the separated debris to its intended location (a discharge chute / port at the outlet end of the main housing separator chamber), such barrier being referred to herein as a debris catch tray. There is also a need for filter identification technology that includes the ability to store data in the filter. There is a further need to monitor pressure and vacuum in the apparatus and to provide multiple types of fans and motors, as well as variable speed control of the motor when needed. The improved, compact, versatile air pre-cleaning filtration apparatus and method of the present disclosure with a disposable air filter cartridge having a debris catch tray addresses these needs in the art. Summary of the Invention

[0015] The present disclosure relates to a compact, self-cleaning air filtration device and method that provides a range of benefits, including reduced intake restriction for engine applications, providing positive air flow pressure for HVAC and ventilation systems, and improved debris separator efficiency at all operating air flow rates. The air filtration device includes several features, including optional filter identification (FID) with data storage, multiple fan and motor combinations, motor speed control, pressure monitoring and control, inclusion of rain caps and / or debris screens, discharge port adapters, discharge slot sealing cap adapters, and the use of a variety of different filter media. The range of media includes high efficiency media for removing very small particles as well as superior durability and maintainability. Various fan and motor combinations can be employed in the device based on the type of filter used. The air filtration device of the present disclosure advantageously reduces the physical space required for installation at a given air flow output, reduces engine air flow restriction, and provides electronic filter identification and data storage capabilities within the air filter. The air filter has an easily serviceable, disposable air filter cartridge that includes a debris catch tray to prevent residual debris within the separator chamber from entering the clean air outlet during filter cartridge maintenance and improves the removal of airborne debris from the pressurized separator chamber. The separator chamber of the disclosed embodiment is elongated and tapered along an axis extending from the inlet to at least one ejector port (also known as a debris ejection slot extension) and the clean air outlet located at the end of the separator chamber. By passing air in a linear direction, restrictions within the air filtration device are significantly reduced, allowing more positive pressurized air flow to be pushed out of the clean air outlet and into the engine or equipment in which the compact, self-cleaning air filtration device is installed. This linearly oriented air flow allows for a more compact design, thereby enabling significantly higher air flow in applications with limited space. The air pre-cleaner filter assembly is a versatile and compact self-cleaning air filtration device for use in confined space applications, which have many requirements for mounting configuration and discharge slot / port mounting orientation to provide clean air to ventilation systems, heat exchangers, heating and air conditioning systems (HVAC), and other equipment with a range of air flow requirements (such as internal combustion engines). The present disclosure according to preferred embodiments represents an improvement over conventional air pre-cleaner assemblies and methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a perspective view of an exemplary air filtering device.

[0017] Figure 2 is a view of the air filter device from the top of the rain cap of the air filter device.

[0018] Figure 3 It is a side view of the air filter unit.

[0019] Figure 4 is a side view of an air filter assembly including a mounting foot, showing Figure 3 opposite side.

[0020] Figure 5 This is a view of the air filter unit from the clean air outlet, showing the Figure 2 opposite side.

[0021] Figure 6A It is a side view of the air filter unit.

[0022] Figure 6B is a cross-sectional view of the air flow head assembly with the optional rain cap.

[0023] Figure 6C is a perspective view of the air flow head assembly.

[0024] Figure 7 It is an exploded perspective view of the air filter unit.

[0025] Figure 8 is a cross-sectional view of an air filter unit.

[0026] Figure 9 It is an exploded side view of the air filter unit.

[0027] Figure 10 is a perspective view of the rain cap of the air filter unit.

[0028] Figure 11 It is a plan view of the top of the rain hat.

[0029] Figure 12 It is a side view of the rain hat.

[0030] Figure 13 It is a plan view of the underside of the rain hat.

[0031] Figure 14 is a perspective view of a motor / fan assembly of an air filtering device with a debris guard.

[0032] Figure 15 is a plan view of the dirty air inlet to the motor / fan assembly.

[0033] Figure 16 is a side view of the motor / fan assembly.

[0034] Figure 17 is a plan view of the dirty air outlet side of the motor / fan assembly.

[0035] Figure 18 is a perspective view of the dirty air inlet side of the vane assembly of an air filtration device.

[0036] Figure 19 is a plan view of the dirty air inlet side of the impeller assembly.

[0037] Figure 20 It is a side view of the blade assembly.

[0038] Figure 21 is a plan view of the dirty air outlet side of the impeller assembly.

[0039] Figure 22 is another perspective view of the dirty air inlet side of the bucket assembly.

[0040] Figure 23 is a perspective view of the dirty air outlet side of the bucket assembly.

[0041] Figure 24 is a perspective view of a separator chamber housing of an air filtration device having a clean air outlet.

[0042] Figure 25 is a side view of the separator chamber housing showing the mounting feet.

[0043] Figure 26 is a side view of the separator chamber housing.

[0044] Figure 27 is a view of the interior of the separator chamber housing viewed from the dirty air inlet side.

[0045] Figure 28 is a view of the separator chamber housing viewed from the clean air outlet side.

[0046] Figure 29 is a plan view of a first end portion of an exhaust port adapter of an air filtering device.

[0047] Figure 30 is a perspective view of the discharge port adapter.

[0048] Figure 31 is a perspective view of an air filtration device with an exhaust port adapter mounted thereon.

[0049] Figure 32 is a plan view of the second end of the discharge port adapter.

[0050] Figure 33 is a side view of the discharge port adapter showing the debris discharge port.

[0051] Figure 34 is a perspective view of an outer filter assembly of an air filtration device.

[0052] Figure 35 is a plan view of the clean air side of the outer filter assembly showing the debris discharge slots.

[0053] Figure 36 is a side view of the outer filter assembly.

[0054] Figure 37 is a plan view of the dirty air side of the outer filter assembly showing the debris ejection slots.

[0055] Figure 38 is an exploded view of the outer filter assembly.

[0056] Figure 39 is a perspective view of the closed end cap of the outer filter assembly.

[0057] Figure 40 is a plan view of the first dirty air side of the closed end cap.

[0058] Figure 41 is a plan view of the second clean air side of the closed end cap.

[0059] Figure 42 is a side view of the closed end cap.

[0060] Figure 43 is a perspective view from the clean air side of the debris catch tray of an air filtration unit.

[0061] Figure 44 is a plan view of the inner surface of the debris catch tray, which is the surface for sealing the filter medium.

[0062] Figure 45 is a plan view of the exterior surface of the clean air side of the debris capture tray.

[0063] Figure 46 is a side view of the crumb catch tray.

[0064] Figure 47 is a perspective view of an air filtration device showing an optional filter identification reader air outlet side adapter attached to the air outlet side.

[0065] Figure 48A is a first perspective view of a filter identification reader air outlet side adapter.

[0066] Figure 48B is a second perspective view of the filter identification reader air outlet side adapter showing internal features including the filter identification reader circuit board.

[0067] Figure 49 is a perspective view of the outer filter assembly with a portion of the outer filter clean side seal cut away to show internal components including an optional filter identification ring.

[0068] Figure 50A is a perspective view showing an optional drain slot sealing cap adapter for an air filtration device.

[0069] Figure 50B is a perspective view of an air filter unit with a drain slot sealing cap adapter installed thereon.

[0070] Figure 51 is a side view of an air filter unit showing the locking pin assembly.

[0071] Figure 52A is Figure 51 Circle and mark " Figure 52A ” is an enlarged view of the part.

[0072] Figure 52B It is an enlarged perspective view of the electrical connector of the air filtration device.

[0073] Figure 53A is a dirty air side view of the air filter unit with the locking pin assembly installed.

[0074] Figure 53B is a dirty air side view of the air filter unit with the locking pin assembly removed.

[0075] Figure 54 It is along Figure 26 A cross-sectional view taken along line 54-54 in FIG. 5 shows the interior of the separator chamber housing with the outer filter assembly installed as viewed from the clean air side.

[0076] Figure 55 is a graph comparing example flow rates in an air filtration device with a safety filter installed and without the safety filter installed.

[0077] Figure 56 is a perspective view of an air filtration unit showing an optional debris screen installed on the air filtration unit.

[0078] Figure 57 is a side view of an air filter unit showing a debris screen installed on the air filter unit.

[0079] Figure 58 is another side view of the air filter unit showing the debris screen installed on the air filter unit.

[0080] Figure 59 is a perspective view of a debris screen.

[0081] Figure 60 is a side view of the debris screen.

[0082] Figure 61 is a plan view of the base and mounting flange of the debris screen.

[0083] Figure 62is a flow chart showing the air flow through the air filtration unit. DETAILED DESCRIPTION

[0084] Exemplary embodiments of self-cleaning air filtration devices and methods are described below.

[0085] like Figures 1 to 9 As shown in FIG, a self-cleaning air filtration device 1 includes a removable air flow head assembly 109 having a rain cap 2, a motor / fan assembly 9, and a vane (louver) assembly 10. The air filtration device 1 also includes an outer filter assembly 20, an optional inner filter assembly 19, and a conical separator chamber housing 11. The separator chamber housing 11 is disposed downstream of the air flow head assembly 109 relative to the direction of air flow in the air filtration device 1 during use. These components of the air filtration device 1 are assembled together so that the longitudinal axis X extends through the center of each component.

[0086] (1) Air flow head assembly

[0087] Air flow head assembly 109 is configured to be held together by fasteners 3. More specifically, fasteners 3 are inserted into receiving bosses 41 of rain cap 2, receiving bosses 47 of motor / fan assembly 9, and receiving bosses 48 of impeller assembly 10. Fasteners 3 may be, for example, metal bolts, rivets, or other such attachment members. In this embodiment, air flow head assembly 109 is shown as having four fasteners 3 and four corresponding receiving bosses 41, 47, and 48, respectively. However, the number of fasteners and receiving bosses is not limited to four and may be more or less than four. Figure 6B and Figure 6C The air flow head assembly 109 is shown in an assembled state with the rain cap 2, motor / fan assembly 9 and impeller assembly 10 secured together.

[0088] like Figure 10 and Figure 12 As can be seen in FIG, the rain cap 2 is formed by a conical head and a plurality of mounting feet (in the present embodiment, four) extending from the head in a direction parallel to the axial direction defined by the longitudinal axis X of the air filter device 1. The conical head is a raised plate member that projects outwardly in a first axial direction (i.e., a direction away from the remaining components of the air filter device 1), the first axial direction being opposite to the second axial direction. The inner surface of the conical head has a cross member extending between four receiving bosses 41 for structural support. The rain cap 2 is further provided with a receiving boss 41 for receiving the fastener 3. The rain cap 2 can be made, for example, of a polymer composite resin.

[0089] like Figures 14 to 17As shown in FIG. 4 , the motor / fan assembly 9 includes a fan assembly 43. The fan assembly 43 includes a debris guard member 42, fan blades 44, a fan motor 45, electrical wiring 46, and a receiving boss 47. The debris guard member 42 is made of, for example, a polymer composite resin and includes a plurality of circumferentially extending guard beams separated by radially extending separation beams. The debris guard member 42 is used to prevent debris that could damage the fan assembly 43 from entering the fan assembly 43, and also prevents a user's hands and fingers from entering the fan assembly 43.

[0090] A fan motor 45 is provided at the center of the fan assembly 43 and is powered by electrical wiring 46. The electrical wiring 46 is connected to a power source (e.g., a battery not shown) via an electrical connector 18 described below. The fan motor 45 is configured to drive the fan blades 44 using the electricity supplied via the electrical wiring 46. The fan motor 45 can be made, for example, of metal and / or polymer composite resin. The fan motor 45, as shown, is electrical and can be a brushed or brushless motor. Advantageously, the air filtration device 1 is constructed of a relatively compact fan motor 45 and fan assembly 43, thereby helping to reduce the physical size of the device, and the location of the fan motor 45 on the dirty side of the air flow used to cool the motor ensures an extended motor life compared to conventional devices. Other motor and fan configurations, such as those including a hydraulic motor, may also be used.

[0091] Fan blades 44 are provided on the inner side (second axial side) of the motor / fan assembly 9. In the present embodiment, seven fan blades 44 are provided, but the fan blades 44 are not limited to this number, and there may be more or less than seven fan blades 44 provided to the motor / fan assembly 9. The fan blades 44 are spaced apart from each other in the circumferential direction and are arranged to rotate when driven by the fan motor 45. The fan blades 44 may be made of, for example, a polymer composite resin.

[0092] like Figures 18 to 23 As seen in FIG. 1 , the bucket assembly 10 includes a tapered air flow redirector 50 at the center of the bucket assembly 10 and a circumferential wall 24 extending radially outward from the air flow redirector 50 to the bucket assembly 10 (see FIG. 1 ). Figure 7 ) of a plurality of blades 51. The air flow deflector 50 is a raised plate member that protrudes outward in a first axial direction (i.e., a direction away from the blades 51). The air flow deflector 50 is positioned at the center of the blade assembly 10 and on the inlet air side, facing the back of the fan blades 44 that guide the air flow into the blades 51. The circumferential wall 24 includes a mounting surface 49 on which the motor / fan assembly 9 is mounted (see Figure 18). Circumferential wall 24 further has a radially outer surface from which receiving boss 48 extends radially outward. On an opposite second axial side of bucket assembly 10, a mounting surface 55 is provided for mounting bucket assembly 10 to separator chamber housing 11 as discussed below. Bucket assembly 10 further includes a recess 53 in which an electrical connector mounting groove 56 is provided that is configured to receive electrical connector 18, described below.

[0093] Each of the blades 51 has first and second oppositely facing surfaces that are angled relative to the longitudinal axis X. The plurality of blades 51 are arranged in a circumferential direction and spaced apart from one another. A plurality of guard members 52 are provided between adjacent pairs of blades 51 as a safety measure to prevent, for example, a user's finger from passing through the blade assembly 10. In this embodiment, three guard members 52 extend between each adjacent pair of blades 51, but the number of guard members 52 may be more or less than three. The guard members 52 extend circumferentially between the blades 51. All components of the blade assembly 10 may be made, for example, of metal and / or a polymer composite resin.

[0094] The bucket assembly 10 is further provided with a plurality of locking slots 17 along the mounting surface 55, which are arranged to receive the mounting tabs 16 of the separator chamber housing 11 as discussed below. The locking slots 17 are arranged in a circumferential direction and are spaced apart from each other. Each locking slot 17 is longer in the circumferential direction than in the radial direction. Figure 18 and Figure 22 As seen in FIG, each locking slot 17 is open in the first and second axial directions to receive a corresponding mounting tab 16. After the mounting tab 16 is inserted into the locking slot 17, the vane assembly 10 (or the entire air flow head assembly 109) is rotated relative to the separator chamber housing 11 to securely assemble the air filtration device 1.

[0095] The inner surface of the air flow diverter 50 is further provided with alignment pins 38. The alignment pins 38 are made of, for example, a polymer composite resin, and are provided to align the air flow head assembly 109 with the outer filter assembly 20, as described below.

[0096] like Figures 1 to 3 as well as Figures 51 to 54 As seen in FIG, the air flow head assembly 109 (the rain cap 2, the motor / fan assembly 9, and the blade (louver) assembly 10) is configured to be mounted to the separator chamber housing 11 via a locking pin assembly 97. The locking pin assembly 97 is made of, for example, metal and / or polymer composite resin, and includes first and second locking pin bosses 4, a locking pin 5, and a locking pin retainer 96. Figure 1 、 Figure 22 and Figure 23 As seen in FIG, a first locking pin boss 4 is provided on the outer circumferential edge of the bucket assembly 10. Figure 1 and Figure 24 As seen in FIG, the second locking pin boss 4 is provided on the outer circumferential edge of the first axial end of the separator chamber housing 11. When assembled, the first locking pin boss 4 and the second locking pin boss 4 are aligned so that the locking pin 5 passes through both the first locking pin boss 4 and the second locking pin boss 4. Figure 1 、 Figure 51 and Figure 52A As seen in FIG, locking pin retainer 96 is a flexible member configured to retain locking pin 5 in an assembled state. For example, locking pin retainer 96 may have a stiffness less than that of locking pin 5. A first end of locking pin retainer 96 is secured to the head of locking pin 5 by passing through an opening in the head. A second, opposite end of locking pin retainer 96 has an opening configured to receive the opposite end of locking pin 5, thereby preventing the locking pin 5 from being accidentally removed from first and second locking pin bosses 4, 4.

[0097] like Figure 1 、 Figure 51 、 Figure 52A and Figure 52B As seen in FIG, air filtration device 1 is provided with an electrical connector 18 disposed within mounting recess 56 of impeller assembly 10. Electrical connector 18 is an adapter configured to connect electrical wiring 46 to a power source. Air filtration device 1 includes a safety feature that prevents removal of airflow head assembly 109 from separator chamber housing 11 without first removing electrical connector 18. Specifically, electrical connector 18 prevents rotation of airflow head assembly 109 relative to separator chamber housing 11 and, therefore, prevents removal of mounting tab 16 (described below) from locking slot 17 (discussed below). Therefore, the male and female portions of electrical connector 18 must be disconnected from each other in order to remove airflow head assembly 109 from separator chamber housing 11.

[0098] (2) Separator chamber housing

[0099] like Figures 24 to 28As seen in the figure, the separator chamber housing 11 is shaped to taper in the second axial direction (i.e., toward the clean air outlet 8). In other words, the diameter of the separator chamber housing 11 gradually decreases from the first axial end (at the air inlet 57) to the second axial end (at the clean air outlet 8). The separator chamber housing 11 is provided with the mounting tabs 16 discussed above. A plurality of mounting tabs 16 are arranged in a circumferential direction and spaced apart from one another. Each mounting tab 16 is longer in the circumferential direction than in the radial direction. As described above, each mounting tab 16 is received in a corresponding locking slot 17 of the impeller assembly 10 and then rotated until the first and second locking pin bosses 4 align for insertion of the locking pin 5, thereby securing the air flow head assembly 109 to the separator chamber housing 11. Together with the locking pin assembly 97, the coupling of the mounting tabs 16 with the locking slots 17 ensures a secure assembly of the air flow head assembly 109 to the separator chamber housing 11. Furthermore, as described above, once the electrical connector 18 (male and female portions) is connected to provide power, the air flow head assembly 109 cannot be removed from the separator chamber housing 11 (i.e., the mounting tab 16 cannot be removed from the locking slot 17) without first disconnecting the electrical connector 18.

[0100] The separator chamber housing 11 has an air inlet 57 on a first axial side and a clean air outlet 8 on an opposite second axial side. Figure 24 and Figure 25 As seen in Figure 8 As shown in , the separator chamber housing 11 has a debris separator chamber 34 axially arranged between the air inlet 57 and the clean air outlet 8. The air inlet 57 is longer in diameter than the clean air outlet 8. The separator chamber housing 11 can be made of metal and / or polymer composite resin, for example. In use, the drive of the motor / fan assembly 9 causes the air laden with debris to be pushed through the blade assembly 10, which produces a centripetal rotating air flow, which is then pushed into the air inlet 57 and the separator chamber housing 11. In the separator chamber housing 11, the debris is pushed radially outward under the air flow pressure to rotate along the inner wall of the separator chamber housing 11. Due to the tapered structure of the separator chamber housing 11, the debris-laden airflow maintains velocity and energy as it rotates because the tapered structure reduces the area inside the separator chamber housing 11, thereby collapsing the space and the debris-laden airflow until the debris passes through the debris discharge chute extension 12 (discussed below) to exit the air filtration device 1, while the remaining air passes through the outer filter assembly 20 under the action of centripetal force, is filtered, and exits as clean air through the clean air outlet 8.

[0101] The separator chamber housing 11 has a plurality of mounting bosses 6 extending radially outward from the outer circumferential surface of the separator chamber housing 11. In the present embodiment, four mounting bosses 6 are provided. However, the number of mounting bosses 6 is not limited to four, and may be more or less than four. The mounting bosses 6 are configured to mount the air filter device 1 to a support structure, such as an engine or other equipment to which the air filter device 1 is provided, in a plurality of orientations. The plurality of possible mounting orientations provide advantageous adaptability for the use of the air filter device 1 in various applications. The mounting bosses 6 are elongated members made, for example, of metal and / or polymer composite resin. Each mounting boss 6 has an opening on its free end for mounting the air filter device 1 to the support structure. A marking surface 61 is provided between the mounting bosses 6 for providing markings or other indicia about the air filter device 1.

[0102] On a first axial side thereof, the separator chamber housing 11 comprises a mounting surface 58 surrounding the air flow inlet 57. The mounting surface 58 is arranged to cooperate with the mounting surface 55 of the bucket assembly 10. The mounting tabs 16 are formed on the mounting surface 58.

[0103] On its second axial side, the separator chamber housing 11 has an outlet sealing surface 60 surrounding the clean air outlet 8. An air outlet sealing bead 59 is provided on the outlet sealing surface 60 at the edge of the clean air outlet 8. Figure 24 As shown in FIG, a vacuum / pressure port 13 is on the inner circumferential surface of the clean air outlet 8 , the vacuum / pressure port 13 being configured to receive an optional mechanical pressure / vacuum sensor or an electrical pressure / vacuum sensor (not shown) for sensing the pressure of the air flow at the clean air outlet 8 .

[0104] like Figures 24 to 28 As seen in FIG. 1 , the separator chamber housing 11 has a plurality of debris discharge chute extensions 12 configured to align with the debris discharge chute 72 of the debris capture tray 27 described in detail below. In the present embodiment, four debris discharge chute extensions 12 are provided spaced apart around a circumferential portion of the separator chamber housing 11. However, the number of debris discharge chute extensions 12 is not limited to four and may be as few as one or more than four. As shown in FIG. Figure 27 and Figure 28 As will be appreciated, each debris discharge slot extension 12 has a first serrated surface and a second surface extending radially outwardly from the first serrated surface to an outer circumferential surface to facilitate discharge of debris from the separator chamber housing 11 .

[0105] The separator chamber housing 11 further includes a mounting surface 63. The mounting surface 63 is configured to receive an optional exhaust port adapter 64, an optional FID (Filter Identification) reader air outlet side adapter 83, and an optional exhaust tank sealing cap adapter 93.

[0106] (3) Discharge port adapter

[0107] The discharge port adapter 64 is shown in Figures 29 to 33 and includes a plurality of alignment slots 65, a debris discharge port 66, a horizontal sealing surface 67, a vertical sealing surface 68, a discharge port exit opening 69, and fastener holes 70. The alignment slots 65 are each configured to receive a mounting boss 15 (shown in FIG. 1 ) positioned on the separator chamber housing 11 at each of the debris discharge slot extensions 12. Figure 24 Fastener 85 (shown in Figure 47 1 and 12. A plurality of fasteners 85 are provided in the discharge port adapter 64 to secure the discharge port adapter 64 to the separator chamber housing 11 by passing through a fastener hole in each mounting boss 15 and through each of the fastener holes 70 of the discharge port adapter 64. The fasteners 85 are, for example, metal or polymer composite resin screws, bolts, rivets, or other such attachment members. Debris exits the discharge port adapter 64 via the discharge port exit opening 69 and the debris discharge port 66. The horizontal sealing surface 67 mates with the mounting surface 63. The vertical sealing surface 68 mates with an axially facing surface (facing in the second axial direction) of the separator chamber housing 11 that is positioned on the first axial side of the debris discharge chute extension 12. The discharge port adapter 64 can be made, for example, of a polymer composite resin. Figure 31 An exhaust port adapter 64 is shown mounted on the separator chamber housing 11. The optional exhaust port adapter 64 advantageously allows exhaust of debris to be directed through a single port, the debris exhaust port 66, which can be adapted to exhaust the debris-laden air to a specific location or to the exterior, such as an engine compartment or other equipment compartment, as desired.

[0108] (4) Filter read characteristics

[0109] Figure 47 、 Figure 48A and Figure 48BA modified arrangement 82 of the air filtration device 1 is shown, having an optional FID reader air outlet side adapter 83 mounted at the clean air outlet 8. The FID reader air outlet side adapter 83 is an annular member that fits onto the mounting surface 63. The FID reader air outlet side adapter 83 includes electrical wiring 84, fasteners 85, a plurality of alignment slots 65, a wire seal 86, a plurality of vertical mounting supports 87, a horizontal sealing surface 88, an air gap 89, a vertical circular slip-fit mounting support 90, an FID reader circuit board 106, an electrical connector 107, and fasteners 108. The electrical wiring 84 is connected to a power source (e.g., a battery (not shown)) for providing power to the FID reader air outlet side adapter 83. The alignment slots 65 are each configured to receive a corresponding mounting boss 15, and fasteners 85 are provided to secure the FID reader air outlet side adapter 83 to the separator chamber housing 11 by passing through each fastener hole in each mounting boss 15 and each fastener hole 70 in the FID reader air outlet side adapter 83. Additional fasteners 85 are provided at the removable panel adjacent the wire seal 86 to facilitate access through the panel, inside which the FID reader circuit board 106 is connected to the electrical wiring 84 via electrical connectors 107 (see Figure 48B ). Fasteners 108 are provided within the interior of the panel to fasten the FID reader circuit board 106 to the surface of the FID reader air outlet side adapter 83. The electrical connector 107 is made, for example, of metal and / or a polymer composite resin and electrically connects the circuitry of the FID reader circuit board 106 to the electrical wiring 84. The fasteners 108 are, for example, metal bolts, rivets, or other such attachment members. The wire seal 86 is formed, for example, by a nut or other fastener and an O-ring seal that prevents moisture from entering the FID reader air outlet side adapter 83. The horizontal sealing surface 88 mates with the mounting surface 63. The vertical mounting support 87 is arranged to mate with the outer circumferential surface of the separator chamber housing 11 extending between the debris discharge chute extension 12, wherein the axial edge of the vertical mounting support 87 is arranged to mate with the axially facing surface (facing the second axial direction) of the separator chamber housing 11 located on the first axial side of the debris discharge chute extension 12. In order not to hinder the discharge of debris through the debris discharge chute extension 12, an air gap 89 is provided between adjacent vertical mounting supports 87, such as Figure 48A . A vertical circular slip-fit mounting support 90 mates with an outer circumferential surface of the separator chamber housing 11 disposed on a second axial side of the mounting surface 63. The FID reader air outlet side adapter 83 can be made, for example, of metal and / or a polymer composite resin. The FID reader air outlet side adapter 83 advantageously allows for reading a filter identification ring ("FIR") 92 on the clean air side of the air filtration device 1, as described below.

[0110] As mentioned above, the FID (Filter Identification) reader air outlet side adapter 83 and the filter identification ring ("FIR") 92 are optional components. The FID reader circuit board 106 includes circuitry and an antenna to power and communicate with the FIR 92. The FID reader circuit board 106 is configured to receive filter-related data from the FIR 92. Features of the FIR 92 and the FID reader circuit board 106 (also described as a "control module" or "RCM") are described in detail in U.S. application Ser. No. 16 / 022,941, filed on June 29, 2018 (now U.S. Patent No. 10,850,222, issued on December 1, 2020), which is incorporated herein by reference in its entirety. Additional features of the FIR 92 and the FID reader circuit board 106 are described in detail in U.S. application Ser. No. 17 / 138,052, which is incorporated herein by reference in its entirety. Additionally, although the FIR 92 is described in this application as having an annular shape, the filter identification device can have various configurations. For example, the FIR 92 can be a filter identification chip embedded in the outer filter clean side seal 22. Figure 49 As shown in FIG, the FIR 92 is provided on the “clean side” of the air flow (ie, where the air flow passes after debris is removed by the outer filter media 35).

[0111] (5) Discharge trough sealing cap adapter

[0112] The optional drain chute sealing cap adapter 93 is shown in Figure 50A and Figure 50B , and includes a plurality of alignment slots 65 and fastener holes 70. As with the discharge port adapter 64, the alignment slots 65 are each configured to receive a corresponding mounting boss 15, and fasteners 85 are provided to secure the discharge tank sealing cap adapter 93 to the separator chamber housing 11 by passing through each of the fastener holes in each mounting boss 15 and each of the fastener holes 70 of the discharge tank sealing cap adapter 93. Figure 50B The drain chute sealing cap adapter 93 is shown mounted on the separator chamber housing 11. The drain chute sealing cap adapter 93 can be made of, for example, a polymer composite resin. The drain chute sealing cap adapter 93 advantageously allows for sealing of the debris drain chute extension 12 when the separator chamber housing 11 is used without the self-cleaning feature.

[0113] (6) Filter assembly

[0114] Figures 34 to 46 and Figure 49 Features of the outer filter assembly 20 are shown. The outer filter assembly 20 includes an outer filter clean side seal 22, a debris catch tray 27, a two-part outer screen 28, a closed end cap 29, an outer filter media 35, and an optional inner screen 36.

[0115] (6-1) External filter media

[0116] The outer filter medium 35 removes debris from the air passing through the air filter device 1. The filter structure of the present disclosure allows for the use of a variety of different filter media and is ideally suited for advanced high-efficiency media. For example, the outer filter medium 35 can include a variety of media, including but not limited to natural or synthetic fiber media; can include carbon wrap, carbon pellets, felt wrap, or foam; or can be any media with high-efficiency properties. The outer filter medium 35 can be formed from a single media or multiple media, including but not limited to the media types mentioned above.

[0117] (6-2) Screen assembly

[0118] The outer filter medium 35 is surrounded and protected by the outer screen 28. In addition, an optional inner screen 36 can be positioned inside the outer filter medium 35 for additional structural support. Both the inner screen 36 and the outer screen 28 can be made, for example, from a polymer composite resin. The inner screen 36 is optional, and depending on the type of media used in the outer filter medium 35, the outer screen 28 can be provided without the inner screen 36. The inner screen 36, the outer filter medium 35, and the outer screen 28 are held in place on the first axial side by the closed end cap 29. For example, the inner screen 36, the outer filter medium 35, and the outer screen 28 can be secured to the closed end cap 29 using glue, urethane, closed-cell foam, epoxy, rubber, or any other bonding agent that securely fastens the inner screen 36, the outer filter medium 35, and the outer screen 28 to the closed end cap 29 without damaging the outer filter medium 35.

[0119] On the second axial side, the inner screen 36, the outer filter medium 35, and the outer screen 28 are held in place by the outer filter clean side seal 22, described in detail below. At the center of the outer screen 28, the two screen halves of the outer screen 28 are held in place by a latching mechanism that provides alignment of the two screen halves and holds them together during and after the manufacturing process. The latching mechanism can have a plurality of protrusions on one end of the outer screen 28 and a plurality of receiving slots on the other end of the outer screen 28 into which the protrusions are inserted, as described in detail in U.S. Application No. 17 / 138,052, filed on December 30, 2020, and incorporated herein by reference in its entirety.

[0120] (6-3) External filter cleaning side seal

[0121] The outer filter clean side seal 22 is formed, for example, from urethane. More specifically, the outer filter clean side seal 22 can be formed from cold cast urethane, as described in detail in U.S. Application No. 17 / 138,052, which is incorporated herein by reference in its entirety. For illustrative purposes only, Figure 38 The outer filter clean side seal 22 is shown as a separate element. However, the outer filter clean side seal 22 is actually formed integrally with the optional inner screen 36, outer filter medium 35, outer screen 28, and debris catch tray 27. Similar to the process described in U.S. application Ser. No. 17 / 138,052, during the manufacturing process, a mold is provided for cold pouring of urethane to form the outer filter clean side seal 22. When the debris catch tray 27, optional inner screen 36, outer filter medium 35, and outer screen 28 are installed in the mold, the urethane is poured so as to flow into the open area to securely hold together the assembled inner screen 36, outer filter medium 35, outer screen 28, debris catch tray 27, and the optional filter identification ring ("FIR") 92 described below (if included). Figure 49 In other words, the urethane seal 22 holds all of these components together in an advantageously secure manner after curing, embedded within the urethane of the outer filter clean side seal 22. Figure 49 The outer filter assembly 91 is shown with a portion of the outer filter clean side seal 22 cut away for illustrative purposes to show how the optional FIR 92, debris catch tray 27, outer screen 28, and outer filter media 35 fit within the outer filter clean side seal 22. Figure 8 As can be seen in FIG, the separator chamber housing 11 has an axially extending sealing surface 40 that abuts the inner circumferential surface of the outer filter clean side seal 22 to seal the radially outer edge of the clean air outlet 8. In addition, the separator chamber housing 11 has a radially extending sealing surface 62 that abuts the axially facing surface (facing in the second axial direction) of the outer filter clean side seal 22 to seal the clean air outlet 8. The inner circumferential surface of the outer filter clean side seal 22 forms an air filter clean side outlet 71 (see FIG. 1 ) that communicates with the clean air outlet 8. Figure 35 ).

[0122] (6-4) Chip catcher tray

[0123] Figures 43 to 46The features of the debris catch tray 27 are shown. The debris catch tray 27 is included in (and embedded in) the outer filter clean side seal 22 described above. The debris catch tray 27 includes a plurality of filter alignment ridges 26, a debris discharge slot 72, a plurality of support tabs 73, an inner axially facing wall 78, an inner circumferential wall 79, an outer circumferential wall 80, and an outer axially facing wall 81. The inner axially facing wall 78 faces in a first axial direction and surrounds the support tabs 73. The inner circumferential wall 79 faces in a radial direction and, together with the inner axially facing wall 78, defines a space within the debris catch tray 27 where debris circulates before exiting through the debris discharge slot 72. The outer axially facing wall 81 faces in a second axial direction (toward the clean air outlet 8) and surrounds the support tabs 73. The outer circumferential wall 80 faces radially outward and, when installed, faces the inner circumferential surface of the separator chamber housing 11.

[0124] Each of the filter alignment ridges 26 is arranged to mate with a corresponding one of a plurality of filter alignment grooves 25 formed on the inner surface of the separator chamber housing 11, as shown in FIG. Figure 27 . Additionally, as briefly described above, the debris ejection slot 72 is configured to align (axially and circumferentially) with one of the debris ejection slot extensions 12 . Depending on the rotational position of the outer filter assembly 20 , the debris ejection slot 72 may align with either of the debris ejection slot extensions 12 . For example, Figure 54 It is along Figure 26 54-54 in FIG, and shows the debris ejection trough 72 aligned with one of the debris ejection trough extensions 12. The mating arrangement of the filter alignment ridge 26 and the filter alignment groove 25 provides a safety feature that advantageously ensures that the debris ejection trough 72 will always be aligned with one of the debris ejection trough extensions 12, regardless of the rotational position of the outer filter assembly 20. In other words, the mating arrangement of the filter alignment ridge 26 and the filter alignment groove 25 prevents the outer filter assembly 20 from being installed in the separator chamber housing 11 without aligning the debris ejection trough 72 with one of the debris ejection trough extensions 12. In this embodiment, four debris ejection trough extensions 12 are provided, and thus four filter alignment ridges 26 and four filter alignment grooves 25 are arranged circumferentially. Thus, there are four rotational positions in which the outer filter assembly 20 can be installed. However, the number is not limited to four, and more or fewer debris discharge chute extensions 12 , filter alignment ridges 26 , and filter alignment grooves 25 may be provided as long as the number of filter alignment ridges 26 and filter alignment grooves 25 corresponds to the number of debris discharge chute extensions 12 .

[0125] Support tabs 73 are provided and are circumferentially spaced apart, as shown. Figure 43The support tabs 73 are arranged to support the outer filter media 35 and the optional FIR 92, as shown in FIG. Figure 49 All components of the debris collection tray 27 are formed of, for example, a polymer composite resin.

[0126] (6-5) External filter closed end cap

[0127] Figures 39 to 42 Features of the outer filter closure cap 29 are shown. As described above, the outer filter closure cap 29 holds the optional inner screen 36, outer filter medium 35, and outer screen 28 in place on the first axial side using, for example, glue. More specifically, as Figure 41 As seen in FIG, the second axial side of outer filter closure end cap 29 includes an adhesive surface 75 surrounded by a raised vertical inner wall 76, which together form a tray in which, for example, hot melt glue can be retained during the manufacturing process. Vertical inner wall 76 is in turn surrounded and encircled by a raised vertical outer wall 77. Adhesive surface 75 is configured to receive, for example, hot melt glue, during the manufacturing process to adhere inner screen 36, outer filter medium 35, and outer screen 28 to the first axial side.

[0128] The outer filter closure end cap 29 is provided with a handle 30 on a first axial side to facilitate installation of the outer filter assembly 20 into the separator chamber housing 11. The center of the handle 30 is provided with an alignment hole 31 configured to receive (and align) an alignment pin 38. Because the alignment pin 38 passes through the handle 30 and extends from the air flow diverter 50 (as described above), the alignment pin 38 advantageously ensures proper alignment between the air flow power head assembly 109 (rain cap 2, motor / fan assembly 9, and impeller assembly 10) and the outer filter assembly 20. The alignment pin 38 ensures that the outer filter assembly 20 is centered within the separator chamber housing 11.

[0129] (6-6) Internal filter assembly

[0130] Inner filter assembly 19 is provided as an optional secondary filter (also referred to as a "safety filter") that may be positioned within the interior of outer (primary) filter assembly 20, specifically within inner screen 36 (if included) (see Figure 7 and Figure 9). The inner filter assembly 19 includes an inner filter clean side seal 21, an inner filter media 32, and an inner filter closure end cap 33. Like the outer filter media 35, the inner filter media 32 can include a variety of media, including but not limited to natural fiber or synthetic fiber media; it can include a carbon wrap, granular carbon, felt wrap, or foam. If the outer filter media 35 becomes defective or begins to lose its ability to properly filter debris, allowing debris to pass through the outer filter media 35, the debris will collect on the outer surface of the inner filter media 32, thereby reducing the air flow leaving the air filtration device 1 due to the lower debris loading capacity of the inner filter media 32. Therefore, the user can be easily notified of problems with the outer filter media 35.

[0131] The inner filter cleaning side seal 21 can be made of urethane, for example. The inner filter closing end cap 33 can be made of a polymer composite resin, for example. Figure 55 As shown in , at higher flow rates, the air filtration device 1 tends to have more restricted air flow when the inner filter assembly 19 is installed than when the inner filter assembly 19 is not installed. However, when the inner filter assembly 19 is installed, the level of air flow restriction is still acceptable for system performance. Figure 55 The flow rates and parameters given in are exemplary only and do not limit the scope of the present disclosure.

[0132] In the air flow power head assembly 109 as Figure 1 After assembly to the separator chamber housing 11 as shown in FIG, the air filtering device 1 is completely assembled and ready for operation. Figures 51 to 54 The assembled state of the air filter device 1 is shown with the removable optional rain cap 2 removed as a modified arrangement 94. Figure 51 As shown in FIG, assembly 95 includes only the motor / fan assembly 9 and the impeller assembly 10, without the rain cap 2. Figure 53A The assembled state is shown in which the locking pin 5 is inserted into the first and second locking pin bosses 4, and Figure 53B The assembled condition is shown with the locking pin assembly 97 removed.

[0133] (7) Debris screen

[0134] Figures 56 to 59 Features of the optional debris screen 100 are shown. Figure 56Arrangement 99 is shown, in which the fully assembled air filtration device 1 additionally includes a debris screen 100. Debris screen 100 is provided to fill the space between the rain cap 2 and the motor / fan assembly 9 and extends axially therebetween. Debris screen 100 advantageously prevents airborne debris, too large to pass through the air filtration device 1, from entering the space. This is particularly useful in landfill operations, agriculture, logging, and other environments with high concentrations of airborne debris. Debris screen 100 is made, for example, of metal and includes a top 101, a perforated circumferential side surface 102, mounting holes 103, a mounting flange 104, and an air gap 105. Top 101 is mounted adjacent to (but not in contact with) the inner surface of the rain cap 2. Mounting flange 104 is mounted adjacent to (and in contact with) a first axial side of the motor / fan assembly 9. Perforated circumferential side surface 102 includes a plurality of holes, thereby allowing air to enter the air filtration device 1. A plurality of mounting holes 103 are provided circumferentially spaced apart on the mounting flange 104 and are configured to receive the same fastener 3 inserted into the receiving boss 41 of the rainhat 2, the receiving boss 47 of the motor / fan assembly 9, and the receiving boss 48 of the impeller assembly 10. Each of the air gaps 105 is sized and configured to receive a corresponding one of the mounting feet of the rainhat 2 and a corresponding one of the receiving bosses 47 of the motor / fan assembly 9.

[0135] (8) Air filtration method

[0136] You can refer to Figure 62 Understand the air filtration methods of the present disclosure. Figure 62 is an image of air flow through the air filtration device 1 with the rain cap 2 removed. The method includes using the vacuum effect created by the motor / fan assembly 9 to draw debris laden air into the air flow inlet 57. The stratified debris laden air is then Figure 62Air flow A is shown in FIG. After exiting the motor / fan assembly 9, the air flow is propelled downstream by the positive pressure effect generated by the motor / fan assembly 9 and the tapered separator chamber housing 11. More specifically, the debris-laden air flows under pressure (the positive pressure generated by the motor / fan assembly 9) along a linear flow path, where centripetal force causes the debris-laden air flow to rotate about axis X under the pressure, thereby forming a debris-layered rotating air flow A with heavier-than-air debris particles in the radially outermost orbit of the pressurized rotating air flow. The tapered shape of the separator chamber housing 11, together with the air pressure generated by the motor / fan assembly 9, maintains a high-energy air flow, where the gradually decreasing diameter of the separator chamber housing 11 causes the air flow to collapse toward the debris collection tray 27. As the centripetally rotating debris-laden air flow is propelled into the tapered separator chamber housing 11, it travels in a linear direction downward along the wall of the separator chamber housing 11 toward the second axial end. The centripetal air flow velocity is maintained by the contraction area (i.e., the gradually decreasing diameter) of the conical separator chamber housing 11 and the pressurized air flow provided by the motor / fan assembly 9. The debris particles trapped in the centripetal air flow pattern move along the inner side wall of the separator chamber housing 11 and are pushed downwardly along the linear path of the air flow toward the clean air outlet end. As the debris continues to be pushed downstream by the air flow through the separator chamber housing 11 toward the second axial end, the centripetal force causes the debris to move radially outward toward the inner side wall of the separator chamber housing 11. The debris is then captured in the debris capture tray 27, which is contained in the outer filter clean side seal 22 located at the back of the separator chamber housing 11. The debris is then guided under pressure out of the debris discharge slot 72 on the debris capture tray 27, which is aligned with the debris discharge slot extension 12 molded into the end of the separator chamber housing 11, and is forced out back into the environment as Figure 62 As shown in .

[0137] When the pressurized centripetally rotating air is pushed linearly (axially) downward along the separator chamber housing 11 toward the second axial end, Figure 62 The radially inner air flow B shown in FIG is the debris-laden air that has been freed of most of the fine particles of debris surrounding the outer filter assembly 20. This air flow B enters through the outer filter assembly 20, is filtered (cleaned) by the outer filter assembly 20, and continues to flow along the longitudinal axis X as the clean air flow C. The filtered (cleaned) air flow C is carried along a linear flow path inside the filter assembly 20 toward the clean air outlet 8 at the end of the separator chamber housing 11, as shown in FIG. Figure 62. This linear, directional air flow creates minimal air flow restriction, allowing the energy generated by the motor / fan assembly 9 to be used more efficiently to move large volumes of air and produce significant centripetal separation efficiency and pressure through the air filtration device 1, allowing for much higher air flows in applications with limited space. Additionally, the linear air flow pattern in the separator chamber housing 11 prevents turbulence in the air flow, which reduces restriction and increases separator efficiency. Air is drawn into the outer filter assembly 20 along its length and flows to the clean air outlet 8 in the same direction as the swirling airborne debris flow to the debris catch tray 27. The combination of pressurized air, the centripetally swirling air flow, the conical separator chamber housing 11, the outer air filter assembly 20, and the debris catch tray 27 that forces debris out of the debris discharge chute 72 allows debris accumulated on the outer air filter assembly 20 to be ejected by the pressurized, centripetally swirling air in the conical separator chamber housing 11. With the above features, the air filter device 1 can meet the varying air flow requirements of an engine or other equipment on which the air filter device 1 is installed.

[0138] More specifically, during use, a positive air pressure is advantageously maintained within the air filtration device 1. Positive pressure can be understood as a pressure that positively propels the air flow from the motor / fan assembly 9 to the clean air outlet 8 while simultaneously exerting a centripetal force on the air flow to ensure that debris is pushed radially outward, thereby minimizing the accumulation of debris on the outer filter assembly 20. The positive pressure is caused by the motor / fan assembly 9 compressing the air molecules within the air filtration device 1. The positive pressure generated by the motor / fan assembly 9 compressing the air molecules within the filter chamber housing 11 causes air to pass through the filter and, downstream, out of the debris discharge chute extension 12. This positive air pressure prevents the debris discharge chute extension 12 from becoming an air inlet. In other words, the motor / fan assembly 9 is driven to generate a sufficiently strong air flow to achieve exhaust at the debris discharge chute extension 12 at the maximum rated air flow through the clean air outlet 8, without allowing outside air or debris to enter through the debris discharge chute extension 12.

[0139] The conical separator chamber housing 11 reduces the circumferential portion of the air flow path, causing the centrifugal air flow to accelerate within the separator chamber housing 11 toward the clean air outlet 8. When the air flow enters the separator chamber housing 11 under the pressure generated by the fan blades 44 and the centripetal acceleration caused by the blades 51, the debris in the air is pushed radially outward by the centrifugal force. Since the air flow through the air filter device 1 is linear, the swirling air flow enters the outer filter medium 35 at the center of the debris separator chamber 34 (see Figure 8), thereby flowing toward the clean air outlet 8, causing the air flow to be straightened as it passes through the outer filter media 35. The separator chamber housing 11 tapers inwardly toward the clean air outlet 8, allowing the separated debris circling around the inner sidewall of the separator chamber housing 11 to continue to accelerate, thereby flowing toward the second axial end of the separator chamber housing 11. The separated debris circulates into the debris catch tray 27 and is pushed out by the positive air flow pressure generated by the fan blades 44 through the debris discharge slot 72 integrated into the outer filter clean side seal 22, which is aligned with at least one debris discharge slot extension 12 included in the air outlet end of the separator chamber housing 11. The air flow entering the outer filter media 35 is filtered as it flows inwardly through the outer filter media 35, moves in a linear direction to the center of the separator chamber housing 11, and flows out as clean air through the clean air outlet 8 to the equipment on which it is installed (or to the environment if not installed on equipment).

[0140] Therefore, in operation, fan motor 45 is powered via electrical wiring 46, and debris-laden air is drawn into air filtration device 1 via fan blades 44. The debris-laden air passes through motor / fan assembly 9, circling toward blade assembly 10. Any air that contacts the center of blade assembly 10 is redirected by airflow diverter 50 toward blades 51. Upon contacting and passing between blades 51, the air is accelerated and forms a vortex. The outer wall of separator chamber housing 11 tapers inward toward the back side of separator chamber housing 11 (toward the second axial end). This reduces the space at the back side of separator chamber housing 11, maintaining the centrifugal separation velocity of the air as it accelerates from the radial arrangement of blades 51 and passes through separator chamber housing 11. This causes the debris-laden air to circulate for centrifugal separation, pushing particulate debris toward the outer wall of separator chamber 11. The remaining air passes through outer filter assembly 20 and is cleaned by outer filter media 35. At the same time, debris that has been removed from the air in the debris separator chamber 34 enters the debris catch tray 27 where it circulates within the debris catch tray 27 until forced out by pressure through the debris discharge chute 72. Because the debris discharge chute 72 is aligned with one of the debris discharge chute extensions 12, the debris will then be discharged back into the environment through the corresponding debris discharge chute extension 12. At the same time, only clean air passes through the center of the outer filter assembly 20, through the outer filter clean side seal 22, and finally exits through the clean air outlet 8.

[0141] (9) Beneficial effects

[0142] As described above, the features of the disclosed air filtration device 1 and air filtration method have many advantages. The linear air flow direction along the longitudinal axis X within the air filtration device 1 significantly reduces air flow restriction and allows more positive pressurized air to be pushed out of the clean air outlet 8, while forcing debris that has been removed from the air back into the environment via the debris discharge slot 72 and the aligned debris discharge slot extension 12. This linear directional air flow produces minimal air flow restriction, allowing the energy generated by the motor / fan assembly 9 to be more efficiently used to flow large amounts of air to the equipment to which the device is attached, while generating significant centripetal separation efficiency and pressure through the compact size of the air filtration device 1, thereby allowing much higher air flow in applications with limited space. In addition, the linear air flow pattern in the conical separator chamber housing 11 prevents air flow turbulence, thereby reducing air flow restriction and improving separator efficiency. Air is drawn into the outer filter assembly 20 along its length and flows to the clean air outlet 8 in the same direction as the airborne debris flows around to the debris capture tray 27.

[0143] Additionally, the tapered structure of the separator chamber housing 11 reduces the air flow path as the air flow moves toward the second axial end, thereby causing the pressurized centrifugal swirling air to accelerate within the separator chamber housing 11 toward the clean air outlet 8. At the same time, the tapered structure maintains the centrifugal separation velocity of the pressurized air, thereby swirling the debris-laden air to centrifugally separate the particulate debris and push the particulate debris to the inner sidewall of the separator chamber 11 and the debris catch tray 27 for discharge to the external environment via the debris discharge chute 72 and the aligned debris discharge chute extension 12.

[0144] Another advantage of the disclosed air filtration device 1 is the provision of an alignment pin 38. Because the alignment pin 38 extends through the handle 30 and from the air flow diverter 50, the alignment pin 38 advantageously ensures proper alignment between the air flow power head assembly 109 and the outer filter assembly 20. The alignment pin 38 ensures that the outer filter assembly 20 is centered within the separator chamber housing 11.

[0145] Yet another advantage of the disclosed air filtration device 1 is the provision of a debris catch tray 27. Debris catch tray 27 is included in (and embedded in) the outer filter clean side seal 22 and facilitates debris removal by providing a space (formed by inner axially facing wall 78 and inner circumferential wall 79) in which debris circulates before being discharged through the debris discharge trough 72. Depending on the rotational position of the outer filter assembly 20, the debris discharge trough 72 can be aligned with either of the debris discharge trough extensions 12. The mating arrangement of the filter alignment ridge 26 and the filter alignment groove 25 provides a safety feature that advantageously ensures that the debris discharge trough 72 will always align with one of the debris discharge trough extensions 12, regardless of the rotational position of the outer filter assembly 20. In other words, the mating arrangement of the filter alignment ridge 26 and the filter alignment groove 25 prevents the outer filter assembly 20 from being installed in the separator chamber housing 11 without aligning the debris discharge trough 72 with one of the debris discharge trough extensions 12.

[0146] Furthermore, due to the provision of debris ejection chute 72 and debris ejection chute extension 12, air filter device 1 is a self-cleaning device that does not require maintenance between air filter changes to remove separated airborne debris. Instead, as described in detail above, the pressurized, centripetal air generated within air filter device 1 ensures the removal of debris through debris ejection chute extension 12. Furthermore, since the debris is captured in debris catch tray 27, it will not fall out of air filter device 1 during filter maintenance. Debris catch tray 27 also prevents debris from falling into clean air outlet 8 when outer filter assembly 20 is removed.

[0147] In addition, the optional provision of an FID (Filter Identification) reader air outlet side adapter 83 and a filter identification ring ("FIR") 92 allows for the automated exchange of filter information and performance data. This allows the machine operator to know, for example, the filter part number, performance characteristics, and the filter's operating time during operation. The FIR 92 can store data collected over the life of the filter. Attachment of the FID reader air outlet side adapter 83 to the mounting surface 63 of the separator chamber housing 11 on the clean air side allows for efficient reading of the FIR 92 embedded in the outer filter clean side seal 22 on the clean air side.

[0148] Additionally, the vacuum / pressure port 13 provided on the inner circumferential surface of the clean air outlet 8 is advantageously configured to receive an optional mechanical or electrical pressure / vacuum sensor for sensing and reading the pressure of the air flow at the clean air outlet 8. This facilitates monitoring for varying the pressure of the air flow through the air filtering device 1 as needed, and monitoring the restriction to air flow caused by the outer filter assembly 20 over time.

[0149] The air filtration device 1 also advantageously allows for the attachment of a variety of adaptable optional accessories. The mounting surface 63 of the separator chamber housing 11 is configured to accommodate one of a discharge port adapter 64, an FID (Filter Identification) reader air outlet side adapter 83, and a discharge chute sealing cap adapter 93. Each of these adapters provides different advantages, and as described above, all are easily attached to and removed from the separator chamber housing 11. The discharge port adapter 64 advantageously fits onto the air outlet side of the tapered separator chamber housing 11, allowing the debris discharge chute extension 12 to be converted into a round tubular discharge port for under-hood installation in a vehicle. The discharge chute sealing cap adapter 93 advantageously seals the debris discharge chute extension 12 if the separator chamber housing 11 is used without the self-cleaning feature.

[0150] Yet another advantage of the disclosed air filtration device 1 is the provision of an optional debris screen 100. The debris screen 100 advantageously prevents the ingress of airborne debris that is too large to pass through the air filtration device 1. This is particularly useful in landfill operations, agriculture, logging, and other areas where environments with high concentrations of large, airborne debris are present.

[0151] In addition, the detachable air flow head assembly 109 including the rain cap 2, the motor / fan assembly 9 and the blade (louver) assembly 10 allows for adaptation to different machines and equipment. For example, the rain cap 2 is optional and is easily mounted to the motor / fan assembly 9 and the blade assembly 10 using the same fasteners 3.

[0152] Furthermore, at comparable airflow rates, the compact air filtration device 1 of the present disclosure is significantly smaller in physical size and weight than comparable air filtration pre-cleaner devices. Due to the provision of mounting bosses 6 and multiple debris ejection slot extensions 12, the air filtration device 1 can also be mounted in any orientation that allows for servicing and maintenance. Thus, the air filtration device 1 offers maximum installation flexibility to both OEM (original equipment manufacturer) designers integrating the device into equipment and to aftermarket installers.

[0153] Additionally, providing the locking slots 17 of the vane assembly 10, which are arranged to receive the mounting tabs 16 of the separator chamber housing 11, advantageously facilitates a simple lock-and-twist mating structure between the separator chamber housing 11 and the air flow head assembly 109. This in turn allows for quick and efficient air filter cartridge replacement.

[0154] Additionally, the debris catch tray 27 has a debris discharge chute 72 that uses four filter alignment ridges 26 that mate with four filter alignment grooves 25 on the inside of the separator chamber housing 11 to select which of the debris discharge chute extensions 12 at the end of the separator chamber housing 11 will align with the debris discharge chute 72. This ensures that airborne debris will be discharged from the separator chamber housing 11 regardless of the mounting position of the outer filter assembly 20.

[0155] Furthermore, the separator chamber housing 11 is elongated and tapered along the longitudinal axis X from the air inlet 57 to the clean air outlet 8. This configuration allows air to flow in a linear direction through the separator chamber housing 11 and into the outer filter assembly 20. This air flow pattern reduces turbulence and maximizes air flow through the compact air filtration device 1. This air flow pattern also reduces air flow restriction within the air filtration device 1, thereby allowing more air to be pushed out of the clean air outlet 8 and into the engine or other equipment on which the air filtration device 1 is mounted.

[0156] Exemplary embodiments of the present invention have been described above. It should be noted that the above exemplary embodiments are merely examples of the present invention, and the present invention is not limited to the embodiments described in detail. It should be understood that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. Therefore, such changes and modifications are intended to be covered by the present disclosure.

Claims

1. An air filter device comprising: an air flow head assembly including a motor-driven fan assembly and a blade assembly, the air flow head assembly defining a dirty air inlet where debris-laden air is drawn into the air filtration device using the fan assembly; a filter assembly including a filter media, the filter assembly being configured to remove debris from the debris-laden air; as well as A separator chamber housing, wherein the filter assembly is disposed inside the separator chamber housing, wherein The air flow head assembly is disposed on a first axial side of the separator chamber housing relative to a longitudinal axis of the air filtering device. The separator chamber housing has a chamber inlet at the first axial side and a clean air outlet at a second axial side of the separator chamber housing opposite the first axial side, The filter assembly has a first axial end adjacent the chamber inlet and a second axial end adjacent the clean air outlet, The separator chamber housing includes at least one debris discharge chute extension configured to discharge the debris from the interior space of the separator chamber housing to the surrounding environment, and the filter assembly including a debris capture tray disposed at the second axial end, the debris capture tray having a debris discharge chute aligned with and in communication with the at least one debris discharge chute extension for discharging debris from the interior space of the separator chamber housing to the ambient environment, in The debris catch tray includes a plurality of filter alignment ridges provided on an outer circumferential surface of the debris catch tray, The separator chamber housing includes a plurality of filter alignment grooves formed on an inner surface of the separator chamber housing, and the filter alignment ridge is configured to mate with the filter alignment grooves such that the debris discharge trough is aligned with the at least one debris discharge trough extension.

2. The air filter device according to claim 1, wherein The air flow head assembly further includes a removable rain cap configured to be mounted to a first axial side of the fan assembly, wherein The bucket assembly is mounted to a second axial side of the fan assembly.

3. The air filter device according to claim 1, wherein The separator chamber housing is tapered such that a diameter of the separator chamber housing decreases from the first axial side to the second axial side.

4. The air filtering device according to claim 1, further comprising: A locking pin assembly is configured to lock the air flow head assembly to the separator chamber housing.

5. The air filter device according to claim 4, wherein: The locking pin assembly includes a first locking pin boss, a second locking pin boss and a locking pin, The first locking pin boss is provided on the outer circumferential surface of the bucket assembly, The second locking pin boss is provided on an outer circumferential surface of the first axial side of the separator chamber housing, and the locking pin extends through both the first and second locking pin bosses to lock the air flow head assembly to the separator chamber housing.

6. The air filtering device according to claim 1, further comprising: a plurality of fasteners configured to secure the air flow head assembly, wherein The fan assembly has a plurality of first receiving bosses, The blade assembly has a plurality of second receiving bosses, and Each of the fasteners extends through a corresponding one of the first receiving bosses and a corresponding one of the second receiving bosses.

7. The air filtering device according to claim 2, further comprising: a plurality of fasteners configured to secure the air flow head assembly, wherein The fan assembly has a plurality of first receiving bosses, The blade assembly has a plurality of second receiving bosses, The rain cap has a plurality of third receiving bosses, and Each of the fasteners extends through a corresponding one of the third receiving bosses, a corresponding one of the first receiving bosses, and a corresponding one of the second receiving bosses.

8. The air filtering device according to claim 1, further comprising: an alignment pin configured to align the air flow head assembly with the filter assembly, wherein The alignment pin extends from the bucket assembly, The filter assembly includes a first alignment aperture, and The alignment pin is received in the first alignment hole.

9. The air filtering device according to claim 8, wherein The filter assembly further includes a closed end cap disposed at the first axial end. The closed end cap includes a handle projecting from a surface of the closed end cap in a first axial direction toward the air flow head assembly, and The first alignment hole is formed in the handle.

10. The air filtering device according to claim 1, wherein the separator chamber housing including a plurality of mounting tabs circumferentially arranged around a radially outer surface of the separator chamber on the first axial side of the separator chamber, The bucket assembly includes a plurality of locking slots circumferentially arranged about a radially outer surface of the bucket assembly on a second axial side of the bucket assembly, and Each of the locking slots is arranged to receive a respective one of the mounting tabs to secure the air flow head assembly to the separator chamber housing.

11. The air filtering device according to claim 1, wherein The filter assembly further includes a sealing member disposed at the second axial end of the filter assembly, the debris catch tray being integrally formed with the sealing member.

12. The air filtering device according to claim 11, wherein The filter assembly further includes a filter identification device embedded in the sealing member, the filter identification device being configured to store data related to the filter assembly.

13. The air filtering device according to claim 12, further comprising A filter identification reader device is removably attached to the second axial side of the separator chamber housing, wherein the filter identification reader device includes circuitry configured to provide power to and communicate with the filter identification device.

14. The air filtering device according to claim 13, wherein The filter identification reader device includes an annular member attached to the second axial side of the separator chamber housing, a plurality of vertical mounting supports extending axially from the annular member, and a plurality of air gaps disposed between adjacent pairs of the vertical mounting supports. The separator chamber housing includes a plurality of said debris discharge chute extensions, and Each of the debris ejection slot extensions is positioned in a respective one of the plurality of air gaps.

15. The air filtering device according to claim 14, wherein The filter identification reader device further includes an alignment slot formed in each of the vertical mounting supports, the separator chamber housing includes a mounting boss positioned at each of the debris discharge chute extensions, and each alignment slot is configured to receive a corresponding one of the mounting bosses to secure the filter identification reader device to the separator chamber housing.

16. The air filtering device according to claim 12, wherein The debris catch tray includes a plurality of support tabs spaced circumferentially thereabout, the support tabs being arranged to support the filter media and the filter identification device.

17. The air filtering device according to claim 2, further comprising A removable debris screen is provided between the rain cap and the fan assembly, wherein The debris screen includes a perforated circumferential surface extending circumferentially around the debris screen and extending axially between the rainhat and the fan assembly.

18. The air filtering device according to claim 17, wherein The debris screen further includes a plurality of air gaps spaced about a circumferential portion of the debris screen.

19. The air filtering device according to claim 1, further comprising an electrical connector configured to connect the electrical wiring of the fan assembly to a power source, wherein The electrical connector is disposed in a mounting groove formed in an outer circumferential surface of the bucket assembly, and the electrical connector is configured to prevent removal of the air flow head assembly from the separator chamber housing.

20. An air filtration method comprising: drawing debris-laden air into the air filtration unit using a motor-driven fan assembly located in the air filtration unit; forming a centripetal rotating flow of the debris-laden air about a longitudinal axis of the air filtering device using a blade assembly positioned downstream of the fan assembly to stratify the flow so that debris moves radially outward to an outermost orbit of the centripetal rotating flow, the centripetal rotating flow being formed in a separator chamber housing, a filter assembly configured to remove the debris from the debris-laden air being disposed within the separator chamber housing, the separator chamber housing being positioned downstream of the blade assembly; causing air to flow from an innermost orbit of the centripetally rotating flow through the filter assembly such that the air that has passed through the filter assembly is clean air, wherein the clean air passes through the filter assembly in a linear direction to a clean air outlet of the separator chamber housing; as well as The debris laden air is returned from the stratified centripetal rotating flow to the environment by causing the debris laden air to pass through a debris discharge slot formed in a debris catch tray of the filter assembly and then through a debris discharge slot extension formed in the separator chamber housing that is in communication with and aligned with the debris discharge slot, wherein The debris catch tray includes a plurality of filter alignment ridges provided on an outer circumferential surface of the debris catch tray, The separator chamber housing includes a plurality of filter alignment grooves formed on an inner surface of the separator chamber housing, and the filter alignment ridge is configured to cooperate with the filter alignment grooves so that the debris discharge trough is aligned with the debris discharge trough extension, The fan assembly and the separator chamber housing apply continuous pressure and continuous centripetal force to the debris-laden air, causing the debris-laden air to pass through the separator chamber housing in the linear direction to the debris capture tray before returning to the environment.

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