Self-cleaning air filtration device and method

Abstract

An air filtration device includes: an air flow power head assembly including a fan assembly and a vane assembly; a filter assembly; and a separator outdoor housing, wherein the filter assembly is disposed inside the separator outdoor housing. The separator outdoor housing has a chamber inlet at a first axial side of the separator outdoor housing and a clean air outlet at a second axial side of the separator outdoor housing opposite 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 outdoor housing includes at least one debris discharge groove extension configured to discharge debris from an internal space of the separator outdoor housing. The filter assembly includes a debris collection tray disposed at the second axial end, and the debris collection tray has a debris discharge groove aligned with the at least one debris discharge groove extension.

Description

[0001] This application is a divisional application of a Chinese patent application with application number 202110872050.9, filing date July 30, 2021, and titled "Self-Cleaning Air Filter Device and Method". Technical Field

[0002] The present disclosure relates to an improved air filter device and air filtration method for efficiently removing heavier-than-air particulate debris from air carrying debris to provide a clean air stream to equipment using the air filter device and method. Background Art

[0003] Air pre-filters and air filtration methods for centrifugally separating heavier-than-air debris from air by means of filters used on internal combustion engines, ventilation systems, and other equipment that inhale air carrying debris are known. Such air pre-filters include powered air pre-filters and air filtration methods that employ a motor-driven fan to draw air carrying debris into the air pre-filter, and air pre-filters and air filtration methods that rely only on the vacuum applied to the air pre-filter and the air filtration method by equipment supplied with clean air (such as an internal combustion engine) to draw air carrying debris into the air pre-filter. Examples of the assignee's prior air pre-filters and filtration methods are shown in the following U.S. patents, all of which are incorporated herein by reference in their entirety:

[0004] U.S. Patent No. 5,656,050;

[0005] U.S. Patent No. 5,766,315;

[0006] U.S. Patent No. 6,319,304;

[0007] U.S. Patent No. 6,338,745;

[0008] U.S. Patent No. 6,406,506;

[0009] U.S. Patent No. 6,425,943;

[0010] U.S. Patent No. 6,878,189;

[0011] U.S. Patent No. 7,056,368; and

[0012] U.S. Patent No. 7,452,409.

[0013] Current engine and HVAC air filtration systems suffer from numerous design and performance problems. For example, current systems are based on designs that create significant intake restrictions, resulting in shortened air filter life and negatively impacted engine performance and fuel economy. Moreover, current systems operate under vacuum, which prematurely shortens filter life due to the higher initial intake restriction, thus requiring more frequent filter maintenance. Current air filtration systems typically include an air pre-filter that traps airborne debris within the device, thus requiring manual removal of the captured debris. Other current technologies use dump valves that allow the weight of the captured debris to overcome the vacuum created within the air pre-filter / filtration system and physically fall out of the air filtration system; however, this dump valve often clogs when there is moisture or mixed debris in the air stream. Current systems can use vacuum devices to remove the separated airborne debris from the air filtration system, which requires additional components to capture and remove the removed debris. Such systems also tend to clog when there is moisture or mixed debris in the air stream.

[0014] In addition, the physical size and weight of current technology air filtration systems that produce a given air flow to downstream devices can create installation and serviceability issues. Due to variations in construction and performance requirements, known air filtration systems may require custom manufacturing of the pre-filter, air filtration system, and / or their mounting components. This customization limits the scope of application of known air filtration systems and adversely affects manufacturing time and cost. Examples of such variations between applications that require individual customization include: the required separate components for pre-filtering and disposing of debris centrifugally separated from the pre-filtering device and that must be discharged to the atmosphere; the location of the filter and the direction of the air flow; the location of the clean air outlet for providing clean air from the air filtration system to the engine or device using the air filtration system; the physical size and style of the filter; the location of the available support structures for mounting the air filtration system and its components; and the specific clean air flow rate required to ensure the performance of the downstream system. In the case of powered air pre-filters and air filtration systems, it has been found that the life of the motor of an electric motor-driven fan is shortened due to a reduction in the air flow used to cool the motor when the motor is in the air flow path on the clean side of the filter, because when the filter is loaded, the air flow is reduced and the heat remaining on the motor shortens its life. Further, it has been found that debris accumulating in the separator chamber during filter maintenance can easily enter the clean air outlet, which can respectively result in a shortened engine life or debris entering the HVAC and ventilation systems.

[0015] Accordingly, there is a need for an improved air pre - filtration device and method as follows: which overcomes these drawbacks and limitations of known air pre - filter devices. More specifically, there is a need for an improved air pre - filtration device as follows: which is physically compact, thereby allowing its use in limited - space applications, and is universal for a range of applications where there are different installation configurations and clean air flow rate requirements, thus eliminating the cost and inefficiencies of custom - manufactured air pre - filter systems. There is also a need for an air - filtering method in a compact monolithic power air pre - filter device that can appropriately cool the fan motor as part of its design, thus ensuring an extended motor life. In this regard, there is a need for an improved air pre - filter device as follows: which operates at full efficiency regardless of the air flow requirements of the equipment on which the system is installed, while ensuring that the discharge trough / 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 outside the clean - side outlet during filter maintenance and to direct the separated debris to its intended location (the discharge trough / port at the outlet end of the main housing separator chamber), such a barrier being referred to herein as a debris - trapping tray. There is a further need to incorporate filter identification technology with the ability to store data in the filter. There is a further need to monitor the pressure and vacuum in the device, and to provide multiple types of fans and motors, and, when needed, variable - speed control of the electric motor. The improved, compact, and universal air pre - filtration device and method of the present disclosure with a disposable air filter cartridge having a debris - trapping tray address these needs in the art. Summary of the Invention

[0016] The present disclosure relates to a compact self-cleaning air filtration device and method that provides a series of beneficial effects, including reducing intake restrictions for engine applications, providing positive air flow pressure for HVAC and ventilation systems, and improving debris separator efficiency at all operating air flow rates. The air filtration device incorporates several features, including optional filter identification (FID) with data storage, multiple fan and motor combinations, motor speed control, pressure monitoring and control, incorporating a rain cap and / or debris screen, a discharge port adapter, a discharge trough seal cap adapter, and the use of a variety of different filter media. The media range includes high-efficiency media for removing very small particles as well as superior durability and serviceability. Based on the type of filter used, various fan and motor combinations can be employed in the device. 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 restrictions, and provides the ability for electronic filter identification and data storage inside the air filter, which has a disposable air filter cartridge that is easily serviceable. The easily serviceable disposable air filter cartridge includes a debris capture tray to prevent residual debris inside the separator chamber from entering the clean air outlet during filter cartridge servicing and to improve the discharge of airborne debris from the pressurized separator chamber. The separator chamber of the disclosed embodiments is elongated and tapered in a direction along the axis from the inlet to at least one discharge port (also referred to as a debris discharge trough extension) and the clean air outlet located at the end of the separator chamber. By passing the air in a linear direction, the restrictions inside the air filtration device are significantly reduced, allowing more positively 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 linear directed air flow allows for a more compact design, enabling a much higher air flow in applications with limited space. The air pre-filtration device is a general-purpose and compact self-cleaning air filtration device for use in limited space applications, which has many requirements for installation configuration and discharge trough / port installation 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 the preferred embodiments represents an improvement over conventional air pre-filter devices and methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a perspective view of an exemplary air filtration device.

[0018] Figure 2 is a view of the air filtration device from the top of the rain cap of the air filtration device.

[0019] Figure 3 is a side view of the air filtration device.

[0020] Figure 4 is a side view of an air filtration device including mounting feet, showing the side opposite to Figure 3 the opposite side.

[0021] Figure 5 is a view of the air filtration device from the clean air outlet, showing the side opposite to Figure 2 the opposite side.

[0022] Figure 6A is a side view of the air filtration device.

[0023] Figure 6B is a cross-sectional view of an air flow power head assembly with an optional rain cap.

[0024] Figure 6C is a perspective view of the air flow power head assembly.

[0025] Figure 7 is an exploded perspective view of the air filtration device.

[0026] Figure 8 is a cross-sectional view of the air filtration device.

[0027] Figure 9 is an exploded side view of the air filtration device.

[0028] Figure 10 is a perspective view of the rain cap of the air filtration device.

[0029] Figure 11 is a plan view of the top of the rain cap.

[0030] Figure 12 is a side view of the rain cap.

[0031] Figure 13 is a plan view of the underside of the rain cap.

[0032] Figure 14 is a perspective view of the motor / fan assembly of the air filtration device with a debris protection member.

[0033] Figure 15 is a plan view of the dirty air inlet of the motor / fan assembly.

[0034] Figure 16 is a side view of the motor / fan assembly.

[0035] Figure 17 is a plan view of the dirty air outlet side of the motor / fan assembly.

[0036] Figure 18 is a perspective view of the dirty air inlet side of the impeller assembly of the air filtration device.

[0037] Figure 19 It is a plan view of the dirty air inlet side of the impeller assembly.

[0038] Figure 20 It is a side view of the impeller assembly.

[0039] Figure 21 It is a plan view of the dirty air outlet side of the impeller assembly.

[0040] Figure 22 It is another perspective view of the dirty air inlet side of the impeller assembly.

[0041] Figure 23 It is a perspective view of the dirty air outlet side of the impeller assembly.

[0042] Figure 24 It is a perspective view of the separator outdoor housing of the air filtration device with a clean air outlet.

[0043] Figure 25 It is a side view of the separator outdoor housing, showing the mounting feet.

[0044] Figure 26 It is a side view of the separator outdoor housing.

[0045] Figure 27 It is a view of the interior of the separator outdoor housing as observed from the dirty air inlet side.

[0046] Figure 28 It is a view of the separator outdoor housing as observed from the clean air outlet side.

[0047] Figure 29 It is a plan view of the first end of the discharge port adapter of the air filtration device.

[0048] Figure 30 It is a perspective view of the discharge port adapter.

[0049] Figure 31 It is a perspective view of the air filtration device with the discharge port adapter mounted thereon.

[0050] Figure 32 It is a plan view of the second end of the discharge port adapter.

[0051] Figure 33 It is a side view of the discharge port adapter, showing the debris discharge port.

[0052] Figure 34 It is a perspective view of the outer filter assembly of the air filtration device.

[0053] Figure 35 It is a plan view of the clean air side of the outer filter assembly, showing the debris discharge groove.

[0054] Figure 36 It is a side view of the outer filter component.

[0055] Figure 37 It is a plan view of the dirty air side of the outer filter component, showing the debris discharge groove.

[0056] Figure 38 It is an exploded view of the outer filter component.

[0057] Figure 39 It is a perspective view of the closed end cap of the outer filter component.

[0058] Figure 40 It is a plan view of the first dirty air side of the closed end cap.

[0059] Figure 41 It is a plan view of the second clean air side of the closed end cap.

[0060] Figure 42 It is a side view of the closed end cap.

[0061] Figure 43 It is a perspective view from the clean air side of the debris collection tray of the air filtration device.

[0062] Figure 44 It is a plan view of the inner surface of the debris collection tray, which is the surface for sealing the filter medium.

[0063] Figure 45 It is a plan view of the outer surface of the clean air side of the debris collection tray.

[0064] Figure 46 It is a side view of the debris collection tray.

[0065] Figure 47 It is a perspective view of the air filtration device, showing the optional filter identification reader air outlet side adapter attached to the air outlet side.

[0066] Figure 48A It is a first perspective view of the filter identification reader air outlet side adapter.

[0067] Figure 48B It is a second perspective view of the filter identification reader air outlet side adapter, showing the internal features including the filter identification reader circuit board.

[0068] Figure 49 It is a perspective view of the outer filter component, where a part of the outer filter clean side seal is cut away to show the internal components including the optional filter identification ring.

[0069] Figure 50A It is a perspective view showing the optional discharge groove seal cap adapter of the air filtration device.

[0070] Figure 50B Perspective view of an air filtration device with a discharge chute seal cap adapter mounted thereon.

[0071] Figure 51 Side view of the air filtration device showing the locking pin assembly.

[0072] Figure 52A Is in Figure 51 Circled and labeled " Figure 52A " enlarged view of the portion.

[0073] Figure 52B Enlarged perspective view of the electrical connector of the air filtration device.

[0074] Figure 53A Dirty air side view of the air filtration device with the locking pin assembly installed.

[0075] Figure 53B Dirty air side view of the air filtration device with the locking pin assembly removed.

[0076] Figure 54 Is along Figure 26 Sectional view taken along line 54 - 54 in, showing the interior of the separator housing with the outer filter assembly installed as viewed from the clean air side.

[0077] Figure 55 Graph comparing the exemplary flow rates in the air filtration device with a safety filter installed and the flow rate without the safety filter installed.

[0078] Figure 56 Perspective view of the air filtration device showing an optional debris screen mounted on the air filtration device.

[0079] Figure 57 Side view of the air filtration device showing the debris screen mounted on the air filtration device.

[0080] Figure 58 Another side view of the air filtration device showing the debris screen mounted on the air filtration device.

[0081] Figure 59 Perspective view of the debris screen.

[0082] Figure 60 Side view of the debris screen.

[0083] Figure 61 Plan view of the bottom and mounting flange of the debris screen.

[0084] Figure 62It is a flowchart showing the air flow through the air filtration device. Detailed Description of the Invention

[0085] Exemplary embodiments of a self - cleaning air filtration device and method are described below.

[0086] As Figures 1 to 9 shown, the self - cleaning air filtration device 1 includes a detachable air flow power head assembly 109 having a rain cap 2, a motor / fan assembly 9, and a vane (louver) assembly 10. The air filtration device 1 further includes an outer filter assembly 20, an optional inner filter assembly 19, and a conical separator outdoor housing 11. The separator outdoor housing 11 is disposed downstream of the air flow power head assembly 109 with respect to the direction of the air flow in the air filtration device 1 during use. These components of the air filtration device 1 are assembled together such that the longitudinal axis X extends through the center of each component.

[0087] (1) Air Flow Power Head Assembly

[0088] The air flow power head assembly 109 is configured to be held together by fasteners 3. More specifically, the fasteners 3 are inserted into the receiving bosses 41 of the rain cap 2, the receiving bosses 47 of the motor / fan assembly 9, and the receiving bosses 48 of the vane assembly 10. The fasteners 3 can be, for example, metal bolts, rivets, or other such attachment members. In this embodiment, the air flow power head assembly 109 is shown having four fasteners 3, and each of the four corresponding receiving bosses 41, 47, and 48. However, the number of fasteners and receiving bosses is not limited to four and can be more or less than four. Figure 6B and Figure 6C shows the air flow power head assembly 109 in an assembled state, where the rain cap 2, the motor / fan assembly 9, and the vane assembly 10 are fixed together.

[0089] As Figure 10 and Figure 12 seen, the rain cap 2 is formed by a conical head and a plurality of mounting feet (four in this embodiment) extending from the head in a direction parallel to the axial direction defined by the longitudinal axis X of the air filtration device 1. The conical head is a convex plate member that protrudes outward in a first axial direction (i.e., away from the rest of the air filtration device 1), which is opposite to the second axial direction. The inner surface of the conical head has transverse members extending between the four receiving bosses 41 for structural support. The rain cap 2 is further provided with receiving bosses 41 for receiving the fasteners 3. The rain cap 2 can be made of, for example, a polymer composite resin.

[0090] As Figures 14 to 17As seen, 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 dividing beams. The debris guard member 42 is used to prevent debris that may damage the fan assembly 43 from entering the fan assembly 43 and also prevent a user's hand / fingers from entering the fan assembly 43.

[0091] The fan motor 45 is provided at the center of the fan assembly 43 and is powered by the electrical wiring 46. The electrical wiring 46 is connected to a power source (such as a battery not shown in the figure) through an electrical connector 18 described below. The fan motor 45 is configured to drive the fan blades 44 using the power supplied through the electrical wiring 46. The fan motor 45 can be made of, for example, metal and / or polymer composite resin. The fan motor 45 shown in the figure is electrical and can be a brushed or brushless motor. Advantageously, the air filtration device 1 is composed of a relatively compact fan motor 45 and fan assembly 43, thereby helping to reduce the physical size of the device, and the position 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 can also be used, such as configurations including hydraulic motors.

[0092] The fan blades 44 are provided on the inner side (second axial side) of the motor / fan assembly 9. In this embodiment, seven fan blades 44 are provided, but the number of fan blades 44 is not limited to this, and there can be more or fewer 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 can be made of, for example, polymer composite resin.

[0093] As Figures 18 to 23 seen, the vane assembly 10 includes a conical air flow deflector 50 at the center of the vane assembly 10, and a plurality of vanes 51 that extend radially outward from the air flow deflector 50 to the circumferential wall 24 of the vane assembly 10 (see Figure 7 ). The air flow deflector 50 is a convex plate member that protrudes outward in the first axial direction (i.e., away from the vanes 51). The air flow deflector 50 is positioned at the center of the vane assembly 10 and on the incoming air side, facing the back of the fan blades 44 that direct the air flow into the vanes 51. The circumferential wall 24 includes a mounting surface 49 on which the motor / fan assembly 9 is mounted (see Figure 18). The circumferential wall 24 further has a radially outer surface from which the receiving bosses 48 extend radially outward. On the opposite second axial side of the vane assembly 10, a mounting surface 55 is provided for mounting the vane assembly 10 to the separator outer housing 11 as discussed below. The vane assembly 10 further includes a recess (notch) 53 in which an electrical connector mounting groove 56 is provided that is configured to receive the electrical connector 18 described below.

[0094] Each of the vanes 51 has first and second relatively facing surfaces that are angled with respect to the longitudinal axis X. The plurality of vanes 51 are arranged in a circumferential direction and are spaced apart from each other. A plurality of guard members 52 are provided between adjacent pairs of vanes 51 as a safety measure to prevent, for example, a user's finger from passing through the vane assembly 10. In the present embodiment, three guard members 52 extend between each adjacent pair of vanes 51, but the number of guard members 52 can be more or less than three. The guard members 52 extend circumferentially between the vanes 51. All components of the vane assembly 10 can be made of, for example, metal and / or polymer composite resin.

[0095] The vane 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 outer 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. As Figure 18 and Figure 22 seen, each locking slot 17 is open in the first and second axial directions to receive the 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 power head assembly 109) is rotated relative to the separator outer housing 11 to securely assemble the air filter device 1.

[0096] 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, polymer composite resin and are provided to align the air flow power head assembly 109 with the outer filter assembly 20 as described below.

[0097] As Figures 1 to 3 and Figures 51 to 54 seen, the air flow power head assembly 109 (rain cap 2, motor / fan assembly 9 and vane (louver) assembly 10) is configured to be mounted to the separator outer 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, locking pins 5 and a locking pin retainer 96. As Figure 1 , Figure 22 and Figure 23 seen, the first locking pin boss 4 is provided on the outer circumferential edge of the vane assembly 10.Figure 1 and Figure 24 As seen in Figure 1 and Figure 24 , the second locking pin boss 4 is provided on the circumferential outer edge of the first axial end of the separator housing 11. During assembly, the first locking pin boss 4 and the second locking pin boss 4 are aligned such that the locking pin 5 passes through both the first locking pin boss 4 and the second locking pin boss 4. As Figure 1 、 Figure 51 and Figure 52A As seen in Figure 1 , Figure 51 , and Figure 52A , the locking pin retainer 96 is a flexible member arranged to hold the locking pin 5 in the assembled state. For example, the locking pin retainer 96 may have a stiffness less than that of the locking pin 5. The first end of the locking pin retainer 96 is fixed to the head by passing through an opening in the head of the locking pin 5. The second opposite end of the locking pin retainer 96 has an opening configured to receive the opposite end of the locking pin 5, thereby preventing the locking pin 5 from being inadvertently removed from the first locking pin boss 4 and the second locking pin boss 4.

[0098] As Figure 1 、 Figure 51 、 Figure 52A and Figure 52B As seen in Figure 1 , Figure 51 , Figure 52A , and Figure 52B , the air filtration device 1 is provided with an electrical connector 18 disposed within the mounting groove 56 of the impeller assembly 10. The electrical connector 18 is an adapter configured to connect the electrical wiring 46 to a power source. The air filtration device 1 includes a safety feature that prevents the removal of the air flow power head assembly 109 from the separator housing 11 without first removing the electrical connector 18. Specifically, the electrical connector 18 prevents the rotation of the air flow power head assembly 109 relative to the separator housing 11 and thus prevents the mounting tab 16 (described below) from being removed from the locking slot 17 (discussed below). Accordingly, the male and female portions of the electrical connector 18 must be disconnected from each other in order to remove the air flow power head assembly 109 from the separator housing 11.

[0099] (2) Separator housing

[0100] As Figures 24 to 28As seen in, the separator outer housing 11 is shaped to taper in a second axial direction (i.e., toward the clean air outlet 8). In other words, the diameter of the separator outer housing 11 gradually decreases from a first axial end (at the air flow inlet 57) to a second axial end (at the clean air outlet 8). The separator outer housing 11 is provided with the mounting tabs 16 discussed above. The plurality of mounting tabs 16 are arranged circumferentially and spaced apart from each other. 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 vane assembly 10 and then rotated until the first and second locking pin bosses 4 are aligned for insertion of the locking pin 5, thereby fixing the air flow power head assembly 109 to the separator outer 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 power head assembly 109 to the separator outer housing 11. Also, as described above, once the electrical connectors 18 (male and female parts) are connected to provide power, the air flow power head assembly 109 cannot be removed from the separator outer housing 11 without first disconnecting the electrical connectors 18 (i.e., the mounting tabs 16 cannot be removed from the locking slots 17).

[0101] The separator outer housing 11 has an air flow inlet 57 on a first axial side and a clean air outlet 8 on a relative second axial side, as Figure 24 and Figure 25 seen in. As Figure 8 shown in, the separator outer housing 11 has a debris separator chamber 34 axially disposed between the air flow inlet 57 and the clean air outlet 8. The air flow inlet 57 is longer in diameter than the clean air outlet 8. The separator outer housing 11 can be made, for example, of metal and / or polymer composite resin. In use, the drive of the motor / fan assembly 9 causes air carrying debris to be pushed through the vane assembly 10, which generates a centripetal swirling air flow that is then pushed into the air flow inlet 57 and into the separator outer housing 11. In the separator outer housing 11, the debris is pushed radially outward under the air flow pressure to swirl along the inner wall of the separator outer housing 11. Due to the tapered structure of the separator outer housing 11, the air flow carrying debris maintains speed and energy as it rotates because the tapered structure reduces the area inside the separator outer housing 11, thereby collapsing the space and the air flow carrying debris until the debris exits the air filtration device 1 through the debris discharge slot extension 12 (discussed below), 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.

[0102] The separator outer housing 11 has a plurality of mounting bosses 6 that extend radially outward from the outer circumferential surface of the separator outer 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 filtration device 1 to a support structure, such as an engine or other equipment to which the air filtration device 1 is provided, in a plurality of orientations. The plurality of possible mounting orientations provide advantageous adaptability for the use of the air filtration device 1 in various applications. The mounting bosses 6 are elongated members made of, for example, a metal and / or a polymer composite resin. Each mounting boss 6 has an opening at its free end for mounting the air filtration device 1 to the support structure. A marking surface 61 is provided between the mounting bosses 6 for providing markings or other indicia regarding the air filtration device 1.

[0103] On its first axial side, the separator outer housing 11 includes a mounting surface 58 that surrounds the air inlet 57. The mounting surface 58 is arranged to cooperate with the mounting surface 55 of the vane assembly 10. Mounting tabs 16 are formed on the mounting surface 58.

[0104] On its second axial side, the separator outer housing 11 has an outlet sealing surface 60 that surrounds 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. As Figure 24 shown, the vacuum / pressure port 13 is on the inner circumferential surface of the clean air outlet 8 and is 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.

[0105] As Figures 24 to 28 seen, the separator outer housing 11 has a plurality of debris discharge chute extensions 12 that are configured to align with the debris discharge chute 72 of the debris collection tray 27 described in detail below. In the present embodiment, four debris discharge chute extensions 12 are provided at intervals around the circumferential portion of the separator outer 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 understood from Figure 27 and Figure 28 each debris discharge chute extension 12 has a first serrated surface and a second surface that extends radially outward from the first serrated surface to the outer circumferential surface to facilitate the discharge of debris from the separator outer housing 11.

[0106] The separator outer housing 11 further includes a mounting surface 63. The mounting surface 63 is configured to receive an optional discharge port adapter 64, an optional FID (filter identification) reader air outlet side adapter 83, and an optional discharge slot seal cap adapter 93.

[0107] (3) Discharge port adapter

[0108] 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 seal surface 67, a vertical seal surface 68, a discharge port exit opening 69, and fastener holes 70. The alignment slots 65 are each configured to receive mounting bosses 15 (shown in Figure 24 ), which are positioned on the separator outer housing 11 at each of the debris discharge slot extensions 12. A fastener 85 (shown in Figure 47 ) is provided to secure the discharge port adapter 64 to the separator outer housing 11 by passing through the fastener holes in each of the mounting bosses 15 and through each of the fastener holes 70 of the discharge port adapter 64. The fastener 85 is, for example, a metal or polymer composite resin screw, bolt, rivet, or other such attachment member. Debris exits the discharge port adapter 64 via the discharge port exit opening 69 and the debris discharge port 66. The horizontal seal surface 67 mates with the mounting surface 63. The vertical seal surface 68 mates with an axially facing surface (facing the second axial direction) of the separator outer housing 11 that is positioned on the first axial side of the debris discharge slot extension 12. The discharge port adapter 64 can be made of, for example, a polymer composite resin. Figure 31 The discharge port adapter 64 shown mounted on the separator outer housing 11. The optional discharge port adapter 64 advantageously allows the discharge of debris to be directed through a single port (the debris discharge port 66), which can be adapted to discharge debris-laden air to a specific location or, for example, outside of an engine compartment or other equipment compartment as needed.

[0109] (4) Filter reading feature

[0110] Figure 47 、 Figure 48A and Figure 48BShows a modified arrangement 82 of the air filtration device 1 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 mates to 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 sliding fit mounting support 90, an FID reader circuit board 106, an electrical connector 107, and a fastener 108. The electrical wiring 84 is connected to a power source (such as a battery not shown in the figure) for supplying power to the FID reader air outlet side adapter 83. The alignment slots 65 are each configured to receive a respective mounting boss 15, and fasteners 85 are provided to secure the FID reader air outlet side adapter 83 to the separator outdoor housing 11 by passing through each of the fastener holes in each mounting boss 15 and the fastener holes 70 in the FID reader air outlet side adapter 83. Additional fasteners 85 are provided at a 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 the electrical connector 107 (see Figure 48B ). Fasteners 108 are provided inside 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 of, for example, metal and / or 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 supports 87 are arranged to mate with the outer circumferential surface of the separator outdoor housing 11 that extends between the debris discharge slot extensions 12, wherein the axial edges of the vertical mounting supports 87 are arranged to mate with the axially facing surface (facing the second axial direction) of the separator outdoor housing 11 that is positioned on the first axial side of the debris discharge slot extension 12. To not impede the discharge of debris through the debris discharge slot extension 12, an air gap 89 is provided between adjacent vertical mounting supports 87, as Figure 48A seen. The vertical circular sliding fit mounting support 90 mates with the outer circumferential surface of the separator outdoor housing 11 that is provided on the second axial side of the mounting surface 63. The FID reader air outlet side adapter 83 can be made of, for example, metal and / or polymer composite resin. The FID reader air outlet side adapter 83 advantageously allows for reading of the filter identification ring ("FIR") 92 on the clean air side of the air filtration device 1, as described below.

[0111] As described 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 provide power to and communicate with the FIR 92. The FID reader circuit board 106 is configured to receive filter-related data from the FIR 92. The features of the FIR 92 and the FID reader circuit board 106 (also described as "control module" or "RCM") are described in detail in U.S. Application No. 16 / 022,941, filed on June 29, 2018, and incorporated herein by reference in its entirety (now U.S. Patent No. 10,850,222, issued on December 1, 2020). Additional features of the FIR 92 and the FID reader circuit board 106 are described in detail in U.S. Application No. 17 / 138,052, incorporated herein by reference in its entirety. Additionally, although the FIR 92 is described herein 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. As Figure 49 shown, the FIR 92 is provided on the "clean side" of the air stream (i.e., at the location where the air stream passes after debris has been removed by the outer filter medium 35).

[0112] (5) Discharge slot seal cap adapter

[0113] The optional discharge slot seal cap adapter 93 is shown in Figure 50A and Figure 50B and includes a plurality of alignment slots 65 and fastener holes 70. Like the discharge port adapter 64, the alignment slots 65 are each configured to receive a corresponding mounting boss 15, and a fastener 85 is provided to secure the discharge slot seal cap adapter 93 to the separator outer housing 11 by passing through each of the fastener holes in each mounting boss 15 and each of the fastener holes 70 in the discharge slot seal cap adapter 93. Figure 50B The discharge slot seal cap adapter 93 is shown mounted on the separator outer housing 11. The discharge slot seal cap adapter 93 can be made, for example, of a polymer composite resin. When the separator outer housing 11 is used without the self-cleaning feature, the discharge slot seal cap adapter 93 advantageously allows the sealing of the debris discharge slot extension 12.

[0114] (6) Filter assembly

[0115] Figures 34 to 46 and Figure 49 show the features of the outer filter assembly 20. The outer filter assembly 20 includes an outer filter clean side seal 22, a debris collection tray 27, a two-piece outer screen 28, a closed end cap 29, an outer filter medium 35, and an optional inner screen 36.

[0116] (6-1) Outer filter medium

[0117] The outer filter medium 35 removes debris from the air passing through the air filtration 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 fiber or synthetic fiber media; can include carbon wrap, carbon pellet, felt wrap, or foam; or can be any medium with high-efficiency properties. The outer filter medium 35 can be formed of a single medium or multiple media, including but not limited to the media types mentioned above.

[0118] (6-2) Screen assembly

[0119] The outer filter medium 35 is surrounded and protected by the outer screen 28. Additionally, 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 of, for example, a polymer composite resin. The inner screen 36 is optional, and depending on the type of medium 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 fixed to the closed end cap 29 by using glue, urethane, closed-cell foam, epoxy resin, rubber, or any other binder 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.

[0120] 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 latch mechanism that provides alignment of the two screen halves and holds them together during and after the manufacturing process. The latch mechanism can have a plurality of protrusions on one end of the outer screen 28 and a plurality of receiving slots into which the protrusions are inserted on the other end of the outer screen 28, as detailed in U.S. Application No. 17 / 138,052, filed on December 30, 2020, and incorporated herein by reference in its entirety.

[0121] (6-3) Outer filter clean side seal

[0122] The outer filter clean side seal 22 is formed of urethane, for example. More specifically, the outer filter clean side seal 22 can be formed of cold-poured urethane, as detailed 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, the outer filter medium 35, the outer screen 28, and the debris collection tray 27. Similar to the process described in U.S. Application No. 17 / 138,052, during the manufacturing process, a mold is provided for the cold pouring of urethane to form the outer filter clean side seal 22. When the debris collection tray 27, the optional inner screen 36, the outer filter medium 35, and the outer screen 28 are installed in the mold, the urethane is poured so as to flow into the open areas to securely hold together the assembled inner screen 36, the outer filter medium 35, the outer screen 28, the debris collection tray 27, and an optional filter identification ring ("FIR") 92 (if included) described below, as Figure 49 shown. In other words, the urethane seal 22 holds all these components together in a favorably secure manner after curing, with the urethane embedding the inner screen 36, the outer filter medium 35, the outer screen 28, the debris collection tray 27, and the optional FIR 92 (if included). Figure 49 The outer filter assembly 91 is shown, where, for illustrative purposes, a portion of the outer filter clean side seal 22 has been cut away to show how the optional FIR 92, the debris collection tray 27, the outer screen 28, and the outer filter medium 35 are embedded within the outer filter clean side seal 22. As Figure 8 seen, the separator housing 11 has an axially extending sealing surface 40 that abuts the inner circumferential surface of the outer filter clean side seal 22 so as to seal the radially outer edge of the clean air outlet 8. Additionally, the separator housing 11 has a radially extending sealing surface 62 that abuts the axially facing surface (facing the second axial direction) of the outer filter clean side seal 22 so as 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 that communicates with the clean air outlet 8 (see Figure 35 ).

[0123] (6-4) Debris Collection Tray

[0124] Figures 43 to 46Showing the features of the debris collection tray 27, the debris collection tray 27 is included in (and embedded in) the outer filter cleaning side seal 22 as described above. The debris collection tray 27 includes a plurality of filter alignment ridges 26, a debris discharge groove 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 the first axial direction and surrounds the support tabs 73. The inner circumferential wall 79 faces the radial direction and, together with the inner axially facing wall 78, forms a space inside the debris collection tray 27 where debris orbits before leaving through the debris discharge groove 72. The outer axially facing wall 81 faces the second axial direction (towards the clean air outlet 8) and surrounds the support tabs 73. The outer circumferential wall 80 faces outwards in the radial direction and, when installed, faces the inner circumferential surface of the separator housing 11.

[0125] 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 housing 11, as Figure 27 shown. Additionally, as briefly described above, the debris discharge groove 72 is configured to align (axially and circumferentially) with one of the debris discharge groove extensions 12. Depending on the rotational position of the outer filter assembly 20, the debris discharge groove 72 can align with any one of the debris discharge groove extensions 12. For example, Figure 54 is a cross-sectional view taken along Figure 26 line 54-54 in

[0126] and shows the debris discharge groove 72 aligned with one of the debris discharge groove extensions 12. The mating arrangement of the filter alignment ridges 26 with the filter alignment grooves 25 provides the following safety feature: It advantageously ensures that the debris discharge groove 72 will necessarily align with one of the debris discharge groove extensions 12, regardless of the rotational position of the outer filter assembly 20. In other words, the mating arrangement of the filter alignment ridges 26 with the filter alignment grooves 25 prevents the outer filter assembly 20 from being installed in the separator housing 11 without aligning the debris discharge groove 72 with one of the debris discharge groove extensions 12. In this embodiment, four debris discharge groove extensions 12 are provided, and thus four filter alignment ridges 26 and four filter alignment grooves 25 are circumferentially arranged. Therefore, 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 groove extensions 12, filter alignment ridges 26, and filter alignment grooves 25 can be provided, as long as the number of filter alignment ridges 26 and filter alignment grooves 25 corresponds to the number of debris discharge groove extensions 12.

[0126] The support tabs 73 are provided and are circumferentially spaced apart, as Figure 43as shown. The support tab 73 is arranged to support the outer filter medium 35 and optionally the FIR 92, as Figure 49 shown. All components of the debris collection tray 27 are formed of, for example, a polymer composite resin.

[0127] (6-5) Outer Filter Closing End Cap

[0128] Figures 39 to 42 shows the features of the outer filter closing end cap 29. As described above, the outer filter closing end cap 29 holds the optional inner screen 36, the outer filter medium 35, and the outer screen 28 in place on the first axial side using, for example, glue. More specifically, as Figure 41 seen, the second axial side of the outer filter closing end cap 29 includes an adhesion surface 75 surrounded by a raised vertical inner wall 76, which together form a tray in which, for example, hot melt adhesive can be held during the manufacturing process. The vertical inner wall 76 is in turn surrounded and encircled by a raised vertical outer wall 77. The adhesion surface 75 is configured to receive, for example, hot melt adhesive during the manufacturing process in order to adhere the inner screen 36, the outer filter medium 35, and the outer screen 28 on the first axial side.

[0129] The outer filter closing end cap 29 is provided with a handle 30 on the first axial side to facilitate the installation of the outer filter assembly 20 into the separator housing 11. A alignment hole 31 configured to receive (and align) an alignment pin 38 is provided at the center of the handle 30. Since 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 the correct alignment between the air flow power head assembly 109 (the rain cap 2, the motor / fan assembly 9, and the vane assembly 10) and the outer filter assembly 20. The alignment pin 38 ensures that the outer filter assembly 20 is centered within the separator housing 11.

[0130] (6-6) Inner Filter Assembly

[0131] The inner filter assembly 19 is provided as an optional secondary filter (also referred to as a "safety filter") that can be positioned inside the outer (primary) filter assembly 20, specifically inside the 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 medium 32, and an inner filter closed end cap 33. Like the outer filter medium 35, the inner filter medium 32 can include a variety of media, including but not limited to natural fiber or synthetic fiber media; it can contain carbon wrappings, granular carbon, felt wrappings, or foam. If the outer filter medium 35 becomes defective or begins to lose its ability to properly filter debris such that debris passes through the outer filter medium 35, the debris will collect on the outer surface of the inner filter medium 32, thereby reducing the air flow leaving the air filtration device 1 due to the lower debris loading capacity of the inner filter medium 32. Thus, the user can be easily notified about the problem with the outer filter medium 35.

[0132] The inner filter clean side seal 21 can be made of urethane, for example. The inner filter closed end cap 33 can be made of a polymer composite resin, for example. As Figure 55 shown, at higher flow rates, the air filtration device 1 tends to have a more restricted air flow when the inner filter assembly 19 is installed compared to when the inner filter assembly 19 is not installed. However, when the inner filter assembly 19 is installed, the air flow restriction level is still an acceptable level for system performance. Figure 55 The flow rates and parameters given are merely exemplary and do not limit the scope of the present disclosure.

[0133] After the air flow power head assembly 109 is assembled to the separator outer housing 11 as Figure 1 shown, the air filtration device 1 is fully assembled and ready for operation. Figures 51 to 54 The assembled state of the air filtration device 1 with the removable optional rain cap 2 removed is shown as the modified arrangement 94. As Figure 51 shown, the assembly 95 only includes the motor / fan assembly 9 and the vane assembly 10, without the rain cap 2. Figure 53A The assembled state where the locking pin 5 is inserted into the first and second locking pin bosses 4 is shown, while Figure 53B the assembled state with the locking pin assembly 97 removed is shown.

[0134] (7) Debris screen

[0135] Figures 56 to 59 The features of the optional debris screen 100 are shown. Figure 56Display arrangement 99, wherein the fully assembled air filtration device 1 further includes a debris screen 100. The debris screen 100 is provided to fill the space between the rain cap 2 and the motor / fan assembly 9 and extends axially between the rain cap 2 and the motor / fan assembly 9. The debris screen 100 advantageously prevents airborne debris that is too large to pass through the air filtration device 1 from entering the said space. This is particularly useful in landfill operations, agriculture, logging, and other fields where there is an environment with a high concentration of large airborne debris. The debris screen 100 is made of metal, for example, and includes a top 101, a perforated circumferential side surface 102, mounting holes 103, a mounting flange 104, and air gaps 105. The top 101 is mounted adjacent to (but not in contact with) the inner surface of the rain cap 2. The mounting flange 104 is mounted adjacent to (and in contact with) the first axial side of the motor / fan assembly 9. The perforated circumferential side surface 102 is a surface that includes a plurality of holes to allow air to enter the air filtration device 1. The plurality of mounting holes 103 are provided circumferentially spaced apart on the mounting flange 104 and are configured to receive the same fasteners 3 inserted into the receiving bosses 41 of the rain cap 2, the receiving bosses 47 of the motor / fan assembly 9, and the receiving bosses 48 of the vane assembly 10. Each of the air gaps 105 is sized and configured to receive a corresponding one of the mounting feet of the rain cap 2 and a corresponding one of the receiving bosses 47 of the motor / fan assembly 9.

[0136] (8) Air filtration method

[0137] Reference may be made to Figure 62 understand the air filtration method of the present disclosure. Figure 62 is an image of the air flow through the air filtration device 1 with the rain cap 2 removed. The method includes using the vacuum effect generated by the motor / fan assembly 9 to draw debris-laden air into the air flow inlet 57. The stratified debris-laden air is in Figure 62is shown as air stream A. After leaving the motor / fan assembly 9, the air stream is pushed downstream using the positive pressure effect generated by the motor / fan assembly 9 and the conical separator outer housing 11. More specifically, the debris-laden air flows along a linear flow path under pressure (the positive pressure generated by the motor / fan assembly 9), where centripetal force causes the air stream of the debris-laden air to orbit around axis X under the action of the pressure, thereby forming a rotating air stream A with debris stratification having debris particles heavier than air in the radially outermost orbit of the pressurized rotating air stream. The conical shape of the separator outer housing 11, together with the air pressure generated by the motor / fan assembly 9, maintains a high-energy air stream, where the gradually decreasing diameter of the separator outer housing 11 causes the air stream to collapse towards the debris collection tray 27. When the centripetally orbiting debris-laden air stream is pushed into the conical separator outer housing 11, it travels linearly along the wall of the separator outer housing 11 towards the second axial end. The velocity of the centripetally orbiting air stream is maintained by the constricted area (i.e., the gradually decreasing diameter) of the conical separator outer housing 11 and the pressurized air stream provided by the motor / fan assembly 9. Debris particles trapped in the centripetally orbiting air stream pattern move along the inner wall of the separator outer housing 11 and are pushed downward along the linear path of the air stream towards the clean air outlet end. As the debris continues to be pushed downstream towards the second axial end by the air stream passing through the separator outer housing 11, the centripetal force causes the debris to move radially outward towards the inner wall of the separator outer housing 11. The debris is then trapped in the debris collection tray 27, which is contained in the outer filter cleaning side seal 22 located at the back of the separator outer housing 11. The debris then exits under the action of pressure through the debris discharge slot 72 aligned with the debris discharge slot extension 12 molded into the end of the separator outer housing 11 and is forced out back into the environment, as Figure 62 shown in

[0138] When the pressurized centripetally orbiting air is pushed linearly (axially) downward along the separator outer housing 11 towards the second axial end, Figure 62 the radially inner air stream B shown in is the debris-laden air that surrounds the fine particles that have been stripped of most of the debris of the outer filter assembly 20. This air stream 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 a clean air stream C. The filtered (clean) air stream C is carried along a linear flow path inside the filter assembly 20 towards the clean air outlet 8 at the end of the separator outer housing 11, as Figure 62As shown. This linear directed air flow forms a minimum air flow restriction, thus allowing the energy generated by the motor / fan assembly 9 to be used more efficiently to move a large amount of air, and generating significant centripetal separation efficiency and pressure through the air filtration device 1, thus allowing a much higher air flow in applications with limited space. In addition, the linear air flow pattern in the separator outer housing 11 prevents turbulence in the air flow, which reduces restrictions and improves separator efficiency. Air is inhaled into the outer filter assembly 20 along the length of the outer filter assembly 20 and flows to the clean air outlet 8 in the same direction as the swirling airborne debris flows to the debris collection tray 27. The combination of the pressurized air, the centripetally swirling air flow, the conical separator outer housing 11, the outer air filter assembly 20, and the debris collection tray 27 that forces debris out of the debris discharge chute 72 allows the debris accumulated on the outer air filter assembly 20 to be thrown off by the pressurized centripetally swirling air in the conical separator outer housing 11. With the above characteristics, the air filtration device 1 can meet the varying air flow requirements of the engine or other equipment on which the air filtration device 1 is installed.

[0139] More specifically, during use, a positive air pressure is advantageously maintained in the air filtration device 1. The positive pressure can be understood as such a pressure that positively pushes the air flow from the motor / fan assembly 9 to the clean air outlet 8, while applying a centripetal force to the air flow to ensure that the debris is pushed radially outward, thus minimizing the accumulation of debris on the outer filter assembly 20. The positive pressure is caused by the motor / fan assembly 9 of the air molecules in the compressed air filtration device 1. The positive pressure generated by the motor / fan assembly 9 of the air molecules in the compressed filter outer housing 11 causes the air to pass through the filter and exit from the debris discharge chute extension 12 downstream. 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 strong enough air flow to achieve discharge at the maximum rated air flow through the clean air outlet 8 at the debris discharge chute extension 12, without allowing external air or debris to enter through the debris discharge chute extension 12.

[0140] The conical separator outer housing 11 reduces the circumferential part of the air flow path, thus causing the centripetally swirling air flow to accelerate towards the clean air outlet 8 within the separator outer housing 11. When the air flow enters the separator outer housing 11 under the pressure generated by the fan blades 44 and the centripetal acceleration caused by the vanes 51, the debris in the air is pushed radially outward by the centrifugal force. Since the air flow through the air filtration 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),(9) thus flowing to the clean air outlet 8, so that the air flow is straightened as it passes through the outer filter medium 35. The separator housing 11 tapers inwardly towards the clean air outlet 8, thereby allowing the separated debris that orbits around the inner wall of the separator housing 11 to continue to accelerate and thus flow towards the second axial end of the separator housing 11. The separated debris orbits into the debris collection tray 27 and is pushed out through the debris discharge slot 72 integrated into the clean side seal 22 of the outer filter, and the debris discharge slot 72 is aligned with at least one debris discharge slot extension 12 included in the air outlet end of the separator housing 11. The air flow entering the outer filter medium 35 is filtered as it flows inward through the outer filter medium 35, moves linearly towards the center of the separator housing 11, and exits as clean air through the clean air outlet 8 to the device on which it is installed (or to the environment if not installed on a device).

[0141] Therefore, in operation, the fan motor 45 is powered via the electrical wiring 46, and the air carrying debris is drawn into the air filtration device 1 via the fan blades 44. The air carrying debris passes through the motor / fan assembly 9 and thus orbits into the vane assembly 10. Any air that contacts the center of the vane assembly 10 will be redirected by the air flow diverter 50 to the vanes 51. As the air passes over and between the vanes 51, the air is accelerated and a vortex is formed. The outer wall of the separator housing 11 tapers inwardly towards the back of the separator housing 11 (towards the second axial end), which reduces the space at the back of the separator housing 11 to maintain the centrifugal separation speed of the air as the air accelerates radially through and passes through the separator housing 11, so that the air carrying debris orbits to be centrifugally separated and the particulate debris is pushed against the outer wall of the separator chamber 11. The remaining air passes through the outer filter assembly 20 and is cleaned by the outer filter medium 35. At the same time, the debris that has been removed from the air in the debris separator chamber 34 enters the debris collection tray 27, where it orbits within the debris collection tray 27 until it is forced out via the debris discharge slot 72 under pressure. Since the debris discharge slot 72 is aligned with one of the debris discharge slot extensions 12, the debris will then be discharged back to the environment through the corresponding debris discharge slot extension 12. At the same time, only the clean air passes through the center of the outer filter assembly 20, through the clean side seal 22 of the outer filter, and finally exits through the clean air outlet 8.

[0142] (9) Advantageous effects

[0143] 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 positively pressurized air to be pushed out from the clean air outlet 8, while forcing the debris that has been removed from the air back into the environment via the debris discharge trough 72 and the aligned debris discharge trough extension 12. This linear directed air flow creates minimal air flow restriction, allowing the energy generated by the motor / fan assembly 9 to be used more efficiently to move a large volume of air to the device to which the device is attached, while generating significant centripetal separation efficiency and pressure through the compact size of the air filtration device 1, thus allowing a much higher air flow in applications with limited space. In addition, the linear air flow pattern in the conical separator outer housing 11 prevents air flow turbulence, thereby reducing air flow restriction and increasing separator efficiency. Air is inhaled into the outer filter assembly 20 along the length of the outer filter assembly 20 and flows to the clean air outlet 8 in the same direction as the swirling airborne debris flows to the debris collection tray 27.

[0144] In addition, the conical structure of the separator outer housing 11 reduces the air flow path as the air flow moves towards the second axial end, causing the pressurized centripetally swirling air to accelerate towards the clean air outlet 8 within the separator outer housing 11. At the same time, the conical structure maintains the centrifugal separation speed of the pressurized air, causing the air carrying debris to swirl to centrifugally separate the particulate debris and push the particulate debris against the inner sidewall of the separator chamber 11 and the debris collection tray 27 for discharge to the external environment via the debris discharge trough 72 and the aligned debris discharge trough extension 12.

[0145] Another advantage of the disclosed air filtration device 1 is the provision of alignment pins 38. Since the alignment pins 38 pass through the handle 30 and extend from the air flow diverter 50, the alignment pins 38 advantageously ensure the correct alignment between the air flow power head assembly 109 and the outer filter assembly 20. The alignment pins 38 ensure that the outer filter assembly 20 is centered within the separator outer housing 11.

[0146] Another advantage of the disclosed air filtration device 1 is the provision of a debris collection tray 27. The debris collection tray 27 is included in (and embedded within) the outer filter cleaning side seal 22 and facilitates the removal of debris by providing a space (formed by the inner axially facing wall 78 and the inner circumferential wall 79) in which the debris orbits before being discharged through the debris discharge slot 72. Depending on the rotational position of the outer filter assembly 20, the debris discharge slot 72 can be aligned with any one of the debris discharge slot 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 slot 72 will necessarily be aligned with one of the debris discharge slot 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 housing 11 without aligning the debris discharge slot 72 with one of the debris discharge slot extensions 12.

[0147] Furthermore, due to the provision of the debris discharge slot 72 and the debris discharge slot extensions 12, the air filtration device 1 is a self-cleaning device that does not require maintenance between air filter replacements for the removal of separated airborne debris. Instead, as described in detail above, the pressurized centripetal orbiting air generated within the air filtration device 1 ensures the removal of debris through the debris discharge slot extensions 12. Also, since the debris is trapped in the debris collection tray 27, the debris will not fall out of the air filtration device 1 during filter maintenance. The debris collection tray 27 also prevents debris from falling into the clean air outlet 8 when the outer filter assembly 20 is removed.

[0148] Additionally, the optional provision of the FID (Filter Identification) reader air outlet side adapter 83 and the filter identification ring ("FIR") 92 allows for the automatic exchange of filter information and performance data. This allows the machine operator to know, for example, the filter part number, performance characteristics, and the operating time of the filter during operation. The FIR 92 can store data collected over the life of the filter. The attachment of the FID reader air outlet side adapter 83 to the mounting surface 63 of the separator housing 11 on the clean air side allows for efficient reading of the FIR 92 embedded within the outer filter cleaning side seal 22 at the clean air side.

[0149] 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 the pressure for changing the air flow through the air filtration device 1 as needed and monitoring the restriction to the air flow caused by the outer filter assembly 20 over time.

[0150] The air filtration device 1 also advantageously enables the attachment of various adaptable optional accessories. The mounting surface 63 of the separator outer 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 slot seal cap adapter 93. Each of these adapters offers different advantages, and as described above, all of the adapters are easily attachable to and removable from the separator outer housing 11. The discharge port adapter 64 advantageously mates with the air outlet side of the tapered separator outer housing 11, allowing the debris discharge slot extension 12 to be converted into a circular tubular discharge port for under-hood installation in a vehicle. If the separator outer housing 11 is used without the self-cleaning feature, the discharge slot seal cap adapter 93 advantageously seals the debris discharge slot extension 12.

[0151] Another advantage of the disclosed air filtration device 1 is the provision of an optional debris screen 100. The debris screen 100 advantageously prevents airborne debris that is too large to pass through the air filtration device 1 from entering. This is particularly useful in landfill operations, agriculture, logging, and other fields where there is an environment with a high concentration of large airborne debris.

[0152] In addition, the detachable air flow powerhead assembly 109, which includes a rain cap 2, a motor / fan assembly 9, and a louver assembly 10, allows for adaptation to different machinery and equipment. For example, the rain cap 2 is optional and is easily mounted to the motor / fan assembly 9 and the louver assembly 10 using the same fasteners 3.

[0153] Moreover, at a comparable air flow, the compact air filtration device 1 of the present disclosure is significantly smaller in physical size and weight than a comparable air filtration pre-filter device. Due to the provision of mounting bosses 6 and a plurality of debris discharge slot extensions 12, the air filtration device 1 can also be mounted in any orientation that allows for repair and maintenance. Thus, the air filtration device 1 provides maximum installation flexibility to OEM (original equipment manufacturer) designers who integrate this device into equipment and to aftermarket installers.

[0154] Additionally, the locking slot 17 provided in the louver assembly 10 and arranged to receive the mounting tab 16 of the separator outer housing 11 advantageously facilitates a simple lock-and-twist mating structure between the separator outer housing 11 and the air flow powerhead assembly 109. This in turn allows for quick and efficient air filter cartridge replacement.

[0155] In addition, the debris collection tray 27 has a debris discharge slot 72 that uses four filter alignment ridges 26 that mate with four filter alignment grooves 25 on the inside of the separator housing 11 to select which of the debris discharge slot extensions 12 at the end of the separator housing 11 will align with the debris discharge slot 72. This ensures that, regardless of the installation position of the outer filter assembly 20, airborne debris will be discharged from the separator housing 11.

[0156] In addition, the separator housing 11 is elongated and tapered in the direction of the longitudinal axis X from the air inlet 57 to the clean air outlet 8. This configuration allows air to flow linearly through the separator housing 11 and into the outer filter assembly 20. This air flow pattern reduces turbulence and maximizes the air flow through the compact air filtration device 1. This air flow pattern also reduces air flow restrictions within the air filtration device 1, allowing more air to be pushed out of the clean air outlet 8 and into the engine or the device on which the air filtration device 1 is mounted.

[0157] 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 can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. Accordingly, such changes and modifications are intended to be covered by the present disclosure.

Claims

1. An air filter assembly, the air filter assembly comprising: A filter medium; A closed end cap fixed to the first end of the filter medium; A sealing member fixed to the opposite second end of the filter medium, the second end being open, and the sealing member being open to form a clean air outlet; A screen assembly fixed to a central portion between the first and second ends of the filter medium; And A debris collection tray having a debris discharge groove for discharging debris to the surrounding environment; wherein, The debris collection tray is positioned at the second end of the filter medium; The debris collection tray includes a plurality of support tabs circumferentially spaced apart on the debris collection tray, the support tabs being arranged to support the filter medium and the screen assembly, wherein the support tabs project radially inwardly in a radial direction beyond the filter medium and the screen assembly relative to a central axis passing through the center of the air filter assembly; The debris discharge groove projects radially inwardly from the outer circumferential surface of the debris collection tray; The support tabs continuously extend from a position radially outside the filter medium and the screen assembly to a position radially inside the filter medium and the screen assembly.

2. The air filter assembly according to claim 1, the air filter assembly further comprising: A filter identification device embedded in the sealing member, the filter identification device including a circular antenna and being configured to store and transmit data related to the filter assembly.

3. The air filter assembly according to claim 2, wherein, The debris collection tray includes a plurality of support tabs circumferentially spaced apart on the debris collection tray, the support tabs being arranged to support the filter medium, the screen assembly and the filter identification device, wherein the support tabs project radially inwardly in a radial direction beyond the filter medium, the screen assembly and the filter identification device relative to a central axis passing through the center of the air filter assembly.

4. The air filter assembly according to claim 1, wherein, The debris collection tray includes a plurality of filter alignment ridges provided on the outer circumferential surface of the debris collection tray.

5. The air filter assembly according to claim 4, wherein, The debris discharge groove is positioned adjacent to one of the filter alignment ridges.

6. The air filter assembly according to claim 4, wherein, The filter alignment ridges are positioned at 90-degree intervals around the outer circumferential surface of the debris collection tray.

7. The air filter assembly according to claim 4, wherein, The plurality of filter alignment ridges includes four filter alignment ridges.

8. The air filter assembly according to claim 1, wherein, The debris collection tray is integrally formed with the sealing member.

9. The air filter assembly according to claim 1, wherein, The debris collection tray is integrally formed with the sealing member such that the support tabs are embedded within the sealing member.

10. The air filter assembly according to claim 3, wherein, the debris collection tray is integrally formed with the sealing member such that the support tabs are embedded within the sealing member.

11. The air filter assembly according to claim 1, wherein, the screen assembly includes an outer screen positioned around an outer surface of the filter medium.

12. The air filter assembly according to claim 1, wherein, the screen assembly includes an inner screen and an outer screen, the inner screen being positioned inside the filter medium and the outer screen being positioned around an outer surface of the filter medium.

13. The air filter assembly according to claim 11, wherein, the outer screen has a first outer screen half and a second outer screen half, the first outer screen half and the second outer screen half being fixed together by a latching mechanism.

14. The air filter assembly according to claim 13, wherein, the latching mechanism includes a plurality of protrusions and a plurality of receiving slots configured to receive the protrusions to fix the first outer screen half and the second outer screen half together.

15. The air filter assembly according to claim 1, wherein, the closed end cap includes a handle protruding from a surface of the closed end cap facing away from the filter medium, and a first alignment hole is formed in the handle.

16. The air filter assembly according to claim 1, wherein, the sealing member is made of urethane and the debris collection tray is embedded within the sealing member.

17. The air filter assembly according to claim 1, wherein, a second end of the filter medium is embedded within the sealing member.

18. The air filter assembly according to claim 1, wherein, the end cap is fixed to a first end of the filter medium using glue.

19. The air filter assembly according to claim 1, wherein, the screen assembly is made of plastic.

20. The air filter assembly according to claim 1, wherein, the debris discharge slot extends between (i) an inner circumferential surface of the debris collection tray facing the screen assembly and (ii) an outer circumferential surface of the debris collection tray.

21. The air filter assembly according to claim 12, the air filter assembly further including another filter medium positioned inside the inner screen.

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