Filter assembly with unique shape

Abstract

A method of manufacturing a media pack includes winding a filter media around a central axis into a media roll; and cutting the media roll into at least two media packs of at least two media packs along at least two cutting lines. The media roll is cut along at least one plane parallel to the central axis.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 088,099, filed October 6, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This application generally relates to filter assemblies for use in air intake systems, etc. Background Technology

[0004] Typically, the intake system is housed in a very space-constrained under-hood environment with extremely limited available space for installation. Therefore, the intake components of the air filter assembly need to be uniquely packaged to provide a compact package volume and high shape flexibility to fit and surround other under-hood components. Furthermore, it is desirable for the air filter assembly (especially the air filter element) to be low-cost. Figures 1A to 1B An example of filter component 90 is shown. Figure 1A The limited amount of space and the unusual shape of space available for the filter assembly 90 (e.g., within a vehicle) are shown. In order to fit within this limited and unusually shaped space, the filter assembly 90 is also small and unusually shaped, and the resulting available space for the filter element within the housing of the filter assembly 90 is also relatively small and unusually shaped.

[0005] While conventional pleated cylindrical air filters can be replaced with traditional filter elements featuring circular, oblong, or rectangular flow surfaces, encapsulating air filters within the engine compartment is becoming increasingly challenging due to the continuous reduction in available space as vehicle size and weight are minimized to optimize fuel efficiency. This necessitates air cleaners that better fit around the duct or align with the gradually sloping body panel without sacrificing cost or performance. Summary of the Invention

[0006] Different embodiments provide a method of manufacturing a media assembly, the method comprising: winding a filter medium around a central axis into a media roll; and cutting the media roll along at least two cutting lines into at least two media packages for at least two media assemblies. The media roll is cut along at least one plane parallel to the central axis.

[0007] Various other embodiments provide a media assembly comprising: a media package including multiple layers of filter media; a first side plate; and a second side plate. The media package defines an inlet flow surface, an outlet flow surface, a first sidewall, a second sidewall, a radially inner edge, and a radially outer edge. Each of the first and second sidewalls extends axially between the inlet and outlet flow surfaces and radially between the radially inner and radially outer edges. The first side plate is positioned along and seals with the first sidewall such that fluid entering through the inlet flow surface cannot exit the media package through the first sidewall. The second side plate is positioned along and seals with the second sidewall such that fluid entering through the inlet flow surface cannot exit the media package through the second sidewall. The media package is formed by winding filter media into a media roll around a central axis and cutting the media roll along at least two cutting lines to form the first and second sidewalls.

[0008] Various other embodiments provide a filter element including a media assembly. The media assembly includes: a media package comprising multiple layers of filter media; a first side plate; and a second side plate. The media package defines an inlet flow surface, an outlet flow surface, a first side wall, a second side wall, a radially inner edge, and a radially outer edge. Each of the first and second side walls extends axially between the inlet and outlet flow surfaces and radially between the radially inner and radially outer edges. The first side plate is positioned along and seals against the first side wall such that fluid entering through the inlet flow surface cannot exit the media package through the first side wall. The second side plate is positioned along and seals against the second side wall such that fluid entering through the inlet flow surface cannot exit the media package through the second side wall. The media package is formed by winding filter media into a media roll around a central axis and cutting the media roll along at least two cutting lines to form the first and second side walls.

[0009] These and other features, together with the organization and manner of their operation, will become apparent from the following detailed description when considered in conjunction with the accompanying drawings, wherein the same elements have the same reference numerals in the several drawings described below. Attached Figure Description

[0010] Figure 1A It is, for example, a three-dimensional view of the space inside a vehicle that can be used for conventional filter components.

[0011] Figure 1B yes Figure 1A A 3D view of the filter assembly.

[0012] Figure 2A This is a perspective view of the media assembly of a filter element according to one embodiment.

[0013] Figure 2B yes Figure 2A A three-dimensional view of the media components.

[0014] Figure 3 This is a perspective view of the media assembly of a filter element according to another embodiment.

[0015] Figure 4A This is a perspective view of a media roll according to another embodiment.

[0016] Figure 4B It has cutting lines Figure 4A A three-dimensional view of the media roll.

[0017] Figure 4C It comes from Figure 4A A three-dimensional view of the media assembly of the media roll.

[0018] Figure 5A This is an end view of a media roll according to yet another embodiment.

[0019] Figure 5B It has cutting lines Figure 5A An end view of the media volume.

[0020] Figure 6 This is an end view of a media roll with cut lines according to another embodiment.

[0021] Figure 7 This is an end view of a media assembly according to one embodiment.

[0022] Figure 8A This is an end view of a media assembly according to another embodiment.

[0023] Figure 8B This is an end view of a media assembly according to yet another embodiment.

[0024] Figure 9 This is an end view of a media assembly according to yet another embodiment.

[0025] Figure 10A This is an end view of two attached media assemblies according to one embodiment.

[0026] Figure 10B This is an end view of two attached media assemblies according to another embodiment.

[0027] Figure 11A This is an end view of a media roll with cut lines according to one embodiment.

[0028] Figure 11B This is an end view of a media roll with cut lines according to another embodiment.

[0029] Figure 12A This is an end view of a media roll with cut lines according to yet another embodiment.

[0030] Figure 12B This is an end view of a media roll with cut lines according to yet another embodiment.

[0031] Figure 13 This is a schematic diagram of a method for manufacturing a media assembly according to one embodiment. Detailed Implementation

[0032] Referring generally to the accompanying drawings, the various embodiments disclosed herein relate to a media assembly for an air filter element and a method of manufacturing the media assembly, wherein the media assembly can have a variety of different unique shapes depending on the desired application and available space. The media assembly is dimensionally flexible and can be manufactured quickly, easily, and cost-effectively in a variety of different shapes and sizes as needed. Furthermore, the media assembly and the method of manufacturing the media assembly described herein are low-cost and efficient, particularly for smaller media assemblies.

[0033] Figures 2A to 3 Different embodiments of a filter element 10 of a filter assembly according to one embodiment are shown. The filter element 10 includes a media assembly 20 and can be used with an engine. The filter element 10 may include other components, such as at least one end plate or end cap positioned along an end of the media assembly 20. The filter element 10 may be positioned within the housing of the filter assembly, for example... Figures 1A to 1B The housing of the filter assembly 90 shown.

[0034] The media assembly 20 includes a media package 30, side plates 40, and a central support 22. Optionally, the media assembly 20 may be a right-angle flow element or include a right-angle flow element through which unfiltered and filtered fluids flow at approximately 90° to each other. As further described herein, the shape and size of the media assembly 20 can be uniquely and easily manufactured according to desired construction.

[0035] Media assembly 20 can be formed into a variety of unique shapes without the need for specialized manufacturing equipment. By having unique media assembly shapes (and being able to easily manufacture media assemblies with various shapes), media assembly 20 can be fitted into a wide range and numerous areas within a filter assembly, and into uniquely shaped filter housings with unusual and distinctive shapes and sizes, depending on the desired application and construction. Media assembly 20 also provides further encapsulation freedom without sacrificing cost or performance. According to one embodiment, media assembly 20 can be fitted around a supercharged air cooler (CAC) pipe. Alternatively or additionally, media assembly 20 can be fitted above the engine and against the cab wall. This flexibility in size and shape can also limit or prevent the use and installation of substandard or counterfeit media assemblies.

[0036] Media package 30 (which may be referred to as media segment) is filter media roll 35 (such as...) Figure 4A The medium package 30 (as shown and further described herein) is a portion of a filter media roll 35 and is formed by the filter media roll 35. The media roll 30 is configured to filter a fluid, such as air, and includes at least one (preferably multiple) layer of filter media 32, wherein the multiple layers of filter media 32 are substantially parallel and concentric with each other. The multiple layers of filter media 32 include an innermost layer 32a and an outermost layer 32b, as shown... Figure 4C As shown. The innermost layer 32a is the first layer of filter media 32 wound into a media roll 35 and defining the inner side 33 of the media package 30. The outermost layer 32b is the last layer of filter media 32 wound into a media roll 35 and defining the outer side 34 of the media package 30. The innermost layer 32a is closer to the central axis 38 (and closer to the central support 22 and / or core 23) in the radial direction than the outermost layer 32b. The innermost layer 32a and the outermost layer 32b follow and have the same curvature (between the two cut sides 31) and have substantially the same axial length (between the two flow surfaces 37). According to different embodiments (where the media package 30 is at least partially curved), the outermost layer 32b is longer than the innermost layer 32a.

[0037] The media package 30 is formed, as further described herein, by winding filter media 32 around a central axis 38 into a media roll 35; and cutting the media roll 35 along at least two cutting lines 14 to form two cut side surfaces 31 (which may be referred to as a first sidewall and a second sidewall). The same media package 30 can include multiple different types of filter media 32 by winding different filter media 32 into the same media roll 35. For example, the filter media 32 within the media package 30 may include a corrugated filter media comprising multiple corrugations, which may include different corrugation heights to provide multiple corrugation heights within the same media package 30.

[0038] like Figures 2B to 3 As shown, each media package 30 (particularly multilayer filter media 32) has and defines two parallel and opposing radially extending flow surfaces 37 through which the fluid to be (or being) filtered flows. The flow surfaces 37 extend radially between an inner side 33 and an outer side 34 along a plane substantially perpendicular to the central axis 38 of the media package 35. One flow surface 37 is an inlet flow surface, and the other is an outlet flow surface. Therefore, fluid flows through the media package 30 in a direction parallel to the central axis 38 (i.e., fluid flows between the two flow surfaces 37 along the axial direction of the media package 30). Optionally, the flow surfaces 37 may be substantially flat and parallel to each other.

[0039] Each media package 30 (particularly multilayer filter media 32) has and defines two flat, radially extending cut edges, cut surfaces, cut ends, or cut sides 31 located at opposite radial ends of the media package 30 and at the points where the media package 30 is cut from the media roll 35 (as further described herein). The first and second cut sides 31 (i.e., the first and second sidewalls) extend axially between two flow surfaces 37, radially between an inner side 33 and an outer side 34, and along a plane substantially parallel to the central axis 38 of the media roll 35. The two cut sides 31 are substantially perpendicular to the two flow surfaces 37 (and optionally also perpendicular to the inner side 33 and the outer side 34). Depending on the relative orientation of the two cut lines 14 forming the two cut sides 31, the cut sides 31 may be parallel to each other or at an angle.

[0040] Each media package 30 (particularly multilayer filter media 32) also includes and defines two arcuate sides: a radially inner surface or inner side 33 and a radially outer surface or outer side 34. The inner side 33 is radially closer to the central axis 38 of the media roll 35 (from which the media package 30 is cut) and is the innermost side of the innermost layer 32a (first layer) of the filter media 32. The outer side 34 is radially away from the central axis 38 of the media roll 35 (from which the media package 30 is cut) and is the outermost side of the outermost layer 32b (last layer) of the filter media 32. If the media package 30 includes a central support 22, the central support 22 extends axially along the inner side 33 (and radially inward from the inner side 33). Both the inner side 33 and the outer side 34 extend axially between the two flow surfaces 37 and between the inner side 33 and the outer side 34. Two cut sides 31 are located at opposite ends of the inner side 33 and the outer side 34. The inner side 33 and the outer side 34 extend axially, substantially parallel to the central axis 38 of the media roll 35. The two cut sides 31, the two flow surfaces 37, the inner side 33 and the outer side 34 form all the outermost sides of the media package 30 (and thus form the overall shape of the media package 30).

[0041] Depending on the embodiment (and depending on how the filter medium 32 is wound into the media roll 35 and where the media roll 35 is cut), the multilayer filter medium 32 is curved around the central axis 38 and forms an arched shape. Therefore, the inner side 33 (of the media package 30 and the innermost layer 32a of the multilayer filter medium 32) and the outer side 34 (of the media package 30 and the outermost layer 32b of the multilayer filter medium 32) each have an arcuate shape (depending on the overall cross-sectional shape of the media roll 35 and the number and positioning of the cutting lines 14), extending axially parallel to each other and sharing a common central axis (i.e., the central axis 38). The shapes of the inner side 33 and the outer side 34 can be matched (where the inner side 33 is smaller than the outer side 34). Because the outer side 34 is wound around the inner side 33, the inner side 33 has a smaller arc length than the outer side 34. Depending on how the medium roll 35 is wound (and the shape of the central support 22 and / or core 23), the inner side 33 and the outer side 34 can have a circular or rounded arc shape (while the cut side 31 can be straight or flat).

[0042] According to one embodiment, filter media 32 may include a variety of different types of filter media, including but not limited to pleated media, corrugated media, tetrahedral media, or variations thereof, such as any filter media disclosed in PCT application No. PCT / US2019 / 065259, the entire contents of which are incorporated herein by reference. U.S. Patent No. 8,397,920 describes a tetrahedral filter media that filter media 32 may include, filed October 14, 2011, and granted March 19, 2013, entitled “PLEATED FILTER ELEMENT WITHTAPERING BEND LINES”, assigned to Cummins Filtration IP, Inc., the entire contents of which are incorporated herein by reference for all purposes. Some configurations of tetrahedral filter media may include multiple inlet tetrahedral flow channels and multiple outlet tetrahedral flow channels. The inlet tetrahedrons merge at the central portion of the tetrahedral filter media, thereby allowing air to flow axially across the inlet tetrahedral channels before passing through the tetrahedral filter media. This arrangement provides additional dust carrying capacity on the upstream side of the medium, which increases the overall dust capacity of the filter.

[0043] The filter medium 32 may include, for example, corrugated, flat, grooved, or pleated filter media. For example, the filter medium 32 may have a pleated arrangement with, for example, arcuate or fan-shaped pleats. Optionally, the filter medium 32 may have deep pleats (which can be used for right-angle flow). The pleats may fan out radially inward or outward, depending on the desired configuration. The multiple layers of filter media 32 within the media roll 35 (and therefore within the media package 30) may be curved in a manner parallel to each other due to how the filter media 32 is wound around itself.

[0044] The filter media disc or roll 35 is filter media 32 rolled up or layered around a central axis 38 before being cut into multiple media packages 30 (as further described herein). Depending on how the media roll 35 is formed by rolling up the filter media 32, the media roll 35 can have various cross-sectional shapes (wherein the cross-section is taken along a plane perpendicular to the axial length of the media roll 35 and the central axis 38). For example, the media roll 35 can have a circular, oblong, elliptical, or rectangular cross-sectional shape. The media roll 35 can be a complete ring. The central axis 38 extends in the axial direction of the media roll 35.

[0045] Depending on the shape of the media roll 35 and how the media roll 35 is cut (as further described herein), the media package 30 can have a variety of different shapes, which allows the media package 30 to be assembled in a variety of different spaces. For example, depending on the desired configuration, the media package 30 can be relatively long or short.

[0046] A first side plate 40 and a second side plate 40 (which may be referred to as end plates) are positioned along and extend substantially parallel to the two side walls (e.g., axially between the inlet flow surface and the outlet flow surface and radially between the inner side 33 (e.g., the inner edge) and the outer side 34 (e.g., the outer edge). Specifically, the first side plate 40 is positioned along and seals the first cut side surface 31 of the media package 30 (i.e., the first side wall) such that fluid entering through the inlet flow surface 37 cannot exit the media package 30 through the first cut side surface 31. The second side plate 40 is positioned along and seals the second cut side surface 31 of the media package 30 (i.e., the second side wall) such that fluid entering through the inlet flow surface 37 cannot exit the media package 30 through the second cut side surface 31. The side plates 40 may be molded or otherwise fixed to the cut end 31 of the media package 30 to ensure that fluid does not escape through the cut end 31. Side plate 40 extends along the entire cut side surface 31, extends axially along the length of the medium package 30 between the two flow surfaces 37, and extends radially between the inner side 33 and the outer side 34. (Example) Figures 2A to 2BAs shown, the media assembly 20 includes two side plates 40 positioned along opposite cut sides 31 of the media package 30. According to one embodiment, the side plates 40 may include gaskets, such as peripheral gaskets. According to different embodiments, the side plates 40 may be polyurethane or a high-modulus sealant (and thus securing the side plates 40 to each cut side 31 includes potting each cut side 31 in polyurethane or a high-modulus sealant).

[0047] The central support 22 is positioned along the inner side 33 of the media package 30. The central support 22 extends between the two cut sides 31 and axially between the two flow surfaces 37. Before being cut with the media roll 35, the central support 22 may be cylindrical or annular. The central support 22 may be, for example, a paper ring, a fiberboard ring, or a polymer ring, and extends directly along the filter media 32 of the media package 30.

[0048] The media assembly 20 (particularly the media package 30) can be configured or shaped into a variety of different shapes and sizes according to desired construction (e.g., the available space within the media assembly 20 within the filter assembly). For example, the media package 30 (and therefore the entire media assembly 20) can have a variety of different arcuate shapes, such as... Figures 2A to 3 As shown. Figures 2A to 2B As shown, the medium package 30 is shaped into approximately 1 / 4 of a circle. (As indicated...) Figure 3 As shown, the medium package 30 is shaped into a circle that is approximately 1 / 2 the size of a circle.

[0049] Figures 4A to 4C , Figures 5A to 5B and Figure 13 A manufacturing process 200 for forming or manufacturing media assembly 20 is illustrated, which allows for the easy production of media packages 30 (and thus media assembly 20) of various shapes and sizes. As further described herein, at 210, filter media 32 is first wound or coiled around a central axis 38 to form a master media roll 35 of filter media 32. At 220, depending on the desired number, shape, and size of the media packages 30, the media roll 35 is then cut along multiple (at least two) cutting lines 14 into multiple (at least two) individual media packages 30 of multiple (at least two) media assemblies 20. This manufacturing process is cost-effective and can produce a large number of media packages 30 of various shapes and sizes as described herein. This manufacturing process reduces the total amount of time required to produce multiple media packages 30. In contrast, stacking multiple layers of filter media into similar shapes to produce individual media packages would present many manufacturing challenges and would not be cost-effective.

[0050] At 210, the filter medium 32 is rolled or wound into a filter medium roll 35 (e.g., Figure 4A , Figure 5A and Figure 13(As shown). The filter medium 32 is wound around a central axis 38 that extends along the axial height of the filter medium roll 35. One type or more different types of filter media 32 can be wound into the same media roll 35, depending on the desired configuration.

[0051] Alternatively, during the manufacturing process, the filter media 32 can be attached to the central support 22 (e.g., Figure 4A (as shown) and / or a reusable internal center winding loop or core 23 (as shown) Figure 5A (As shown) and wound around the central support 22 and / or the inner central winding loop or core 23. The central support 22 and / or core 23 are both positioned within the radial center of the media roll 35 and extend axially along and centered on the central axis 38. The core 23 can be positioned within the central support 22 to provide support for the central support 22. In use, the central support 22 remains attached to the filter media 32 (and can be cut along with the media roll 35), while the core 23 can be removed from the media roll 30. Therefore, the core 23 can be removed from the media roll 35 before cutting, and the central support 22 can be cut within the media roll 35.

[0052] According to one embodiment, the filter medium 32 is attached to and wound around one of the central support 22 or the core 23. A hot melt or adhesive forms a seal between the leading edge of the filter medium 32 and the central support 22 or the core 23. According to another embodiment, the filter medium 32 is attached to the central support 22, and the central support 22 slides or is positioned on the core 23 (i.e., the core 23 is positioned within the central support 22). Thus, the filter medium 32 is wound around the central support 22 and the core 23. By positioning the central support 22 on the core 23 (and radially between the core 23 and the filter medium 32), the central support 22 prevents the hot melt or adhesive from reaching the core 23. According to yet another embodiment, the filter medium 32 is not attached to the central support 22 or the core 23, but is wound around itself.

[0053] The central support 22 and / or core 23 (around which the filter media 32 is wound) can have a variety of different cross-sectional shapes to form the media roll 35 into a desired shape. The media roll 35 has a cross-sectional shape corresponding to that of the central support 22 and / or core 23. According to one embodiment, the central support 22 and / or core 23 (and therefore the media roll 35) has a circular shape (e.g., Figures 5A to 5B As shown), oblong, triangular, square (as shown) Figures 11A to 11B (as shown), elliptical, rectangular (as shown) Figures 12A to 12BThe cross-sectional shape may be pentagonal or hexagonal (as shown in the diagram), where the cross-section is taken along the axial length perpendicular to the central support 22 and the core 23 and along a plane perpendicular to the central axis 38 and corresponding to the flow surface 37. The cross-sectional shape may include any number and variation of arcs and flat and / or curved sides or edges.

[0054] If the cross-sectional shape of the central support 22 and / or the core 23 is square or rectangular, the corners may be rounded (and the media roll 35 has a corresponding shape, such as...). Figures 11A to 12B (As shown). The final shape of the media roll 35 may include straight portions and curved portions (as shown). Figures 12A to 12B (As shown), this depends on how the filter media 32 is wound and the shape of the center support 22 and / or core 23. For example, with a square center support 22 or core 23, four identical media packages 30 can be produced without any waste. Similarly, pentagonal or hexagonal center supports 22 or core 23 can produce five and six identical media packages 30, respectively.

[0055] The filter medium 32 is wound around the central axis 38 multiple times (i.e., any number of times) to produce a multi-layered (i.e., any number of layers) filter medium 32. Therefore, the total length of the filter medium 32 (and the thickness of the filter medium 32) determines the outer radius of the media roll 35 (and thus the size of the media bundle 30 between the inner side 33 and the outer side 34). Therefore, by using filter medium 32 with longer or shorter lengths, the size of the media bundle 30 (particularly the radial distance between the inner side 33 and the outer side 34) can be easily adjusted during manufacturing. Additionally, the outer diameter of the central support 22 and / or the core 23 sets or determines the inner diameter of the central hole of the media roll 35 (through which the central axis 38 extends). Once the filter medium 32 is wound into the media roll 35, a hot melt or adhesive can form a seal between the trailing edge of the filter medium 32 and the outermost layer 32b (top layer) of the filter medium 32.

[0056] Optionally, the heat-melting of the filter media 32 can be skipped along the area where the cutting is performed. Additionally, small waste portions can be incorporated to eliminate start and stop points. The media roll 35 may be wound with recesses.

[0057] At 220 (e.g.) Figure 4B , Figure 5B and Figure 13As shown), after the filter media 32 has been wound into a media roll 35, a cutting device cuts the filter media roll 35 along at least two cutting lines 14, creating at least two slits and cutting it into at least two individual segments or pieces that form at least two individual media packages 30. The media roll 35 is cut along at least one plane parallel to the central axis 38 and parallel to the flow direction through the media package 30 (and substantially perpendicular to the radial plane of the filter media roll 35). Each cutting line 14 extends along a plane parallel to the central axis 38. Figure 5A As shown, the media roll 35 can be cut along arrow 12 (i.e., along each cutting line 14). Each cut may extend only through one or both sides of the media roll 35 (i.e., on opposite sides of the central axis 38, thereby forming two separate cutting lines 14 that are radially aligned with each other and form a straight line). Optionally, after the filter media roll 35 has been cut, the filter media roll 35 can be cooled and any debris from the cut can be removed.

[0058] Various cutting devices can be used to cut the filter media roll 35 (i.e., to form the cutting lines 14 in the filter media roll 35). For example, depending on the embodiment, a sharp edge or a laser can be used to cut the media roll 35. Optionally, the media roll 35 can be cut by the same person who wound the filter media 32 into the media roll 35. Optionally, the media roll 35 can be rotated by a certain degree to form each cut.

[0059] Depending on the desired size, shape, and quantity of media packages 30, any number, angle, and position of cuts can be formed in the media roll 35 to form any number, shape, and size of media packages 30. Depending on the position of the cut lines 14, the resulting cut media packages 30 (from the same media roll 35) can be identical or different in shape and / or size, depending on the desired configuration of the media packages 30. At least two cuts are formed in the media roll 35 along at least two cut lines 14 to form or produce at least two media packages 30 from a single media roll 35. Therefore, multiple media packages 30 can be formed or produced from a single media roll 35, which reduces manufacturing costs compared to conventional methods of manufacturing media packages. The cut lines 14 can be straight or curved.

[0060] according to Figure 6 and Figures 12A to 12B In the various embodiments shown, a total of two cuts are formed along two cutting lines 14 (approximately 180° apart), thereby cutting the media roll 35 in half and effectively producing two media packages 30. Alternatively, the two cutting lines 14 may be aligned with each other and extend through the central axis 38, thereby producing two identical media packages 30. The two media packages 30 may be semicircular or substantially semicircular (e.g., ...). Figure 6(As shown), and the two cut sides 31 can be potted simultaneously or simultaneously or form a seal with the side plate 40 (as further described herein). This method produces unique shapes faster and more economically than currently produced shapes. In particular, a single through cut (which creates two aligned cut lines 14 on opposite sides of the central axis 38) can be formed quickly and easily, and a single potting sequence replaces two separate mold and potting tasks.

[0061] According to various other embodiments, at least three cuts are formed along three cutting lines 14, thereby producing at least three media packets 30. Figure 4B and Figures 11A to 11B In one embodiment shown, a total of four cuts are formed along four cutting lines 14 (separated from each other by approximately 90°), thereby producing four media packages 30. The media roll 35 can be cut and rotated in 90° increments to produce four individual media packages 30. According to... Figure 5B In another embodiment shown, a total of eight cuts are formed along eight cutting lines 14 (separated from each other by approximately 45°), thereby producing eight individual media packages 30. The media roll 35 can be cut and rotated in 45° increments to produce eight media packages 30.

[0062] The cutting lines 14 may be aligned with each other on opposite sides of the central axis 38 or may not be aligned with each other on opposite sides of the central axis 38, depending on the desired cutting scheme and construction of the medium package 30. For example, according to various embodiments (such as... Figures 5B to 6 , Figure 11A and Figures 12A to 12B As shown), one or more cutting lines 14 may extend through the central axis 38, thereby avoiding the generation of any debris. Two cutting lines 14 may be aligned with each other (in a single line), extending straight through the central axis 38 and on opposite sides of the central axis 38. In the resulting medium package 30, the cut sides 31 may be angled relative to each other (e.g., Figures 8A to 8B (As shown).

[0063] According to various other embodiments, one or more cutting lines 14 may not extend through the central axis 38, and cutting lines 14 on opposite sides of the central axis 38 may not be aligned with each other (e.g., Figure 11B As shown). Depending on the orientation of the cutting line 14, the cut sides 31 in the resulting medium package 30 can be substantially parallel to each other (as shown). Figure 9 (As shown).

[0064] Depending on the number and relative positions of the cuts (and the size and shape of the media roll 35), media packages 30 of different sizes and shapes can be produced. Therefore, various media packages 30 of different shapes and sizes can be easily generated or produced from a single media roll 35, and the dimensions of the media package 30 can be easily changed according to desired construction and size. For example, as... Figure 7 As shown, the arc length along the outer side 34 of the medium package 30 varies depending on the angle θ and the distance between the cut side 31. Figure 8A A medium package 30 with a relatively small arc length and angle θ is shown, while Figure 8B A media package 30 with a relatively large arc length and angle θ is shown. Furthermore, the inner diameter R1 and outer diameter R2 vary depending on the shape and size of the media roll 35, as well as the quantity and thickness of the filter media 32 (and the central support 22 and / or core 23). The radial distance between the inner side 33 and the outer side 34 depends on the thickness and number of layers of the filter media 32.

[0065] The media package 30 can have a variety of different arcuate shapes, depending on the original shape of the media roll 35 and how the media roll 35 is cut. According to one embodiment, the media package 30 is an annular segment, compared to the cubic or cylindrical shape of a conventional in-line filter element. While the media package 30 can have a variety of different shapes and sizes, according to different embodiments, the inner side 33 and the outer side 34 can be at least partially curved or arcuate.

[0066] After the media package 30 has been cut from the media roll 35, the media package 30 may optionally be expanded to different radial thicknesses to change the capacity and limit of the media package 30 (without changing the corrugation height of the filter media 32). To expand the media package 30, the multiple layers of filter media 32 may be further radially spaced apart from each other.

[0067] At 230 (e.g.) Figure 4C and Figure 13 As shown), after the media package 30 has been cut from the media roll 35 and optionally expanded, the side plates 40 are secured to each cut side surface 31 of the media package 30. According to one embodiment, the media package 30 is either side-filled with the side plates 40 or the media package 30 is side-filled into the side plates 40, thereby forming a media assembly 20. Specifically, as... Figure 4C As shown, side plates 40 are positioned and attached to each of the two cut sides 31 of the media pack 30 (extending along the two cut lines 14 that form and define the media pack 30). Each side plate 40 forms a seal with one of the two cut sides 31 of at least two media packs 30. The side plates 40 may each extend along the entire axial and radial length of the media pack 30 (along a plane extending parallel to the central axis 38) and along the entire cut side 31 of the media pack 30.

[0068] Once the media assembly 20 has been produced, multiple media assemblies 20 (or individual media packages 30) can be easily combined and attached together without any additional processing. The media assemblies 20 (especially the media packages 30) can be attached together in various different ways and relative orientations to form a variety of different overall shapes. Optionally, these shapes can have complex opposing curvatures that would not normally be produced by simple winding and / or cutting methods. For example, as... Figure 10A As shown, two media assemblies 20 (specifically two media packets 30) are positioned adjacent to each other (and optionally abut and attach to each other), wherein their cut sides 31 face each other (and optionally abut and attach to each other). The two media packets 30 face opposite directions (i.e., the inner side 33 of one media packet 30 is close to the outer side 34 of the other media packet 30, and vice versa), thereby forming an S-shape between the two media packets 30. Figure 10B In another embodiment shown, two media assemblies 20 (in particular two media packets 30) are positioned adjacent to each other (and optionally adjacent to and attached to each other), wherein the inner side 33 of one media packet 30 is adjacent to and faces the outer side 34 of the other media packet 30 (and optionally adjacent to and attached to each other). Thus, the two media packets 30 are stacked on top of each other.

[0069] At 240 (e.g.) Figure 13 As shown, media assembly 20 (alone or in combination with other media assemblies 20) is attached to, positioned within, and mounted within the frame. Media assembly 20 may include various gaps or gapped segments to be mounted to the frame. According to one embodiment, multiple media assemblies 20 may be potted or attached to each other within the same frame. A seal may be formed between the multiple media assemblies 20 and the frame. The multiple media assemblies 20 (within a single frame) may be identical or different from each other (e.g., in shape and size) and may be oriented relative to each other to produce a variety of different configurations. After the media assemblies 20 have been attached together and / or attached to the frame, the media assembly 20 (alone or in combination with other media assemblies 20) may be used or positioned within the filter housing of the filter assembly.

[0070] Due to the construction of the media assembly 20, the filter element inherently possesses anti-warping properties and provides a natural dust collection pool as a pre-cleaner. For example, one advantage of the curved shape (e.g., annular segment shape) of the media pack 30 is that the shape of the housing (in which the media pack 30 is used) can therefore include corresponding arched or curved sidewalls, which are inherently stronger and less prone to warping than flat housing walls. Therefore, the housing can have shallower support ribs (compared to a housing with flat housing walls), which reduces the overall packaging volume and housing material cost. Additionally, in off-highway applications, the downward-facing arched surfaces of the media pack 30 (i.e., the inner side 33 or the outer side 34, as further described herein) can be used to create a dust collection pool that naturally guides dust to a dust drain valve.

[0071] The media roll 35 described herein is tightly coiled and wound. Furthermore, a seal is formed along the two cut sides 31 of the media package 30 obtained from the media roll 35, without the need for any additional coiling operation to form a seal along the second cut side 31 (as further described herein).

[0072] Each of the various embodiments disclosed herein may have any aspect, feature, component, and construction of other embodiments, unless otherwise stated.

[0073] As used herein, the term "about" and similar terms are intended to have a broad meaning consistent with common and acceptable usage by those skilled in the art to which the subject matter of this disclosure relates. The term "about" as used herein means ±5% of a reference measurement, position, or dimension. Those skilled in the art who read this disclosure will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the range of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or irrelevant modifications or alterations to the described and claimed subject matter are considered to be within the scope of the invention as set forth in the appended claims.

[0074] As used herein, the terms “joint” and “attachment” mean that two components are directly joined to each other. Such a joint can be fixed (e.g., permanent) or movable (e.g., removable or releasable).

[0075] References to the location of elements (e.g., "top", "bottom", etc.) herein are used only to describe the orientation of the various elements in the accompanying drawings. It should be noted that the orientation of the various elements may differ according to other exemplary embodiments, and such variations are intended to be covered by this disclosure.

[0076] It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. While only a few embodiments are described in detail in this disclosure, those skilled in the art will readily understand that numerous modifications are possible (e.g., variations in the size, scale, structure, shape, and proportion of various elements, parameter values, mounting arrangements, use of materials, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described herein. For example, the positions of elements may be reversed or otherwise varied, and the nature, number, or position of discrete elements may be altered or changed. According to alternative embodiments, the order or sequence of any processes may be changed or reordered. Other substitutions, modifications, alterations, and omissions may also be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of the invention.

Claims

1. A method of manufacturing a media pack, the method comprising: winding a filter media around a central axis into a media roll; and cutting the media roll into at least two media packs of at least two media assemblies along at least two cutting lines, the media roll being cut along at least one plane parallel to the central axis, wherein the at least two cutting lines extend radially between an inner side and an outer side of the media roll.

2. The method of claim 1, further comprising: fixing a side plate to one of the two cut ends of one of the at least two media packs.

3. The method of claim 1, further comprising: mounting the at least two media packs into a frame.

4. The method of claim 1, further comprising: potting the at least two media packs so as to form a sealing member on at least one cut side of the at least two media packs.

5. The method of any one of claims 1 to 4, further comprising: attaching the media pack to a second media pack to form an S-shape.

6. The method of any one of claims 1 to 4, wherein, the media roll is cut such that the at least two cutting lines are aligned with each other and extend through the central axis, thereby resulting in at least two identical media packs.

7. The method of any one of claims 1 to 4, wherein, the media roll is cut using a laser.

8. A media pack, the media pack comprising: a media pack comprising a plurality of layers of filter media, the media pack defining an inlet flow face, an outlet flow face, a first side wall, a second side wall, a radially inner edge, and a radially outer edge, the first and second side walls each extending axially between the inlet and outlet flow faces and radially between the radially inner and outer edges; a first side plate positioned along the first side wall and forming a seal with the first side wall such that fluid entering through the inlet flow face cannot exit the media pack through the first side wall; and a second side plate positioned along the second side wall and forming a seal with the second side wall such that fluid entering through the inlet flow face cannot exit the media pack through the second side wall, the media pack being formed by winding the filter media around a central axis into a media roll and cutting the media roll along at least two cutting lines to form the first and second side walls, wherein the at least two cutting lines extend radially between an inner side and an outer side of the media roll.

9. The media assembly of claim 8, wherein, the plurality of layers of filter media are curved around the central axis and form an arc shape.

10. The media assembly of claim 8, wherein, the plurality of layers of filter media comprise an innermost layer and an outermost layer, the innermost layer defining the radially inner edge of the media pack, the outermost layer defining the radially outer edge of the media pack.

11. The media assembly of claim 8, wherein, the plurality of layers of filter media comprise an innermost layer and an outermost layer, the outermost layer having the same axial length and curvature as the innermost layer, the innermost layer defining the radially inner edge of the media pack, the outermost layer defining the radially outer edge of the media pack.

12. The media pack of any one of claims 8 to 11, further comprising a central support extending axially over the media roll and configured to support the media roll.

13. The media assembly of claim 12, wherein, the media pack is positioned proximate a second media pack such that the radially inner edge of the media pack is attached to a radially outer edge of the second media pack.

14. The media assembly of claim 12, wherein, After the media pack has been cut out, the multiple layers of filter media are spaced further apart radially from each other so as to increase the radial thickness of the media pack.

15. The media assembly of claim 12, wherein, The formed media roll is a square with rounded corners such that when the media roll is cut a plurality of identical media packs are formed.

16. A filter element, the filter element comprising: a media pack comprising multiple layers of filter media, the media pack defining an inlet flow face, an outlet flow face, a first side wall, a second side wall, a radially inner edge, and a radially outer edge, the first side wall and the second side wall each extending axially between the inlet flow face and the outlet flow face and radially between the radially inner edge and the radially outer edge; a first side panel positioned along the first side wall and forming a seal with the first side wall such that fluid entering through the inlet flow face cannot exit the media pack through the first side wall; and a second side panel positioned along the second side wall and forming a seal with the second side wall such that fluid entering through the inlet flow face cannot exit the media pack through the second side wall, the media pack is formed by winding the filter media around a central axis into a media roll; and cutting the media roll along at least two cutting lines to form the first side wall and the second side wall, wherein the at least two cutting lines extend radially between an inner side and an outer side of the media roll. the media pack is formed by winding the filter media around a central axis into a media roll; and cutting the media roll along at least two cutting lines to form the first side wall and the second side wall, wherein the at least two cutting lines extend radially between an inner side and an outer side of the media roll.

17. The filter element of claim 16, wherein, the multiple layers of filter media include an innermost layer and an outermost layer that is longer than the innermost layer, the innermost layer defining the radially inner edge of the media pack, the outermost layer defining the radially outer edge of the media pack.

18. The filter element of claim 16, wherein, 19. The filter element of any of claims 16 to 18, wherein: the first side panel is positioned such that the first side panel extends axially along an entire length of the first side wall; and the second side panel is positioned such that the second side panel extends axially along an entire length of the second side wall. the formed media roll comprises a circular segment.

20. The filter element of any of claims 16-18, wherein, the media pack is formed by winding the filter media around a central axis into a media roll; and cutting the media roll along at least two cutting lines to form the first side wall and the second side wall, wherein the at least two cutting lines extend radially between an inner side and an outer side of the media roll.

Images