Filter assembly with alignment features

Abstract

A filter assembly includes a filter element and a housing assembly. The filter element includes filter media and a frame. The housing assembly houses the filter media and includes a housing base and a housing cover. The housing base includes a base end portion, and the housing cover includes a cover end portion. The frame is secured to and encloses at least an outer periphery of the filter media. The frame is positionable axially between and attachable to the housing base and the housing cover such that the frame engages the base end portion and the cover end portion and a seal is formed between at least one of the housing base and the housing cover and the frame.

Description

[0001] Cross-reference to related applications This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 108,568, filed November 2, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] This application generally relates to filter assemblies for use in air intake systems, etc. Background Technology

[0003] In thermal under-hood applications, various conventional polymer housings 190 (such as...) Figure 1 (As shown) They are widely used in air filter assemblies. In-line flow filters require a large flow area to minimize confinement. However, these large, open polymer housings 190 tend to warp, making it difficult to maintain the air filter assembly and hindering the alignment of the sealing interface of the housing 190 (leading to leakage). Summary of the Invention

[0004] Various embodiments provide a filter assembly including a filter element and a housing assembly for receiving a filter medium. The filter element includes the filter medium and a frame. The housing assembly includes a housing base and a housing cover. The housing base includes a base end portion, and the housing cover includes a housing end portion. The frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positioned between the housing base and the housing cover and is attachable to the housing base and the housing cover such that the frame engages with the base end portion and the cover end portion, and a seal is formed between the frame and at least one of the housing base and the housing cover.

[0005] Various embodiments provide a filter assembly, the filter assembly comprising: Filter element, the filter element including filter media and frame; and A housing assembly for accommodating the filter element, the housing assembly including a housing base and a housing cover, the housing base including a base end portion and the housing cover including a cover end portion. The frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positioned between the housing base and the housing cover and is attached to the housing base and the housing cover such that the frame engages with the end portions of the base and the end portions of the cover, and a seal is formed between at least one of the housing base and the housing cover and the frame.

[0006] In some embodiments, the frame includes a plurality of extensions that align the frame with at least one of the housing base and the housing cover.

[0007] In some embodiments, at least one of the housing base and the housing cover includes an attachment wall corresponding to and aligned with the plurality of extensions of the frame.

[0008] In some embodiments, a portion of the plurality of extensions extends axially along at least a portion of the outer periphery of at least one of the housing base or the housing cover.

[0009] In some embodiments, a portion of the plurality of extensions extends axially along at least a portion of the inner periphery of at least one of the housing base or the housing cover.

[0010] In some embodiments, the attachment wall of at least one of the housing base and the housing cover includes a plurality of positioning features, a first subset of the plurality of positioning features including an inward recess portion, and a second subset of the plurality of positioning features having an outward recess portion, the plurality of positioning features being configured to interlock with the plurality of extensions.

[0011] In some embodiments, the plurality of extensions includes at least one of an axially extending inner extension and an axially extending outer extension, such that at least one of the axially extending inner extension and the axially extending outer extension is intermittently positioned along the flange of the frame.

[0012] In some embodiments, the frame includes at least one alignment rib extending circumferentially around the frame, the alignment rib aligning at least one of the housing base and the housing cover with the frame.

[0013] In some embodiments, at least one of the housing base and the housing cover includes a lip that extends radially outward from an axial end of the at least one of the housing base and the housing cover to abut the inner wall of the frame.

[0014] Various embodiments provide a filter element including a filter medium and a frame fixed to and surrounding at least the outer periphery of the filter medium. The frame is axially positioned between a housing base and a housing cover of a housing assembly and is attachable to the housing base and housing cover of the housing assembly such that the frame engages with a base end portion of the housing base and a cover end portion of the housing cover, the filter medium is accommodated within the housing assembly, and a seal is formed between at least one of the housing base and the housing cover and the frame.

[0015] In some embodiments, the frame includes a plurality of extensions that align the frame with at least one of the housing base and the housing cover.

[0016] In some embodiments, the frame includes a flange extending radially and circumferentially around the outer periphery of the filter medium, the flange including a plurality of extensions including at least one of an axially extending inner extension and an axially extending outer extension, such that at least one of the axially extending inner extension and the axially extending outer extension is intermittently positioned along the flange.

[0017] In some embodiments, the plurality of extensions extend axially above and axially below the flange.

[0018] In some embodiments, a seal is formed by a gasket engaging at least one of the housing base and the housing cover with the frame, the gasket being positioned and extending radially along the flange between the inner surfaces of the plurality of extensions.

[0019] In some embodiments, the gasket includes a first portion on a first side of the flange and a second portion on a second side of the flange, the first side of the flange being opposite to the second side of the flange, the first portion of the gasket being configured to form a seal between the frame and the housing base, and the second portion of the gasket being configured to form a seal between the frame and the housing cover.

[0020] Various embodiments provide a filter assembly, the filter assembly comprising: A filter element, the filter element comprising a filter medium and a frame, the frame being fixed to and surrounding at least the outer periphery of the filter medium; and A housing assembly for accommodating the filter element, the housing assembly comprising: A housing base, the housing base including a base end portion; The housing cover includes a housing end portion; Fasteners; and A fastener support component, the fastener support component being connected to at least one of the housing base and the housing cover; The frame is axially positioned between the housing base and the housing cover and is attached to the housing base and the housing cover.

[0021] In some embodiments, the fastener support member includes an attachment tab extending radially from the outer surface of at least one of the housing base and the housing cover, the attachment tab including a recess receiving at least one of a first axial end and a second axial end of the fastener to secure the fastener to the attachment tab.

[0022] In some embodiments, the filter assembly further includes a frame fastener support member, the frame fastener support member including a support tab extending radially outward from the outer surface of the frame, the support tab axially supporting the attachment tab when the frame, the housing base and the housing cover are joined together.

[0023] In some embodiments, the fastener includes a first axial end and a second axial end, and wherein the fastener support member includes a fastening support arm extending radially outward on the outer surface of at least one of the housing base and the housing cover, the fastening support arm including a notch, at least one of the first axial end and the second axial end of the fastener being fixed in the notch to facilitate rotation of the fastener.

[0024] In some embodiments, the housing base includes a base fluid port and the housing cover includes a cover fluid port, the base fluid port and the cover fluid port facilitating fluid inflow and outflow from the filter assembly.

[0025] Various embodiments provide a filter assembly including a filter element and a housing assembly for receiving a filter medium. The filter element includes the filter medium and a frame. The frame is fixed to and surrounds at least the outer periphery of the filter medium. The housing assembly includes a housing base, a housing cover, fasteners, and fastener support members. The housing base includes a base end portion, and the housing cover includes a housing end portion. The fastener support members are coupled to at least one of the housing base and the housing cover. The frame is axially positioned between the housing base and the housing cover and is attachable to the housing base and the housing cover.

[0026] These and other features, as well as their organization and operation, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which the same elements have the same reference numerals throughout the several drawings described below. Attached Figure Description

[0027] Figure 1 This is a perspective view of a standard filter housing.

[0028] Figure 2A This is a perspective view of a filter assembly according to one embodiment.

[0029] Figure 2B yes Figure 2A The side view of the filter component.

[0030] Figures 3A to 3B This is a perspective view of a filter element according to various embodiments.

[0031] Figure 4 yes Figure 2A An exploded view of the filter assembly (excluding the filter media).

[0032] Figure 5 yes Figure 2A A perspective view of the base of the housing of the filter assembly.

[0033] Figure 6 yes Figure 2A A perspective view of the housing cover of the filter assembly.

[0034] Figure 7A yes Figure 2A A perspective view of the frame of the filter component.

[0035] Figure 7B yes Figure 2A A cross-sectional view of a portion of the frame and a portion of the housing assembly of the filter assembly.

[0036] Figure 8 yes Figure 2A A cross-sectional view of a portion of the filter assembly.

[0037] Figure 9 yes Figure 2A A cross-sectional view of a portion of the filter assembly.

[0038] Figure 10 This is a cross-sectional view of a portion of a filter assembly according to another embodiment.

[0039] Figure 11 This is a cross-sectional view of a portion of a filter assembly according to yet another embodiment.

[0040] Figure 12 This is a cross-sectional view of a portion of a filter assembly according to yet another embodiment.

[0041] Figure 13 This is a perspective view of a filter assembly according to another embodiment.

[0042] Figure 14 yes Figure 13 An exploded view of the filter assembly (excluding the filter media).

[0043] Figures 15A to 15B yes Figure 13 A perspective view of the frame of the filter component.

[0044] Figure 16 yes Figure 13 A cross-sectional view of a portion of the frame of the filter assembly and a portion of the housing assembly.

[0045] Figure 17 yes Figure 13 A cross-sectional view of a portion of the filter assembly. Detailed Implementation

[0046] Referring generally to the accompanying drawings, the various embodiments disclosed herein relate to filter assemblies including filter elements and housing assemblies. The filter element includes a filter medium and a frame. The configuration of the frame and housing assembly ensures alignment and sealing of the filter element and housing assembly to prevent leakage and warping of the filter assembly. The frame is positioned and configured as an intermediate structure axially positioned between the housing base and the housing cover.

[0047] exist Figures 2A to 2B The image shows a filter assembly 110 according to one embodiment. The filter assembly 110 includes a housing assembly 112 and a filter element 160, which can be attached to various guiding and positioning features as further described herein. The filter assembly 110 can be used to filter fluids such as air. For reference, the axial direction refers to the direction substantially parallel to the fluid flow through the housing assembly 112 and the filter element 160. The radial direction refers to the direction substantially perpendicular to the fluid flow through the housing assembly 112.

[0048] The configuration of filter assembly 110 helps protect and retain filter element 160, improves the ease of maintenance of filter assembly 110, forms an improved seal to prevent leakage, and can be used with a variety of different filter elements utilizing axial seals. Furthermore, the size and volume of filter assembly 110 (particularly housing assembly 112) are minimized, and a variety of different fastening methods and styling options can be used.

[0049] The housing assembly 112 is configured to accommodate or contain the filter element 160 and includes a housing body or base 120 (e.g., Figure 5 (as shown) and housing cover 140 (as shown) Figure 6(As shown). Housing base 120 and housing cover 140 are positioned along opposite sides or axial ends of filter element 160 (with frame 180 of filter element 160 (as described elsewhere herein) located between them). Housing base 120 includes a base fluid port 121, and housing cover 140 includes a cover fluid port 141. One of the base fluid port 121 or cover fluid port 141 is an inlet fluid port, and the other of the base fluid port 121 or cover fluid port 141 is an outlet fluid port. Thus, unfiltered fluid flows into housing assembly 112 of filter assembly 110 through one of the base fluid port 121 or cover fluid port 141 and flows through filter media 162 (to be filtered by filter element 160), and filtered fluid flows out of housing assembly 112 of filter assembly 110 through the other of the base fluid port 121 or cover fluid port 141. Optionally, the housing base 120 and / or housing cover 140 may include various fasteners, such as eccentric latches (e.g., as shown in the image). Figure 13 (As shown), clips or through bolts are used to secure the housing assembly 112 together. The cross-sectional shape of the housing assembly 112 (along a radially extending plane), and the filter element 160, may be substantially elliptical.

[0050] The housing base 120 defines a base opening 123, and the housing cover 140 defines a cover opening 143. One or both of the base opening 123 and / or cover opening 143 are substantially the same in shape and size as (and optionally larger than) the first flow surface 164 and the second flow surface 165 of the filter medium 162 (as otherwise described herein), thereby maximizing the flow area within the housing assembly 112 and allowing the entire filter medium 162 to be fitted within the housing assembly 112 (where at least a portion of the axial flow length of the filter medium 162 is fitted within the housing base 120 and / or housing cover 140). The base fluid port 121 may be directly opposite the base opening 123, and the cover fluid port 141 may be directly opposite the cover opening 143, thereby allowing fluid to flow directly in one direction between the base fluid port 121 and the cover fluid port 141 and between the base opening 123 and the cover opening 143 (while flowing through at least a portion of the filter medium 162 between the base fluid port 121 and the cover fluid port 141 and between the base opening 123 and the cover opening 143).

[0051] like Figures 3A to 3BAs shown, filter element 160 includes filter medium 162 and at least one frame 180 (e.g., an air filter sealing frame). Filter element 160 (specifically filter medium 162) can be fully positioned within at least a portion of housing assembly 112 (e.g., at least partially positioned within housing base 120). Filter medium 162 is configured to filter fluid (e.g., air), and filter medium 162 has and defines: a first flow surface 164 and a second flow surface 165 that are substantially opposite to each other and extend radially, through which the fluid to be filtered (or being filtered) flows; and a sidewall 166 that extends axially between the first flow surface 164 and the second flow surface 165 and circumferentially surrounds the middle portion of filter medium 162 (through which the filtered fluid flows).

[0052] The first flow surface 164 and the second flow surface 165 extend radially along substantially parallel radially extending planes, which are substantially perpendicular to the direction of fluid flow through the filter medium 162 and the sidewall 166. One of the first flow surface 164 or the second flow surface 165 is an inlet flow surface (through which unfiltered fluid flows), and the other is an outlet flow surface (through which filtered fluid flows). Therefore, fluid flows axially through the filter medium 162 between the first flow surface 164 and the second flow surface 165. The first flow surface 164 and the second flow surface 165 may optionally be substantially flat and parallel to each other, and have substantially the same dimensions. However, the filter medium 162 may have other shapes in which the first flow surface 164 and the second flow surface 165 are not parallel to each other or have different dimensions.

[0053] like Figures 3A to 3B As shown, the filter medium 162 can be attached to or encapsulated in the frame 180, such that the frame 180 is fixed to and at least surrounds the outer periphery (particularly the sidewall 166) of the filter medium 162. The frame 180 can be positioned along the axial end of the filter medium 162 (e.g., along the first flow surface 164 or the second flow surface 165) and / or along the sidewall 166 of the filter medium 162. The filter element 160 may include one frame 180 or multiple frames 180. According to... Figures 3A to 3B In one embodiment shown, filter element 160 includes a second frame 182 (in addition to the first frame 180). The second frame 182 may have the same or different configuration as the first frame 180. For example, the second frame 182 may or may not be a sealing frame. The second frame 182 may optionally be positioned along the axial end of the filter medium 162 opposite to the first frame 180.

[0054] Frame 180 may extend axially along only a portion of the axial length or the entire axial length of the filter medium 162. As further described herein, frame 180 may be directly aligned with both housing base 120 and housing cover 140, may be positioned between housing base 120 and housing cover 140, and may be attached to both housing base 120 and housing cover 140 such that a seal is formed between at least one of housing base 120 and housing cover 140 and frame 180. Because frame 180 is axially positioned between housing base 120 and housing cover 140, frame 180 axially separates housing base 120 and housing cover 140 and is an intermediate structure axially positioned between housing base 120 and housing cover 140. Frame 180 defines a frame opening 183 in which at least a portion of the filter medium 162 is positioned and secured. Frame 180 may optionally extend axially above and / or below a first flow surface 164 or a second flow surface 165 of the filter medium 162.

[0055] Figure 4 An exploded view of the housing base 120, housing cover 140, and frame 180 is shown, all of which are attachable together. The frame 180 is axially positioned between the housing base 120 and housing cover 140 (in the axial flow direction through the housing assembly 112). Therefore, the top portion of the housing base 120 is directly attached to and engaged with the bottom portion of the frame 180 (along the base opening 123), and the bottom portion of the housing cover 140 is directly attached to and engaged with the top portion of the frame 180 (along the cover opening 143). The housing base 120 and housing cover 140 are each attached to and engaged with the frame 180 (the frame 180 being an intermediate structure axially positioned between the housing base 120 and housing cover 140), but are not directly attached or engaged together. Therefore, the filter assembly 110 cannot be assembled until the filter element 160 (specifically the frame 180) is installed. Specifically, if the frame 180 is not in place (axially between the housing base 120 and the housing cover 140), the housing base 120 and the housing cover 140 cannot be assembled together. Because the frame 180 interlocks with the housing base 120 and the housing cover 140 (as described separately herein), the configuration of the filter assembly 110 prevents the use of inappropriate filter elements. In contrast, in various conventional filter assemblies, the frame can be inserted into the housing body (rather than being axially positioned between the housing body and the cover), and / or a compression sealing gasket (rather than the frame) can separate the housing body and the cover.

[0056] When the frame 180, the housing base 120, and the housing cover 140 are attached together, the base opening 123, the cover opening 143, and the frame opening 183 are axially aligned with each other (e.g., Figure 8(As shown). The housing base 120, housing cover 140, and frame 180 each include various guiding and positioning features (as further described herein) for alignment and attachment with each other. At least one gasket device 150 (as further described herein) forms a seal between the housing base 120 and the frame body 181 of the frame 180, and between the housing cover 140 and the frame 180. As further described herein, a portion of the frame 180 (i.e., the outer extension 188b) (e.g., a first subset, a second subset, etc.) extends axially along at least a portion of the outer periphery of the housing base 120 and the housing cover 140, and a portion of the frame 180 (i.e., the inner extension 188a) (e.g., a first subset, a second subset, etc.) extends axially along at least a portion of the inner periphery of the housing base 120 and the housing cover 140 (e.g., as shown herein). Figure 8 (As shown).

[0057] like Figure 2B and Figure 5 As shown, the housing base 120 includes a radially extending base end wall 124, an axially extending base side wall or main wall 125, and a base end portion 122. The base end portion 122 includes a radially extending base boss or lip 127, an axially extending base attachment wall 129, and a base axial edge or end 126. The base end wall 124 extends along a radially extending plane substantially parallel to a first flow surface 164 or a second flow surface 165 of the filter medium 162. A base fluid port 121 may extend through and be defined by the base end wall 124. The base end wall 124 is positioned along one axial end of the base main wall 125 (and the base lip 127 is positioned along the other axial end of the base main wall 125). The base main wall 125 and the base attachment wall 129 extend along an axial direction (substantially parallel to the sidewall 166 of the filter medium 162) and circumferentially surround and define the base opening 123. At least a portion of the axial length of the filter medium 162 (i.e., along the sidewall 166) may be circumferentially surrounded by the base main wall 125 and the base attachment wall 129. The base end wall 124 and the base end portion 122 are positioned along the axially opposite ends of the base main wall 125. Alternatively, if the base end portion 122 does not include the base lip 127, the base end portion 122 may include a portion of the base main wall 125.

[0058] A base lip 127 extends radially outward from the axial end of the base main wall 125. The base main wall 125 is positioned along and extends from the inner radial end of the base lip 127, and a base attachment wall 129 is positioned along and extends from the outer radial end of the base lip 127. The base main wall 125 and the base attachment wall 129 extend axially from the base lip 127 in opposite axial directions. The base attachment wall 129 of the housing base 120 (which is an alignment and positioning feature of the housing base 120) extends axially from the outer radial end of the base lip 127 and defines an axial end (e.g., a tip) of the housing base 120. Therefore, the cross-sectional area defined and surrounded by the base attachment wall 129 is larger than the cross-sectional area defined and surrounded by the base main wall 125 (sectioned along a radially extending plane substantially perpendicular to the flow direction through the housing assembly 112). A base axial end 126 is positioned along one axial end of the base attachment wall 129 (opposite to the axial end of the base attachment wall 129 closer to the base main wall 125). The base axial end 126 may be a first axial end, and a portion of the base end wall 124 or the base fluid port 121 may be a second axial end, wherein the first and second axial ends are positioned along opposing axial ends of the housing base 120. The base axial end 126 defines a base opening 123.

[0059] The base attachment wall 129 of the housing base 120 includes a plurality of base guiding and positioning features (i.e., a plurality of base indentation portions 128a and a plurality of base outdentation portions 128b) surrounding the entire circumferential length or periphery of the base attachment wall 129, such as Figure 5 As shown. The base recessed portion 128a is positioned radially inward relative to the base outer recessed portion 128b (and the base outer recessed portion 128b is positioned radially outward relative to the base recessed portion 128a). The base recessed portion 128a and the base outer recessed portion 128b are alternately positioned around the circumferential length of the base attachment wall 129, such that the inner and outer surfaces of the base attachment wall 129 are intermittently stepped radially inward and radially outward around the entire length of the base attachment wall 129. The base recessed portion 128a and the base outer recessed portion 128b can extend continuously (e.g., attached to each other along their axial length), such that the base attachment wall 129 extends continuously around the periphery of the housing base 120. The base recessed portion 128a and the base outer recessed portion 128b are configured to interlock with the inner extension 188a and the outer extension 188b of the frame 180 (as otherwise described herein), wherein the inner extension 188a and the outer extension 188b are alternately positioned on opposite sides of the base attachment wall 129.

[0060] like Figure 2B and Figure 6As shown, the housing cover 140 includes a radially extending cover end wall 144, an axially extending cover side wall or main wall 145, and a cover end portion 142. The cover end portion 142 includes a radially extending cover boss or lip 147, an axially extending cover attachment wall 149, and an axial edge or end 146. The cover end wall 144 extends along a radially extending plane substantially parallel to a first flow surface 164 and a second flow surface 165 of the filter medium 162. A cover fluid port 141 may extend through and be defined by the cover end wall 144. The cover end wall 144 is positioned along one axial end of the cover main wall 145 (and the cover lip 147 is positioned along another axial end of the cover main wall 145). The cover main wall 145 and the cover attachment wall 149 extend in an axial direction (substantially parallel to the side wall 166 of the filter medium 162) and circumferentially surround and define a cover opening 143. At least a portion of the axial length of the filter medium 162 (i.e., along the sidewall 166) may be circumferentially surrounded by the cap main wall 145 and the cap attachment wall 149. The cap end wall 144 and the cap end portion 142 are positioned along the opposing axial ends of the cap main wall 145. Alternatively, if the cap end portion 142 does not include the cap lip 147, the cap end portion 142 may include a portion of the cap main wall 145.

[0061] The cover lip 147 extends radially outward from the axial end of the cover main wall 145. The cover main wall 145 is positioned along and extends from the inner radial end of the cover lip 147, and the cover attachment wall 149 is positioned along and extends from the outer radial end of the cover lip 147. The cover main wall 145 and the cover attachment wall 149 extend axially from the cover lip 147 in opposite axial directions. The cover attachment wall 149 of the housing cover 140 (which is an alignment and positioning feature of the housing cover 140) extends axially from the outer radial end of the cover lip 147 and defines the axial end (e.g., the bottom portion) of the housing cover 140. Therefore, the cross-sectional area defined and enclosed by the cover attachment wall 149 is larger than the cross-sectional area defined and enclosed by the cover main wall 145 (sectioned along a radially extending plane substantially perpendicular to the flow direction through the housing assembly 112). The axial end 146 of the cover is positioned along one axial end of the cover attachment wall 149 (opposite to the axial end of the cover attachment wall 149 closer to the main cover wall 145). The axial end 146 may be a first axial end, and a portion of the cover end wall 144 or the cover fluid port 141 may be a second axial end, wherein the first and second axial ends are positioned along opposite axial ends of the housing cover 140. The axial end 146 defines a cover opening 143.

[0062] The cover attachment wall 149 of the housing cover 140 includes a plurality of guiding and positioning features (i.e., a plurality of inner cover recesses 148a and a plurality of outer cover recesses 148b) surrounding the entire circumferential length or periphery of the cover attachment wall 149, such as Figure 6 As shown. The inner recessed portion 148a is positioned radially inward relative to the outer recessed portion 148b (and the outer recessed portion 148b is positioned radially outward relative to the inner recessed portion 148a). The inner recessed portion 148a and the outer recessed portion 148b are alternately positioned about the circumferential length of the cover attachment wall 149, such that the inner and outer surfaces of the cover attachment wall 149 are intermittently stepped radially inward and radially outward about the entire length of the cover attachment wall 149. The inner recessed portion 148a and the outer recessed portion 148b can extend continuously (e.g., attached to each other along their axial length), such that the cover attachment wall 149 extends continuously about the periphery of the housing cover 140. The inner recessed portion 148a and the outer recessed portion 148b of the cover are configured to interlock with the inner extension 188a and the outer extension 188b of the frame 180 (as described elsewhere herein), wherein the inner extension 188a and the outer extension 188b are alternately positioned on opposite sides of the cover attachment wall 149.

[0063] like Figures 7A to 8 As shown, frame 180 includes a frame body 181 and a gasket assembly 150 (as described elsewhere herein). The frame body 181 is constructed as a single piece and comprises a single integrated integral component that cannot be separated without damage. The frame body 181 of frame 180 may be a polymer support frame. The frame body 181 of frame 180 includes an axially extending inner wall 185 and radially extending bosses, lips, or flanges 187, each of which extends circumferentially around the outer periphery of filter media 162. Inner tabs, ribs, or walls 185 extend axially along the outer surface of filter media 162 (substantially parallel to the sidewalls 166 of filter media 162) (as shown). Figure 8 As shown), and circumferentially surrounds and defines the frame opening 183. At least a portion of the axial length of the filter medium 162 (i.e., along the sidewall 166) may be circumferentially surrounded by the inner wall 185. The inner wall 185 may extend axially above and below the flange 187 (as further described herein and in...). Figure 17 (as shown in the diagram), or it can be positioned along only one axial side of flange 187 and extend from that axial side (as shown in the diagram). Figure 8 (As shown in the diagram). Specifically, one axial end of the inner wall 185 is positioned along and extends axially from the inner radial end of the flange 187. The other axial end of the inner wall 185 abuts against the inner surface of either the base lip 127 or the cover lip 147, depending on the configuration of the filter assembly (e.g., ...). Figure 8(As shown). Flange 187 extends radially outward from inner wall 185, and optionally extends from an axial end of inner wall 185. Inner wall 185 may be positioned along only one or both axial sides of flange 187. Flange 187 is axially positioned between base attachment wall 129 and cap attachment wall 149.

[0064] like Figures 7A to 7B As shown, the frame body 181 of the frame 180 also includes multiple guiding and positioning features (i.e., multiple axially extending inner tabs or extensions 188a and multiple axially extending outer tabs or extensions 188b) that are intermittently positioned along the flange 187 and align the frame 180 with the housing base 120 and / or the housing cover 140. The inner extensions 188a are radially inwardly positioned relative to the outer extensions 188b (and the outer extensions 188b are radially outwardly positioned relative to the inner extensions 188a). The inner extensions 188a and outer extensions 188b are alternately positioned about the circumferential length or periphery of the flange 187. Figure 7A As shown, the inner extension 188a and the outer extension 188b extend axially above and below the flange 187, respectively. Each extension has a first portion or axial end along one axial side of the flange 187 and a second portion or axial end along the other axial side of the flange 187. The inner extension 188a and the outer extension 188b (along the circumferential length or periphery of the flange 187) are circumferentially spaced apart from each other and radially spaced (outwardly spaced) from the inner wall 185 to provide space for receiving the gasket device 150 (as otherwise described herein). Furthermore, the inner extension 188a and the outer extension 188b extend substantially parallel to the axial direction of the inner wall 185. According to another embodiment, the inner extension 188a and the outer extension 188b may be connected to each other along their sides and extend continuously around the entire periphery of the frame body 181 of the frame 180 and the housing assembly 112 (and the base inner recess portion 128a and the base outer recess portion 128b, as well as the cover inner recess portion 148a and the cover outer recess portion 148b, may be alternately spaced apart from each other).

[0065] The inner extension 188a and the outer extension 188b prevent the filter assembly 110 from warping by, for example, guiding (and retaining) long, unsupported sections of the housing base 120 and housing cover 140 into place. Specifically, the inner extension 188a pushes and guides the warped housing base 120 and the warped housing cover 140 radially outward and into place, while the outer extension 188b pulls and guides the warped housing base 120 and the warped housing cover 140 radially inward and into place, thereby preventing or reducing warping in both the radially inward and radially outward directions.

[0066] The inner extension 188a and the outer extension 188b are configured to correspond to and interlock with the base attachment wall 129 and the cover attachment wall 149 of the housing base 120 and the housing cover 140 (specifically, the base inner recess portion 128a, the base outer recess portion 128b, the cover inner recess portion 148a, and the cover outer recess portion 148b), wherein the inner extension 188a and the outer extension 188b are alternately positioned on opposite sides of the base attachment wall 129 and the cover attachment wall 149. The dimensions, number, and relative positioning of the inner extension 188a and the outer extension 188b, as well as the base inner recess portion 128a, the base outer recess portion 128b, the cover inner recess portion 148a, and the cover outer recess portion 148b, correspond and complement each other to cooperate and interlock. The base recess 128a and base outer recess 128b of the housing base 120 are directly aligned and interlocked with the first axial ends of the inner extension 188a and outer extension 188b of the frame 180 (not the housing cover 140). Similarly, the cover inner recess 148a and cover outer recess 148b of the housing cover 140 are directly aligned and interlocked with the second axial ends of the inner extension 188a and outer extension 188b of the frame 180 (not the housing base 120).

[0067] like Figure 2A and Figures 7B to 8 As shown, when the housing base 120 and housing cover 140 are attached to the frame 180, the frame 180 is axially positioned between and attached to the housing base 120 and housing cover 140. The frame 180 is configured to engage with the base end portion 122 of the housing base 120 and the cover end portion 142 of the housing cover 140. For example, according to various embodiments, the axial end portion 126 of the base may engage with a first surface of the flange 187 of the frame body 181, and / or the axial end portion 146 of the cover may engage with a second surface (opposite to the first surface) of the flange 187 of the frame body 181, such as... Figure 8 As shown. Alternatively or additionally, the axial ends (or opposite axial ends) of the inner wall 185 of the frame body 181 may engage with the inner surfaces of the base lip 127 and / or the inner surfaces of the cover lip 147, as shown. Figure 8 As further illustrated below. Alternatively or additionally, the axial end (or the opposite axial end) of the gasket assembly 150 may engage (and form a seal with) the inner surface of the base lip 127 and / or the inner surface of the cap lip 147, as shown below. Figure 8 As further illustrated. Alternatively or additionally, the axial end 126 of the base may engage (and seal therewith) the first axial end of the gasket assembly 150, and / or the axial end 146 of the cover may engage (and seal therewith) the second axial end of the gasket assembly 150 (opposite to the first axial end), as shown below. Figure 17 As shown and described elsewhere in this document.

[0068] like Figure 2A and Figures 7B to 8 As shown, when the housing base 120 is attached to the frame 180, the base attachment wall 129 and the base axial end 126 of the housing base 120 extend along each of the inner extension 188a and the outer extension 188b and are radially positioned and accommodated between each of the inner extension 188a and the outer extension 188b. Specifically, the base attachment wall 129 meanders between the first axial end of the inner extension 188a and the first axial end of the outer extension 188b. The inner extension 188a of the frame 180 is positioned and extends along the inner surface of the base outer recess portion 128b of the base attachment wall 129 of the housing base 120, and the outer extension 188b of the frame 180 is positioned and extends along the outer surface of the base inner recess portion 128a of the base attachment wall 129 of the housing base 120, thereby interlocking the frame 180 and the housing base 120 together. The base outer recess portion 128b of the base attachment wall 129 extends along the front radial outer surface of the inner extension portion 188a, and the base inner recess portion 128a of the base attachment wall 129 extends along the rear radial inner surface of the outer extension portion 188b.

[0069] like Figure 2A and Figures 7B to 8 As shown, when the housing cover 140 is attached to the frame 180, the cover attachment wall 149 and the cover axial end 146 of the housing cover 140 extend along each of the inner extension 188a and the outer extension 188b and are radially positioned and accommodated between each of the inner extension 188a and the outer extension 188b. (Although) Figure 7B The housing base 120 and frame 180 are shown, but the housing cover 140 can be attached to the frame 180 in the same or similar manner (along the opposite axial side of the frame 180). Specifically, the cover attachment wall 149 meanders between the second axial ends of the inner extension 188a and the outer extension 188b. The inner extension 188a of the frame 180 is positioned and extends along the inner surface of the outer recess portion 148b of the cover attachment wall 149 of the housing cover 140, and the outer extension 188b of the frame 180 is positioned and extends along the outer surface of the inner recess portion 148a of the cover attachment wall 149 of the housing cover 140, thereby interlocking the frame 180 and the housing cover 140 together. The outer recess portion 148b of the cover attachment wall 149 extends along the front radial outer surface of the inner extension 188a, and the inner recess portion 148a of the cover attachment wall 149 extends along the rear radial inner surface of the outer extension 188b.

[0070] like Figure 2B and Figure 7AAs shown, the axial heights of the inner extension 188a and the outer extension 188b vary around the circumferential length or periphery of the flange 187 to gradually and smoothly align the frame 180 with the housing base 120 and the housing cover 140. The heights of the inner extension 188a and the outer extension 188b can gradually increase or decrease around the circumferential length or periphery of the flange 187. The inner extension 188a and the outer extension 188b are shortest along the region of the filter assembly 110 most prone to warping (i.e., along the center of the longest straight wall). Specifically, the inner extensions 188a and 188b along the rounded ends or shorter sides of the frame body 181 of the frame 180 (corresponding to regions of the filter assembly 110 with low or no warp) are higher or longer relative to the axial direction than the inner extensions 188a and 188b along the straight or longer sides of the frame body 181 of the frame 180 (corresponding to regions of the filter assembly 110 prone to more warp). According to one embodiment, the shortest extension 191 and the longest extension 193 are... Figure 7A The longer inner extension 188a and the longer outer extension 188b engage with the base attachment wall 129 of the housing base 120 and the cover attachment wall 149 of the housing cover 140 before the shorter inner extension 188a and the shorter outer extension 188b (along a region having low warp or no warp) and extend around or along the base attachment wall 129 of the housing base 120 and the cover attachment wall 149 of the housing cover 140.

[0071] Due to the interlock between the frame 180 and both the housing base 120 and the housing cover 140, unsuitable filter elements (including, for example, various non-genuine filter elements) cannot be used for mounting with either the housing base 120 or the housing cover 140. Furthermore, this interlock ensures that the frame 180 (and therefore the entire filter element 160) is properly aligned with the housing base 120 and the housing cover 140, forming a complete seal. Without the frame 180 (which forms a seal with both the housing base 120 and the housing cover 140), the housing base 120 and the housing cover 140 cannot together form a proper seal.

[0072] like Figure 8As shown, frame 180 also includes a sealing gasket assembly, for example, in the form of a gasket device 150. Due to the relative configuration of gasket device 150 and frame body 181 of frame 180, gasket device 150 will be in a proper sealing position if housing base 120 or housing cover 140 can engage with frame body 181 of frame 180 (i.e., if the correct housing base 120 or housing cover 140 is attached to frame 180). Gasket device 150 allows housing base 120, housing cover 140, and filter element 160 to form a tight seal together, while still being aligned together and allowing gasket device 150 to extend outward. Depending on the desired configuration, the axial ends of gasket device 150 may be rounded and / or flattened.

[0073] At least a portion of the gasket assembly 150 (e.g., a second portion 152) is positioned and extends radially along the flange 187 (above and / or below the flange 187) between the radially inner surfaces of the inner extension 188a and the outer extension 188b and the sidewall 166 of the filter medium 162. Depending on the configuration of the gasket assembly 150, at least a portion of the gasket assembly 150 (e.g., a first portion 151) may extend along the radially outer periphery or surface of the inner wall 185 of the frame body 181 and the radially inner surfaces of the inner extension 188a and the outer extension 188b, and be radially positioned between the radially outer periphery or surface of the inner wall 185 of the frame body 181 and the radially inner surfaces of the inner extension 188a and the outer extension 188b. The gasket assembly 150 may extend continuously around the entire outer periphery of the filter element 160. The axial ends or edges of the housing base 120 and housing cover 140 (along the recessed portion 128a of the base and the recessed portion 148a of the cover, respectively) are radially positioned between the inner wall 185 and the outer extension 188b, and can directly abut against the opposite axial surface of the flange 187.

[0074] like Figure 8 As shown, the washer assembly 150 includes a first section or portion 151 and a second section or portion 152 positioned along opposite sides of the flange 187. According to one embodiment (e.g., as shown in the figure), Figure 9 As shown), the washer assembly 150 includes a washer 153 comprising both a first portion 151 and a second portion 152. Thus, the flange 187 defines at least one hole 186 extending axially through the flange 187, and the washer 153 extends through the at least one hole 186 and along both sides of the flange 187. According to another embodiment, the washer assembly 150 may include only one washer 153, which is positioned only along one axial side of the flange 187 (and there is no washer 153 on the other axial side of the flange 187). According to another embodiment (e.g., as shown), the washer assembly 150 includes a washer 153 positioned along only one axial side of the flange 187 (and there is no washer 153 on the other axial side of the flange 187). According to another embodiment (e.g., as shown), the washer assembly 150 includes a washer 153 comprising both a first portion 151 and a second portion 152. Figure 8As shown, the washer assembly 150 includes two separate washers 153, which are separately attached to opposite axial sides of the flange 187 of the frame body 181, wherein the first washer 153 is a first portion 151 and the second washer 153 is a second portion 152. The first washer 153 may be a lower washer and the second washer 153 may be an upper washer.

[0075] A first portion 151 of the gasket assembly 150 forms a seal between the frame body 181 of the frame 180 and the housing base 120. Specifically, the first portion 151 extends axially between the bottom surface (i.e., the first axial side) of the flange 187 of the frame body 181 and the top inner surface of the base lip 127 of the housing base 120, forming an axial seal between the two. A second portion 152 of the gasket assembly 150 forms a seal between the frame body 181 and the housing cover 140. Specifically, the second portion 152 extends axially between the top surface (i.e., the second axial side) of the flange 187 of the frame body 181 and the bottom inner surface of the cover lip 147 of the housing cover 140, forming an axial seal between the two.

[0076] The gasket assembly 150 can be molded from polyurethane foam (optionally molded separately). The first part 151 and the second part 152 can be molded together or separately.

[0077] According to various embodiments, the washer device 150 may protrude through the frame body 181 or may not protrude through the frame body 181. For example, according to one embodiment (e.g., as shown in the figure below), Figure 9 As shown, the flange 187 of the frame body 181 may define at least one axially extending open through-hole or aperture 186 to allow a gasket device 150 (particularly polyurethane) to be blow-molded between the two axial sides of the flange 187 and extend through the frame body 181, and optionally until it abuts against and reaches the outer surface (e.g., sidewall 166) of the filter medium 162. However, according to various embodiments, the gasket device 150 may be adhered to the outer surface or sidewall 166 of the filter medium 162 or may not be adhered to the outer surface or sidewall 166 of the filter medium 162. According to various embodiments, the frame body 181 may be adhered to the filter medium 162 separately from the gasket device 150, or optionally may be attached to the filter medium 162 by the gasket device 150.

[0078] Figures 9 to 12 Various embodiments of the washer assembly 150 are shown. According to various embodiments (see, for example...), Figure 9The washer assembly 150 extends axially between the lower inner surface of the cap lip 147 and the upper inner surface of the base lip 127. Therefore, the axial height H of the entire washer assembly 150 (including both the first portion 151 and the second portion 152) can be approximately 40-60 mm. The radial width W of the washer assembly 150 (along the base 154) can be approximately 4-10 mm. Therefore, in a particular embodiment, the ratio of the height H to the width W of the washer assembly 150 can be in the range of approximately 4 to 15, and typically approximately 6 to 8.

[0079] The gasket assembly 150 extends at least along the axial height of the frame body 181 and is relatively long and narrow (based on the ratio of the height H to the width W of the gasket assembly 150) to allow the gasket assembly 150 to compress more with less force. Due to its relatively long length, the gasket assembly 150 provides a high compression range to form a seal with warped portions and prevent leakage. The percentage that the gasket assembly 150 can compress is limited and controlled. Due to its relatively narrowness, the gasket assembly 150 helps to minimize the overall size and volume of the filter assembly 110.

[0080] The first part 151 and the second part 152 each include a base 154 extending axially directly from the top or bottom surface of the flange 187. For example... Figure 9 As further shown, the first portion 151 and the second portion 152 also include extensions 156 extending axially from the base 154 (in an axial direction away from the flange 187). The extensions 156 are radially narrower than the base 154 to define recesses 157 along the radial side of the extensions 156 of the first portion 151 or the second portion 152. Using the two extensions 156 along the top and bottom of the washer assembly 150, the washer assembly 150 defines two recesses 157 (i.e., one recess on the top of the washer assembly 150 and one recess on the bottom of the washer assembly 150). The recess 157 on the bottom of the washer assembly 150 provides an area for the poured polyurethane to accumulate. Both the top recess 157 and the bottom recess 157 provide space for compression of the extensions 156. The radially inner side of the extensions 156 can be offset from the radially inner side of the base 154, such that the recesses 157 are positioned along the radially inner side of the extensions 156.

[0081] According to one embodiment, the radial width or thickness T of the extension 156 is approximately 2 to 8 mm, and the axial length R of the extension 156 (and therefore the axial length of the recess 157) is approximately 2 to 30 mm. The thickness T of the extension 156 is small enough to limit the outward increase in the size of the extension 156, but large enough to create a sufficient sealing area.

[0082] According to such Figure 10In another embodiment shown, the first portion 151 and the second portion 152 do not include any extension 156 (and therefore no recess 157). Instead, the base 154 extends along the entire length of the first portion 151 and the second portion 152. Thus, the first portion 151 and the second portion 152 have a constant width W along their axial length, and the thickness T is equal to the width W.

[0083] According to such Figure 11 In another embodiment shown, only one of the first portion 151 and the second portion 152 includes an extension 156 (and the resulting recess 157). The base 154 of the other of the first portion 151 and the second portion 152 extends along the entire length of the other of the first portion 151 and the second portion 152 (such that the other of the first portion 151 and the second portion 152 has a constant width W in its axial length).

[0084] According to such Figure 12 In another embodiment shown, the gasket assembly 150 includes only one of the first portion 151 and the second portion 152 (which may or may not include the extension 156 and the resulting recess 157). The gasket assembly 150 may exclude either the first portion 151 or the second portion 152, or may include only a portion of the axial length of the other of the first portion 151 and the second portion 152 (such that the other of the first portion 151 and the second portion 152 does not extend axially fully between the flange 187 and the base lip 127 of the housing base 120 or the cover lip 147 of the housing cover 140). Thus, the gasket assembly 150 forms a seal between one of the housing base 120 and the housing cover 140 and the frame body 181, but does not form a seal between the other of the housing base 120 or the housing cover 140 and the frame body 181. Figure 12 An example is shown in which the washer assembly 150 includes only a portion of the axial length of a first portion 151 and a second portion 152. Specifically, in Figure 12 In this embodiment, the axial length of the second portion 152 is significantly smaller than the axial length of the first portion 151. For example, the axial length of the second portion 152 may be less than half the axial length of the first portion 151. The second portion 152 does not extend all the way to the cover lip 147 of the housing cover 140. Therefore, Figure 12 The gasket assembly 150 forms a seal between the frame body 181 and the housing base 120, but does not form a seal between the frame body 181 and the housing cover 140.

[0085] According to various embodiments, a seal may be formed between the top of the housing base 120 and the bottom of the housing cover 140. However, according to various embodiments, if a seal is not required between the frame 180 and the housing cover 140, a notch may be included along the axial length of the second portion 152 of the gasket assembly 150.

[0086] exist Figures 13 to 17 Another filter assembly 210 according to another embodiment is shown in the figure. Any aspect, feature, component, advantage, and configuration of filter assembly 110 and filter assembly 210 may be used in another of filter assembly 110 and filter assembly 210 unless otherwise stated. Similar reference numerals are used for filter assembly 210 where applicable. As otherwise described herein, filter assembly 210 includes housing assembly 112 (including housing base 120 and housing cover 140) and filter element 160 (including frame 180 and filter media 162).

[0087] like Figure 13 As shown, the filter assembly 210 includes at least one fastener 230 configured to lock the housing base 120, filter element 160, and housing cover 140 together. Although the fastener 230 is shown as an eccentric latch, it can be other types of fasteners, including but not limited to another type of latch, clip, or through bolt. According to one embodiment, the filter assembly 210 includes four fasteners 230 positioned around the filter assembly 210.

[0088] To provide attachment areas for the fastener 230 and the housing base 120, the housing base 120 further includes a base fastener support member 222, the frame body 181 of the frame 180 further includes a frame fastener support member 282, and the housing cover 140 further includes a cover fastening support member 242 (e.g., Figure 14 (As shown). The base fastener support member 222, frame fastener support member 282, and cap fastening support member 242 together allow the fastener 230 to clamp the filter assembly 210 together. According to one embodiment, one of the base fastener support member 222 and the cap fastening support member 242 rotatably secures a first axial end of the fastener 230 to the housing base 120 or the housing cap 140, regardless of whether the fastener 230 is currently clamping the rest of the filter assembly 210 together. For example, one of the base fastener support member 222 and the cap fastening support member 242 may be a fastening support arm 223. The fastening support arm 223 includes a notch. Figure 14 As shown, the base fastener support member 222 of the housing base 120 is a fastening support arm 223, which is configured to rotatably secure the first axial end of the fastener 230 via a notch.

[0089] Another of the base fastener support member 222 and the cover fastening support member 242 includes an attachment lip or tab 243 extending radially outward from the outer surface of the housing base 120 or the housing cover 140, respectively. The attachment tab 243 includes a notch such that the attachment tab 243 is configured to be received and secured by the second axial end of the fastener 230 (opposite to the first axial end).

[0090] The fastener support member 282 of the frame 180 includes a support tab 283 configured to axially support one side of the attachment tab 243 when the housing base 120, the frame 180, and the housing cover 140 are clamped together. The support tab 283 extends radially outward from the outer surface of the frame body 181 of the frame 180, particularly from the radially outer surface of the flange 187 of the frame body 181. The support tab 283 is positioned in a gap 289 between two alignment ribs 288 (as described separately herein). When the filter assembly 210 is assembled, the support tab 283 is axially clamped between the base fastener support member 222 and the cover fastening support member 242.

[0091] The base fastener support member 222, frame fastener support member 282, and cover fastener support member 242 are complementary to each other and are axially aligned with each other around the periphery of the filter assembly 210. The base fastener support member 222, frame fastener support member 282, and cover fastener support member 242 are positioned along and extend radially from the outer periphery of the housing base 120, frame 180, and housing cover 140 so that the fastener 230 is positioned along the outside of the housing base 120, frame 180, and housing cover 140. The housing base 120, frame 180 and housing cover 140 may each include a plurality of base fastener support members 222, a plurality of frame fastener support members 282 and a plurality of cover fastener support members 242. The plurality of base fastener support members 222, the plurality of frame fastener support members 282 and the plurality of cover fastener support members 242 are spaced apart around the periphery of the housing base 120, the frame 180 and the housing cover 140 and can be axially aligned with each other.

[0092] To clamp the filter assembly 210 together, the housing base 120, frame 180, and housing cover 140 are positioned and nested together, and fastener 230 is subsequently rotated (around a notch in fastening support arm 223, which is one of the base fastener support member 222 and the cover fastening support member 242) to position the second axial end of fastener 230 over and around attachment tab 243 (i.e., the other of the base fastener support member 222 and the cover fastening support member 242). Fastener 230 is also simultaneously positioned around support tab 283 (i.e., fastener support member 282). Fastener 230 can then be snapped or pushed radially inward and axially toward fastening support arm 223, pulling attachment tab 243 axially toward support tab 283 and fastening support arm 223 (and thereby clamping housing base 120, frame 180, and housing cover 140 together).

[0093] like Figures 15A to 15B As shown, instead of having alternating single inner extensions 188a and single outer extensions 188b (as otherwise described herein), the frame body 181 of the frame 180 may include at least one axially extending positioning or alignment extension, tab, or rib 288 (also referred to as an outer wall), which is a guiding and positioning feature of the frame body 181 of the frame 180. The alignment rib 288 is configured to align the frame 180 with the housing base 120 and / or the housing cover 140.

[0094] like Figure 17 As shown, alignment ribs 288 extend axially from flange 187 (and are axially located above and below flange 187). Specifically, each alignment rib 288 includes a first portion 271 (located below flange 187 and extending axially from one axial side of flange 187) and a second portion 272 (located above flange 187 and extending axially from the other opposite axial side of flange 187). The first portion 271 and the second portion 272 of alignment rib 288 may optionally not be axially aligned with each other, but may at least partially be axially offset from each other.

[0095] Alignment ribs 288 may extend and surround the entire circumferential length or periphery of the frame body 181 of frame 180. Alternatively, the frame body 181 of frame 180 may include a plurality of alignment ribs 288 that together extend and surround a large portion of the periphery of frame body 181. At least a portion of each alignment rib 288 (particularly the second portion 272) is circumferentially spaced apart or separated from each other by at least one circumferential gap 289 corresponding (in size and position) to at least one fastener 230. The first portion 271 of each alignment rib 288 may extend continuously (without any gaps) around the entire circumferential length of the periphery of frame body 181. Thus, the gap 289 does not extend axially along the entire axial length of the alignment rib 288 (but rather axially along at least a portion of the length of the second portion 272). Alignment ribs 288 extend along areas of frame body 181 that do not originally correspond to fasteners 230. Each gap 289 provides an area for the fastener 230 to extend between and clamp the base fastener support member 222 and the cover fastener support member 242. The fastener support member 282 is positioned within the gap 289 to align with the base fastener support member 222 and the cover fastener support member 242.

[0096] Each alignment rib 288 extends continuously around the outer periphery of the frame body 181 at a constant radial position (relative to the inner wall 185) and has a smooth inner surface and a smooth outer surface along the outer periphery of the frame body 181 (without notches or including any radially inward or outward portions). The alignment ribs 288 are radially spaced (outwardly spaced) from the inner wall 185 (along the length of the flange 187) to provide space for receiving the gasket assembly 150 (as described separately herein). Additionally, the alignment ribs 288 extend axially substantially parallel to the inner wall 185. Each alignment rib 288 extends circumferentially at a constant radial distance from the inner wall 185, both along its own circumferential length and relative to the other alignment ribs 288.

[0097] like Figure 17 As shown, the inner wall 185 extends axially above and below the flange 187. Therefore, the inner wall 185 includes a first portion (located below the flange 187 and extending axially from one axial side of the flange 187) and a second portion (located above the flange 187 and extending axially from the other axial side of the flange 187). The first and second portions of the inner wall 185 may not be axially aligned with each other, but may be at least partially axially offset from each other. Figure 17 As further shown, the axial height of the inner wall 185 (along each axial side of the flange 187) may be approximately equal to or longer than the axial height of the alignment rib 288 (along one axial side of the flange 187).

[0098] like Figure 14 As shown, instead of having a base recessed portion 128a, a base outer recessed portion 128b, a cover inner recessed portion 148a, and a cover outer recessed portion 148b (as otherwise described herein), the base attachment wall 129 of the housing base 120 and the cover attachment wall 149 of the housing cover 140 each extend continuously around the outer periphery of the housing base 120 and the housing cover 140 at constant radial positions (relative to the base main wall 125 and the cover main wall 145). The base attachment wall 129 and the cover attachment wall 149 each have a smooth inner surface and a smooth outer surface (without a notch or including any radially inward or outward portions) along the outer periphery of the housing base 120 and the housing cover 140, respectively. The housing base 120 and the housing cover 140 may or may not include a base lip 127 and a cover lip 147, respectively. For example, as Figure 17 As shown, the base attachment wall 129 of the housing base 120 is axially aligned with the base main wall 125 and is part of the base main wall 125. The cover attachment wall 149 of the housing cover 140 is partially axially offset from the cover main wall 145, thereby having a shortened cover lip 147.

[0099] like Figures 16 to 17 As shown, when the frame 180 is attached to the housing base 120 and the housing cover 140, the axial end 126 of the base attachment wall 129 of the housing base 120 and the axial end 146 of the cover attachment wall 149 of the housing cover 140 (the axial end 126 of the base and the axial end 146 of the cover) are located at... Figure 17 (As shown in the diagram) it is positioned and radially accommodated between the alignment rib 288 and the inner wall 185. (Although...) Figure 16 A housing cover 140 attached to frame 180 is shown, but housing base 120 can be attached to frame 180 in the same or similar manner (along the opposite axial sides of frame 180). Therefore, alignment ribs 288 and inner walls 185 together prevent filter assembly 210 from warping by, for example, moving portions of housing base 120 and housing cover 140 into place. Specifically, alignment ribs 288 pull and guide the warped housing base 120 and warped housing cover 140 radially inward and into place, while inner walls 185 push and guide the warped housing base 120 and warped housing cover 140 radially outward and into place, thereby preventing or reducing warping in both the radially inward and radially outward directions.

[0100] According to such Figures 15A to 15BIn one embodiment, alignment ribs 288 extend from flange 187 at a constant, uniform axial distance or height along the circumferential length of flange 187 (and along both axial sides of flange 187) of the entire length of alignment rib 288. Furthermore, each alignment rib 288 extends with the same axial height relative to each other. However, according to another embodiment, the axial height of alignment ribs 288 may vary or be tilted (i.e., gradually increase or decrease) around the circumferential length or periphery of flange 187, such that each alignment rib 288 has a different axial height and / or a different axial height along its own circumferential length. This configuration allows for easier assembly of filter assembly 210 by gradually and smoothly aligning frame 180 with housing base 120 and housing cover 140.

[0101] like Figure 16 As shown, the shortest axial portion 291 of the alignment rib 288 runs along the center of a straight or longer side of the frame body 181 of the frame 180 (which corresponds to the area of ​​the filter assembly 210 that is prone to maximum warping). The longest axial portion 292 of the alignment rib 288 runs along the center of a rounded or circular end or a shorter side of the frame body 181 of the frame 180 (which corresponds to the area of ​​the filter assembly 210 that has low warping or no warping). During assembly, the longest portion 292 of the alignment rib 288 engages (along the area with low warping or no warping) before the shortest portion 291 of the alignment rib 288 and extends around or along the base attachment wall 129 of the housing base 120 and the cover attachment wall 149 of the housing cover 140.

[0102] like Figure 17 As shown, frame 180 includes a gasket assembly 150 (as otherwise described herein). The gasket assembly 150 is radially positioned between the inner wall 185 and the alignment rib 288 and axially positioned above and / or below the flange 187. However, instead of extending axially between the flange 187 and the base lip 127 or the cover lip 147 (as otherwise described herein), the gasket assembly 150 extends between the flange 187 and the axial end 126 of the base of the housing base 120 or the housing cover 140, forming a seal (the gasket assembly 150 may also be radially positioned between the inner wall 185 and the alignment rib 288). This configuration forms a seal between the axial end 126 of the base of the housing base 120, the gasket 153, and one axial side of the flange 187, and a seal between the axial end 146 of the cover 140, the gasket 153, and the other axial side of the flange 187. The axial ends of the housing base 120 and the housing cover 140 may optionally be axially offset from each other.

[0103] Each of the various embodiments disclosed herein may have any aspect, feature, component, benefit, and configuration of other embodiments, unless otherwise stated.

[0104] As used herein, the terms “about,” “substantially,” and similar terms are intended to have a broad meaning consistent with the general and acceptable usage of those skilled in the art to which the subject matter of this disclosure pertains. The terms “about” and “substantially” as used herein refer to ±5% of a referenced measurement, location, or dimension. Those skilled in the art who have reviewed 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 values ​​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.

[0105] As used herein, the terms “joint”, “attachment”, etc., refer to two components that are directly joined together. Such a joint can be fixed (e.g., permanent) or movable (e.g., removable or releasable).

[0106] References to the position 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 included in this disclosure.

[0107] It is worth noting that the construction and arrangement of the various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those skilled in the art upon reviewing this disclosure will readily recognize that many modifications (e.g., variations in the size, dimensions, structure, shape and proportion of various elements, values ​​of parameters, installation arrangements, use of materials, color, orientation, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter described herein. For example, the position of elements may be reversed or otherwise altered, and the nature or number of discrete elements or positions may be changed or varied. According to alternative embodiments, the order or sequence of any process may be changed or reordered. Other substitutions, modifications, variations, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the invention.

Claims

1. A filter assembly, comprising: A filter element, the filter element comprising a filter medium and a frame, the frame comprising a plurality of extensions around its entire circumferential length; as well as A housing assembly for accommodating the filter element, the housing assembly including a housing base and a housing cover, the housing base including a base end portion and the housing cover including a cover end portion, wherein at least one of the housing base and the housing cover includes a plurality of positioning features around its entire circumferential length. The frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positionable between the housing base and the housing cover and is attachable to the housing base and the housing cover such that the frame engages with the end portions of the base and the cover, and the plurality of positioning features interlock with the plurality of extensions, forming a seal between at least one of the housing base and the housing cover and the frame. The plurality of extensions includes an axially extending inner extension and an axially extending outer extension, the axially extending inner extension and the axially extending outer extension being alternately positioned along the flange of the frame, and The plurality of positioning features include an inner notch portion and an outer notch portion.

2. The filter assembly according to claim 1, wherein, The attachment wall of at least one of the housing base and the housing cover corresponds to and is aligned with the plurality of extensions of the frame.

3. The filter assembly according to claim 1, wherein, A portion of the plurality of extensions extends axially along at least a portion of the outer periphery of at least one of the housing base or the housing cover.

4. The filter assembly according to claim 1, wherein, A portion of the plurality of extensions extends axially along at least a portion of the inner periphery of at least one of the housing base or the housing cover.

5. The filter assembly according to claim 2, wherein, The attachment wall includes the plurality of positioning features, the plurality of positioning features of the attachment wall including a first subset of the plurality of positioning features of the attachment wall and a second subset of the plurality of positioning features of the attachment wall, the first subset of the plurality of positioning features of the attachment wall including the recessed portion, and the second subset of the plurality of positioning features of the attachment wall having the external recessed portion.

6. The filter assembly according to any one of claims 1-5, wherein, The frame includes at least one alignment rib extending circumferentially around the frame, the alignment rib aligning at least one of the housing base and the housing cover with the frame.

7. The filter assembly according to any one of claims 1-5, further wherein, At least one of the housing base and the housing cover includes a lip that extends radially outward from the axial end of the at least one of the housing base and the housing cover to abut the inner wall of the frame.

8. A filter element, comprising: Filter media; as well as A frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positionable between a housing base and a housing cover of a housing assembly and is attachable to the housing base and housing cover. The frame includes a plurality of extensions around its entire circumferential length, the extensions aligning the frame with at least one of the housing base and housing cover, such that the frame engages and interlocks with a plurality of positioning features of at least one of the base end portion of the housing base and the cover end portion of the housing cover. The filter medium is housed within the housing assembly, and a seal is formed between at least one of the housing base and housing cover and the frame. The plurality of extensions includes an axially extending inner extension and an axially extending outer extension, the axially extending inner extension and the axially extending outer extension being alternately positioned along the flange of the frame, and The plurality of positioning features include an inner notch portion and an outer notch portion.

9. The filter element according to claim 8, wherein, The flange extends radially and circumferentially around the outer periphery of the filter medium, and the flange includes the plurality of extensions.

10. The filter element according to claim 9, wherein, The plurality of extensions extend axially above and axially below the flange.

11. The filter element according to claim 9 or 10, wherein, A seal is formed by a gasket connecting at least one of the housing base and the housing cover to the frame, the gasket being positioned and extending radially along the flange between the inner surfaces of the plurality of extensions.

12. The filter element according to claim 11, wherein, The gasket includes a first portion on a first side of the flange and a second portion on a second side of the flange, the first side of the flange being opposite to the second side of the flange, the first portion of the gasket being configured to form a seal between the frame and the housing base, and the second portion of the gasket being configured to form a seal between the frame and the housing cover.

13. A filter assembly, comprising: A filter element, the filter element comprising a filter medium and a frame; as well as A housing assembly for accommodating the filter element, the housing assembly including a housing base and a housing cover, the housing base including a base end portion and the housing cover including a cover end portion. The frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positioned between the housing base and the housing cover and is attached to the housing base and the housing cover such that the frame engages with the end portions of the base and the cover, and a seal is formed between the frame and at least one of the housing base and the housing cover. The frame includes a plurality of extensions around its entire circumferential length, the plurality of extensions aligning the frame with at least one of the housing base and the housing cover, such that the frame engages and interlocks with a plurality of positioning features of at least one of the base end portion and the cover end portion. Wherein, a portion of the plurality of extensions extends axially along at least a portion of the outer periphery of at least one of the housing base or the housing cover. The plurality of extensions includes an axially extending inner extension and an axially extending outer extension, the axially extending inner extension and the axially extending outer extension being alternately positioned along the flange of the frame, and The plurality of positioning features include an inner notch portion and an outer notch portion.

14. The filter assembly of claim 13, wherein, A portion of the plurality of extensions extends axially along at least a portion of the inner periphery of at least one of the housing base or the housing cover.

15. The filter assembly of claim 13, wherein, At least one of the housing base and the housing cover includes an attachment wall corresponding to and aligned with the plurality of extensions of the frame, wherein the attachment wall of at least one of the housing base and the housing cover includes the plurality of positioning features, a first subset of the plurality of positioning features including the recessed portion, and a second subset of the plurality of positioning features having the external recessed portion, the plurality of positioning features being configured to interlock with the plurality of extensions.

16. A filter assembly, comprising: A filter element, the filter element comprising a filter medium and a frame; as well as A housing assembly for accommodating the filter element, the housing assembly including a housing base and a housing cover, the housing base including a base end portion and the housing cover including a cover end portion. The frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positioned between the housing base and the housing cover and is attached to the housing base and the housing cover such that the frame engages with the end portions of the base and the cover, and a seal is formed between the frame and at least one of the housing base and the housing cover. The frame includes a plurality of extensions around its entire circumferential length, the plurality of extensions aligning the frame with at least one of the housing base and the housing cover, such that the frame engages and interlocks with a plurality of positioning features of at least one of the base end portion of the housing base and the cover end portion of the housing cover. The plurality of extensions includes an axially extending inner extension and an axially extending outer extension, which are alternately positioned along the flange of the frame. The plurality of positioning features include an inner notch portion and an outer notch portion. Additionally, at least one of the housing base and the housing cover includes a lip that extends radially outward from the axial end of the at least one of the housing base and the housing cover and around its entire circumferential length to abut the inner wall of the frame.

17. A filter element, comprising: Filter media; as well as A frame is fixed to and surrounds at least the outer periphery of the filter medium. The frame is axially positioned between a housing base and a housing cover of a housing assembly and is attached to the housing base and the housing cover such that the frame engages with a base end portion of the housing base and a cover end portion of the housing cover. The filter medium is housed within the housing assembly, and a seal is formed between at least one of the housing base and the housing cover and the frame. The frame includes a plurality of extensions that align the frame with at least one of the housing base and the housing cover, such that the frame engages and interlocks with a plurality of positioning features of at least one of the base end portion and the cover end portion. The frame includes a flange extending radially and circumferentially around the entire outer periphery of the filter medium. The flange includes a plurality of extensions around its entire circumferential length, including an axially extending inner extension and an axially extending outer extension, the inner and outer extensions being alternately positioned along the flange. The plurality of positioning features include an inner notch portion and an outer notch portion.

18. The filter element according to claim 17, wherein, The plurality of extensions extend axially above and axially below the flange.

19. The filter element according to claim 17 or 18, wherein, A seal is formed by a gasket connecting at least one of the housing base and the housing cover to the frame, the gasket being positioned and extending radially along the flange between the inner surfaces of the plurality of extensions.

20. The filter element according to claim 19, wherein, The gasket includes a first portion on a first side of the flange and a second portion on a second side of the flange, the first side of the flange being opposite to the second side of the flange, the first portion of the gasket being configured to form a seal between the frame and the housing base, and the second portion of the gasket being configured to form a seal between the frame and the housing cover.

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