Adsorption filter assembly

Abstract

The filter assembly has a housing. The housing has an inner body and an outer body surrounding at least a portion of the inner body. The inner body has a base extending in a lateral direction and a first sidewall extending axially outward from the base. The inner body defines a cavity. The first sidewall defines a peripheral surface portion surrounding the cavity. The first filter media piece extends on the peripheral surface portion and throughout the cavity. The adsorbent member is disposed in the cavity. The outer body has a second sidewall located laterally outward of and surrounding the first sidewall. The second sidewall extends at least 50% of an axial length of the first sidewall. The outer body has a first axial end and a second axial end, and a retention portion extending laterally inward from the first axial end. The retaining portion is positioned axially outward of the first filter media piece.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 339,668, filed on May 9, 2022, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to a sorbent filter assembly and more particularly to a sorbent filter assembly for an electronic device enclosure. Background Art

[0004] Various situations require conditions that allow for the ability to control the moisture content of the air. For example, applications located within electronic device enclosures such as disk drives that contain sensitive electronic components and equipment often require that the humidity level within the enclosure be maintained and regulated for constant operation. Improper humidity levels may interfere with the mechanical and electrical operation of these components and equipment.

[0005] It may also be desirable to eliminate chemical contaminants within the enclosure, such as hydrocarbons, siloxanes, silanes, organic acids, and the like. Chemical contaminants can reduce the efficiency and life of components within the electronic device enclosure. Such chemical contaminants may enter the enclosure from external sources, or be generated within the enclosure during manufacture or use. In the case of a disk drive, the contaminants can gradually damage the drive, resulting in reduced drive performance and even complete failure of the drive. Therefore, disk drives typically have one or more filters that are capable of removing moisture and chemical contaminants from the air within the electronic device enclosure, such as adsorption filters. The disk drive may also have a gas, such as helium, disposed in the electronic device enclosure, which can help further protect the drive. Therefore, the term "air" as used herein encompasses any gaseous chemical compound, such as a gaseous chemical compound that may be present in the disk drive environment.

[0006] Adsorption filters may be used within an enclosure to remove moisture and chemical contaminants from the air within the enclosure. Adsorption filters may contain various types of adsorption materials, such as silica gel, activated carbon, molecular sieves, etc. Adsorption filters may produce adsorption filter particles, which may cause contaminants to enter the enclosure. Summary of the invention

[0007] Some embodiments of the technology disclosed herein relate to a filter assembly having a housing. The housing has an inner body and an outer body connected to the inner body. The inner body has a base and a first sidewall, the base extending in a transverse direction, and the first sidewall extending axially outward from the base for an axial length. The inner body defines a cavity. The first sidewall defines a peripheral surface portion surrounding the cavity. The filter assembly also includes a first filter medium member, which extends on the peripheral surface portion and throughout the cavity. The filter assembly also includes an adsorbent member, which is disposed in the cavity. The outer body includes a second sidewall, which is located laterally outside the first sidewall and surrounds the first sidewall. The second sidewall extends at least 50% of the axial length of the first sidewall. The outer body has a first axial end and a second axial end. The outer body also includes a retaining portion, which extends laterally inward from the first axial end of the second sidewall. The retaining portion is positioned axially outside the first filter medium member.

[0008] Additionally or alternatively, the retaining portion is a second filter media member coupled to the second sidewall and extending over the first filter media member. Additionally or alternatively, the retaining portion is an inner rim portion defining a central opening. In this embodiment, the inner rim portion extends transversely over at least a portion of the peripheral surface portion.

[0009] Additionally or alternatively, the inner surface of the outer body is bonded to the outer surface of the inner body. Additionally or alternatively, the second axial end of the second sidewall is bonded to the base portion. Additionally or alternatively, the first filter media member is bonded to the peripheral surface portion. Additionally or alternatively, the first filter media member is bonded to the retaining portion.

[0010] Additionally or alternatively, the adsorbent member is carbon. Additionally or alternatively, the first filter media member is a microporous membrane. Additionally or alternatively, the inner body is comprised of an impermeable material. Additionally or alternatively, the inner body is rigid. Additionally or alternatively, the second sidewall is comprised of an impermeable material. Additionally or alternatively, the second sidewall is rigid. In some embodiments, the second sidewall is a coating on the first filter media member and the inner body.

[0011] Additionally or alternatively, the filter assembly further comprises an adhesive layer coupled to an outer surface of the base. Additionally or alternatively, the base defines a diffusion channel. Additionally or alternatively, the filter assembly has an intermediate body disposed between the inner body and the outer body. The intermediate body has a laterally extending surface portion, wherein the base is axially positioned between the adsorbent member and the laterally extending surface portion. The intermediate sidewall extends axially outwardly from the laterally extending surface portion by an axial length. The intermediate sidewall is positioned between the first sidewall and the second sidewall. Additionally or alternatively, the inner body is non-rigid. Additionally or alternatively, the intermediate body is rigid.

[0012] Additionally or alternatively, the second sidewall abuts the first sidewall along the length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 75% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 85% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 90% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 95% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends 100% of the axial length of the first sidewall.

[0013] Some embodiments of the technology disclosed herein relate to a method of forming a filter assembly as described in any of the above embodiments. This method includes: forming an inner body as disclosed above. Additionally or alternatively, the inner body has a base extending in a transverse direction. Additionally or alternatively, the inner body has a first sidewall, and the first sidewall extends axially outward from the base for an axial length. Additionally or alternatively, the base and the first sidewall define a cavity. Additionally or alternatively, the first sidewall has a peripheral surface portion surrounding the cavity. Additionally or alternatively, the method also includes: arranging an adsorbent member in the cavity. Additionally or alternatively, the method also includes: arranging a first filter medium member on the peripheral surface portion and throughout the cavity. Additionally or alternatively, the method also includes: connecting an outer body to the inner body. Additionally or alternatively, the second sidewall of the outer body is located laterally outside the first sidewall and surrounds the first sidewall. Additionally or alternatively, the second sidewall extends at least 50% of the axial length of the first sidewall. Additionally or alternatively, the outer body has a first axial end and a second axial end. Additionally or alternatively, the outer body further comprises a retaining portion extending laterally inwardly from the first axial end of the second sidewall. Additionally or alternatively, the retaining portion is positioned axially outwardly of the first filter media element.

[0014] Additionally or alternatively, the method further comprises: disposing a second filter media member on the first filter media member. Additionally or alternatively, the method further comprises: coupling the second filter media member to the second sidewall to define a retaining portion. Additionally or alternatively, the retaining portion is an inner rim portion defining a central opening. Additionally or alternatively, the inner rim portion extends transversely over at least a portion of the peripheral surface portion.

[0015] Additionally or alternatively, the method further comprises: bonding the inner surface of the outer body to the inner surface of the inner body. Additionally or alternatively, the method further comprises: bonding the second axial end of the second sidewall to the base portion. Additionally or alternatively, the method further comprises: bonding the first filter media member to the peripheral surface portion. Additionally or alternatively, the method further comprises: bonding the first filter media member to the retaining portion.

[0016] Additionally or alternatively, the adsorbent member is carbon. Additionally or alternatively, the first filter media member is a microporous membrane. Additionally or alternatively, the inner body is comprised of an impermeable material. Additionally or alternatively, the inner body is rigid. Additionally or alternatively, the second sidewall is comprised of an impermeable material. Additionally or alternatively, the second sidewall is rigid.

[0017] Additionally or alternatively, the method further comprises overmolding the second sidewall onto the first filter medium member and the inner body. Additionally or alternatively, the method further comprises coupling an adhesive layer to an outer surface of the base. Additionally or alternatively, the base defines a diffusion channel. Additionally or alternatively, the inner body is disposed in an intermediate body. The intermediate body has a laterally extending surface portion, wherein the base is axially positioned between the adsorbent member and the laterally extending surface portion. The intermediate sidewall extends axially outwardly from the laterally extending surface portion an axial length. The intermediate sidewall is positioned between the first sidewall and the second sidewall. Additionally or alternatively, the inner body is non-rigid. Additionally or alternatively, the intermediate body is rigid.

[0018] Additionally or alternatively, the second sidewall abuts the first sidewall along the length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 75% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 85% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 90% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends at least 95% of the axial length of the first sidewall. Additionally or alternatively, the second sidewall extends 100% of the axial length of the first sidewall.

[0019] The above summary is not intended to describe every embodiment or every implementation. Instead, a more complete understanding of the illustrative embodiments will become apparent and will be appreciated by referring to the following detailed description of exemplary embodiments and claims in conjunction with the figures in the accompanying specification drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is an exploded perspective view of an example adsorption filter assembly consistent with various embodiments.

[0021] Figure 2A is with Figure 1 Example consistent cross-sectional view.

[0022] Figure 2B yes Figure 2A A cross-sectional view of an alternative example of a filter assembly is depicted in FIG.

[0023] Figure 3is an exploded perspective view of an example adsorption filter assembly consistent with various embodiments.

[0024] Figure 4 is with Figure 3 An example cross-sectional view of an example consistent with an example.

[0025] Figure 5 is an example exploded perspective view of an example adsorption filter assembly consistent with various embodiments.

[0026] Figure 6 is with Figure 5 An example cross-sectional view of an example consistent with an example.

[0027] Figure 7 is an example cross-sectional view of an example mold and adsorbent filter assembly consistent with various embodiments.

[0028] Figure 8 is an example exploded perspective view of an example adsorption filter assembly consistent with various embodiments.

[0029] Fig. 9 is with Figure 8 An example cross-sectional view of an example consistent with an example.

[0030] Fig.10 is a flow chart of an example method of forming a sorption filter assembly consistent with various embodiments.

[0031] The present technology may be more fully understood and appreciated upon consideration of the following detailed description of various embodiments taken in conjunction with the accompanying drawings.

[0032] These figures are drawn primarily for clarity and are therefore not necessarily drawn to scale. In addition, various structures / components, including but not limited to fasteners, electrical components (wiring, cables, etc.), etc., may be shown in diagram form or removed from some or all of the views in order to better illustrate various aspects of the depicted embodiments where the inclusion of such structures / components is not necessary for understanding the various exemplary embodiments described herein. However, the lack of illustration / description of such structures / components in a particular figure should not be construed as limiting the scope of the various embodiments in any way. DETAILED DESCRIPTION

[0033] Filter assemblies consistent with the technology disclosed herein may have a variety of different configurations. Figure 1 An example exploded view of an example filter assembly 100 is depicted, and Figure 2A Depicted Figure 1 sectional view of the filter assembly 100.

[0034] The filter assembly 100 is configured to be disposed in an electronic device enclosure. The filter assembly 100 is generally configured to remove moisture and other chemical contaminants from the electronic device enclosure. The disclosed filter assembly 100 has an inner body 108, an outer body 102, a first filter media member 104, and a sorbent member 106.

[0035] The housing 101 includes an inner body 108 and an outer body 102. The inner body 108 has a first sidewall 109. The outer body 102 has a second sidewall 103. The housing and each of the components of the housing are discussed below, and any materials or material properties discussed with respect to the housing 101 can apply to the components of the housing 101, such as the inner body 108 and the outer body 102. In some embodiments, the housing 101 is constructed of a material that is impermeable to air flow. "Impermeable to air flow" means that the material forming the housing 101 is substantially resistant to air flow passing through the material.

[0036] The housing 101 can have a variety of configurations while remaining consistent with the technology disclosed herein. In the current example embodiment, the housing 101 defines a portion of a cylindrical member that defines a cavity 110. However, in some other embodiments, the housing 101 can define alternative shapes (e.g., a partial sphere, a cube, a cuboid, a prism, a pyramid, a cone, etc.). In some embodiments, such as the embodiments currently depicted, the housing 101 does not define more than one opening that provides (accommodate) fluid communication between the external environment (e.g., a disk drive enclosure) and the cavity 110. In various other embodiments, the housing 101 can define additional openings that provide fluid communication between the external environment and the cavity 110.

[0037] The housing 101 can be constructed of a variety of materials and combinations of materials while being consistent with the technology disclosed herein. In some embodiments, the housing 101 is rigid. The term "rigid" can be defined as a material whose shape is self-supporting under the action of gravity. The rigid configuration can advantageously facilitate placing the filter assembly 100 in an environment, such as a disk drive, in which the filter assembly 100 will be used. The rigid configuration can advantageously facilitate adding the adsorbent member 106 to the cavity 110 during manufacture of the filter assembly 100. In some embodiments, as examples, the housing 101 is constructed of plastic, or metal, or a cured resin. In some embodiments, the housing 101 is constructed of molded plastic. The housing 101 can be polycarbonate. The housing 101 can be nylon.

[0038] The inner body 108 has a first side wall 109 with a peripheral surface portion 112. The inner body 108 may include a base 107 extending in a transverse direction. The transverse direction may be transverse to the axial direction. The inner body 108 may also include a first side wall 109 extending axially outward from the base 107 in the axial direction by an axial length L. The axial length L may be, for example, less than or equal to 35 mm, less than or equal to 30 mm, or less than or equal to 25 mm. The axial length L may be, for example, greater than or equal to 4 mm, greater than or equal to 6 mm. For the purposes of the present disclosure, the axial length L of the first side wall 109 is the axial length of the outer surface of the inner body 108, which axial length includes the thickness of the base (in the axial direction), such as Figure 2A and Figure 2B as shown in .

[0039] Although not currently depicted, in some example embodiments, the base 107 may define a vent port and a diffusion channel, as discussed below with reference to other embodiments. The inner body 108 may define a cavity 110 bounded by the first sidewall 109 and the base 107. The first sidewall 109 may define a peripheral surface portion 112 surrounding the cavity 110.

[0040] The peripheral surface portion 112 is generally configured to be coupled to the first filter media member 104 such that the first filter media member 104 extends throughout the cavity 110. The peripheral surface portion 112 can extend laterally. The peripheral surface portion 112 can surround the cavity 110. The peripheral surface portion 112 can be located at a distal end of the first sidewall 109 relative to the base 107 of the inner body 108. The term "distal end" is used herein to refer to a component or feature that is located relatively far from the base 107. The term "proximal end" is used herein to refer to a component or feature that is located relatively closer to the base 107.

[0041] In some embodiments, such as the embodiments currently depicted, the inner body 108 can include a single chamber positioned within the cavity 110. In other exemplary embodiments, the inner body 108 can include a first chamber and a second chamber positioned within the cavity 110. For example, the first chamber and the second chamber can abut against each other within the cavity 110. The first side wall 109 and the peripheral surface portion 112 can define the first chamber and the second chamber. In various embodiments, the first chamber and the second chamber can be separated from each other by a partition wall extending through the cavity. This configuration can advantageously allow more than one adsorbent member to be placed within the filter assembly 100 while limiting physical or chemical interactions between the adsorbent members.

[0042] The housing 101 (and, in example embodiments, more specifically the inner body 108) and the first filter media member 104 collectively define a cavity 110 between the housing 101 (and, in example embodiments, more specifically the inner body 108) and the first filter media member 104. The first filter media member 104 abuts the cavity 110 to allow fluid communication between the cavity 110 and an environment external to the filter assembly 100. In some embodiments, the first filter media member 104 can be coupled to the inner body 108. The first filter media member 104 can be coupled to a peripheral surface portion 112. In some embodiments, the first filter media member 104 includes a peripheral region 115 that can be coupled to the peripheral surface portion 112. The first filter media member 104 and the peripheral surface portion 112 can be coupled by an adhesive, welding, such as ultrasonic welding or heat welding, or the like.

[0043] The first filter media 104 is configured to provide (accommodate) fluid communication through the first filter media 104, the fluid including water vapor and chemical contaminants. The first filter media 104 can be a variety of different materials and material combinations. The first filter media 104 can be vapor permeable to allow vapor to travel into the filter assembly 100 to be captured by the adsorbent 106. The first filter media 104 can be configured to hinder the flow of liquid water through the first filter media 104. In some but not all embodiments, the first filter media 104 is substantially impermeable to liquid water under normal operating conditions. The first filter media 104 can be a microporous membrane, wherein the term "microporous" is intended to mean that the membrane is defined with pores having an average pore size between 0.001 microns and 5.0 microns. The first filter media 104 can be defined with a pore size in the range of 0.05 microns to 5.0 microns, in the range of 0.2 microns to 4.0 microns, or in the range of 0.5 microns to 3.0 microns. In one example, the first filter media 104 has an average pore size of 1.5 microns. In one example, the first filter media 104 has a maximum pore size of 3.0 microns.

[0044] In some embodiments, the first filter medium 104 can have a solidity of less than 50%, and a porosity of greater than 50%. The first filter medium 104 can have a plurality of nodes interconnected by fibrils. In many embodiments, the first filter medium 104 is an expanded polytetrafluoroethylene (PTFE) membrane. As other examples, the first filter medium 104 can additionally or alternatively be composed of polyamide, polyethylene terephthalate, acrylic, polyethersulfone, and / or polyethylene.

[0045] The first filter medium component 104 can be a laminate or a composite, which includes a microporous membrane, such as a PTFE layer, laminated to a woven or non-woven support layer. In some embodiments, the first filter medium component 104 can have a microporous membrane connected to a striped scrim layer. In some embodiments, the first filter medium component 104 can have three layers, such as a microporous membrane layer positioned between two striped scrim layers. In some other embodiments, the first filter medium component 104 can have three layers, wherein a single striped scrim layer is laminated between two microporous membrane layers. The striped scrim layer is generally configured to increase the strength and / or rigidity of the membrane. In one embodiment, the striped scrim layer is polyester. The striped scrim layer can also be a combination of other materials and materials, such as PE, PET and polypropylene. For example, the PTFE layer can be laminated to a non-woven layer of polyester. In some embodiments, the first filter medium component 104 is a fiber filter material with a supportive striped scrim layer or without a supportive striped scrim layer.

[0046] The cavity 110 is configured to receive the sorbent member 106. The first filter media member 104 is coupled to the inner body 108 across the cavity 110 to isolate the cavity, and thus the sorbent member 106, from the environment external to the filter assembly 100.

[0047] The adsorbent member 106 is generally configured to adsorb chemical contaminants from the cavity 110. The adsorbent member 106 is disposed between the first filter medium member 104 and the inner body 108. In an exemplary embodiment, the adsorbent member 106 is generally configured to adsorb chemical contaminants that flow into the cavity 110 from the external environment. The adsorbent member 106 can be a physical adsorbent member material or a chemical adsorbent member material, such as, for example, a desiccant (i.e., a material that adsorbs water or water vapor) or a material that adsorbs or reacts with volatile organic compounds, acidic gases, or both organic compounds and acidic gases. Suitable adsorbent members include, for example, activated carbon, activated alumina, molecular sieves, silica gel, potassium permanganate, calcium carbonate, potassium carbonate, sodium carbonate, calcium sulfate, or mixtures thereof. In some embodiments, activated alumina is mixed with activated carbon. In an embodiment in which the cavity has multiple chambers, a first adsorbent member can be placed in a first chamber, and a different second adsorbent member can be placed in a second chamber.

[0048] The sorbent member 106 can have a variety of structures, including but not limited to beads, granules, sheets, etc. The sorbent member 106 can have a substantially unbound composition, or the sorbent member 106 can have a composition that can be bound to itself or another material, such as a supporting scrim, by a binder. The sorbent member 106 is configured to be placed into the cavity 110 of the inner body 108. The dimensions of the cavity 110 and the sorbent member 106 are set so that the sorbent member 106 fits completely within the cavity 110.

[0049] The adsorbent member 106 may not be bonded to both the inner body 108 and the first filter media member 104. The filter assembly 100 may not have an adhesive between the adsorbent member 106 and the first filter media member 104. The filter assembly 100 may not have an adhesive between the adsorbent member 106 and the inner body 108. Omitting adhesive from the cavity 110 may advantageously allow the cavity 110 to accommodate more adsorbent members than would be possible if adhesive were provided in the cavity 110. Omitting adhesive from the adsorbent member 106 may advantageously maximize the surface area of ​​the adsorbent member available for filtering. Omitting adhesive may advantageously reduce or eliminate outgassing that may be generated by some types of adhesives. In other exemplary embodiments, an adhesive may be used to bond the adsorbent member 106 to the inner body 108. For example, the adhesive may advantageously retain the adsorbent member 106 and reduce the escape of particles from the adsorbent member 106.

[0050] In various embodiments, inserting the adsorbent member 106 into the cavity 110 during the manufacturing process may cause loose particles to be released from the adsorbent member 106 and deposited in and around the inner body 108. As described above, the first filter medium member 104 can advantageously contain such loose particles that may be deposited within the cavity 110 and on the peripheral surface portion 112. In various embodiments, the outer body 102 is generally configured to retain such loose particles from the adsorbent member 106 so that these particles do not escape to the external environment. This configuration can advantageously prevent loose particles that have been deposited on portions of the outer surface 113 of the inner body 108 from being released into the operating environment of the filter assembly 100. As described above, the first filter medium member 104 can be coupled to the peripheral surface portion 112, and in some embodiments, the first filter medium member 104 includes a peripheral region 115, and the peripheral region 115 can be coupled to the peripheral surface portion 112. In such an embodiment, the first filter media member 104 may also be used to contain loose particles from the sorbent member 106 that may have settled on the peripheral surface portion 112 .

[0051] The outer body 102 generally has a second side wall 103 and a retaining portion 114. The outer body 102 forms a portion of the housing 101 together with the inner body 108. The outer body 102 includes the second side wall 103, which is positioned laterally outward of the first side wall 109. Thus, the outer body 102 surrounds the first side wall 109. The materials used to construct the outer body 102 and the material properties of the outer body 102 are generally consistent with the above description of the housing 101.

[0052] The second sidewall 103 extends at least 50% of the axial length L of the first sidewall 109. The outer body 102 has a first axial end 102a and a second axial end 102b. The first axial end 102a is located at an end relatively far from the base 107 of the inner body 108. The second axial end 102b is located at an end relatively close to the base 107 of the inner body 108. In some embodiments, the second axial end 102b can abut the base 107 of the inner body 108, but other configurations are also possible, which will be discussed below. The second sidewall 103 can extend axially toward the base 107 to the proximal end of the base 107, wherein the "proximal end of the base" is defined as the outer lateral surface of the base 107, so that the second sidewall 103 laterally surrounds the first sidewall 109 and the base 107. In some such embodiments, the second sidewall 103 is positioned laterally outside the first sidewall 109 and the base 107. The base may include a lip 117, and in some such embodiments, the second sidewall 103 is positioned laterally outward of the first sidewall 109, the base 107, and the lip 117. Figure 2B Depicted in Figure 2B and Figure 2A The second side wall 103 is the same as the first side wall 103, except that the second side wall 103 has a proximal end portion 102b, the proximal end portion 102b has a lateral extension portion 105a and an axial extension portion 105b, the lateral extension portion 105a abuts against the lateral surface of the lip portion 117, and the axial extension portion 105b abuts against the outer axial surface of the base 107 (in this embodiment, the outer axial surface is also the outer axial surface of the lip portion 117). Return to Figure 1 and Figure 2A In filter assemblies 100 in which the outer body 102 is a discrete component separate from the inner body 108, the outer body 102 may be placed onto the inner body 108 during the assembly process.

[0053] The inner body 108 and the outer body 102 are generally coupled to prevent the release of loose particles held between the inner body 108 and the outer body 102. This configuration can advantageously keep the outer surface of the filter assembly 100 relatively clean and prevent the release of particles into the electronic device enclosure in which the filter assembly 100 is located. In an example embodiment, the inner body 108 can be coupled to the outer body 102 by, for example, bonding the inner surface of the outer body 102 to the outer surface 113 of the inner body 108 around the perimeter of the inner body 108.

[0054] The outer body 102 and the inner body 108 can be coupled using various methods as known to those of ordinary skill in the art. In an example embodiment, the second sidewall 103 can be a coating on the first filter medium member 104 and the inner body 108. In other example embodiments, the second sidewall 103 forms an interference fit with the first sidewall 109. In other example embodiments, the outer body 102 forms a snap fit with the inner body 108. In other example embodiments, the second sidewall 103 and the first sidewall 109 are coupled by an adhesive, welding such as ultrasonic welding or heat welding, etc. In an example embodiment, the adhesive layer can be coupled to the lip 117 of the base 107 so that the second axial end 102b of the outer body 102 is bonded to the adhesive layer of the base 107. The welding of the outer body 102 and the inner body 108 may include a weld that can be located at any point where the outer body 102 and the inner body 108 abut or are adjacent and are easily welded. This can occur on the axial length L of the first side wall 109, on the base 107, on the retaining portion 114, or at any other location. In addition, the combination between the outer body 102 and the inner body 108 can be continuous around the inner body 108. This can advantageously eliminate passages that may be unbound and open, which may allow particles to escape to the external environment. In some other embodiments, this combination can be at discrete points along the inner body 108, for example. In some embodiments, the first side wall 109 and the second side wall 103 are connected by the overmolding process described below with reference to other examples. Other methods of connecting the inner body 108 / first side wall 109 to the outer body 102 / second side wall 103 known to those of ordinary skill in the art can be used.

[0055] As described above, the second sidewall 103 is generally configured to retain particles between the first sidewall 109 and the second sidewall 103. This configuration can advantageously prevent such particulate matter from escaping to the external environment. In an exemplary embodiment in which the filter assembly 100 is inserted into an electronic device enclosure, the second sidewall 103 can advantageously protect key components of the electronic device from such particles. Typically, the second sidewall 103 retains or covers at least a portion of the outer surface 113 of the first sidewall 109. In an exemplary embodiment, the second sidewall 103 completely surrounds the first sidewall 109.

[0056] In example embodiments, the second sidewall 103 may extend at least 50% of the axial length L of the first sidewall 109. In other example embodiments, the second sidewall 103 may extend at least 25% of the axial length L of the first sidewall 109. In other example embodiments, the second sidewall 103 may extend at least 15% of the axial length L of the first sidewall 109. In other example embodiments, the second sidewall 103 may extend at least 60%, 70%, or 75% of the axial length L of the first sidewall 109. In other example embodiments, the second sidewall 103 may extend at least 80% of the axial length L of the first sidewall 109. In other example embodiments, the second sidewall 103 may extend at least 85%, 90%, or 95% of the axial length L of the first sidewall 109. The second sidewall 103 may extend 100% of the axial length L of the first sidewall 109, such that the second sidewall 103 extends the outer surface 113, lip 117 ( Figure 1 ) and base 107, as described above.

[0057] As described above, the first filter media 104 may be a fibrous or non-fibrous filter material with or without a supportive scrim layer. Over time, the first filter media 104 may degrade, which may result in particulate shedding or loose fibers protruding outwardly from the first filter media 104, particularly around the peripheral region 115 of the first filter media 104. The outer body, and particularly the second sidewall 103 and the retaining portion 114, may advantageously retain particulates from the first filter media 104 from escaping to the external environment.

[0058] The outer body 102 has a retaining portion 114 positioned axially outward of the first filter media element 104. In some embodiments, the retaining portion 114 is generally configured to retain the first filter media element 104 on the inner body 108. The retaining portion 114 extends laterally inward from the first axial end 102a of the second sidewall 103. In some embodiments, the retaining portion 114 can retain the first filter media element 104, which in turn can retain the sorbent element 106 within the inner body 108. The retaining portion can define a central opening 111 to allow diffuse fluid communication between the cavity 110 and the environment of the electronic device enclosure through the first filter media element 104. In example embodiments, the retaining portion 114 can extend laterally inward so that the central opening 111 has a cross-dimension (e.g., diameter or diagonal) of, for example, less than or equal to 25 mm, less than or equal to 10 mm, or less than or equal to 15 mm. In some example embodiments, the central opening 111 has a cross-sectional dimension of, for example, greater than or equal to 5 mm, greater than or equal to 10 mm, or greater than or equal to 15 mm. In example embodiments, the central opening 111 has a cross-sectional dimension of, for example, less than or equal to 800 mm. 2 (square millimeters), less than or equal to 400mm 2 , or less than or equal to 200mm 2 In the exemplary embodiment, the central opening 111 has a flow area greater than or equal to 20 mm. 2 , greater than or equal to 50mm 2 , or greater than or equal to 100mm 2 flow area.

[0059] In some embodiments, including the depicted embodiments, the retaining portion 114 may include an inner rim portion 116 that extends transversely over at least a portion of the peripheral surface portion 112. In some embodiments, including the depicted embodiments, the retaining portion 114 extends transversely over the entire peripheral surface portion 112. The inner rim portion 116 may extend transversely inwardly from the second sidewall 103 by 2 mm to 6 mm. In some embodiments, the inner rim portion 116 extends transversely inwardly beyond the inner boundary of the peripheral surface portion 112 by no more than 5 mm, 4 mm, or 3 mm. The peripheral region 115 of the first filter media member 104 may be axially positioned between the retaining portion 114 and the peripheral surface portion 112. In some embodiments, the retaining portion 114 and the inner rim portion 116 may compress the peripheral region 115 of the first filter media member 104. This may advantageously maintain the position of the first filter media member 104. The inner rim portion 116 may define the central opening 111.

[0060] In some embodiments, first filter media 104 may be coupled to retaining portion 114 such that first filter media 104 extends across central opening 111. For example, first filter media 104 may be coupled to retaining portion 114, or to peripheral surface portion 112, or to both retaining portion 114 and peripheral surface portion 112. First filter media 104 and retaining portion 114 may be coupled by adhesive, welding such as ultrasonic welding or heat welding, etc. In some embodiments, retaining portion 114 and first filter media 104 are coupled by an overmolding process.

[0061] The first filter media member 104 can be spaced axially outward from the sorbent member 106 and form a headspace. In other example embodiments (not shown), the first filter media member 104 can abut the sorbent member 106.

[0062] In some embodiments, the filter assembly 100 can be coupled or mounted to an electronics enclosure. Coupling the filter assembly 100 to the electronics enclosure can include making contact between an adhesive layer coupled to an outer surface of the base 107 and the electronics enclosure.

[0063] During manufacture and assembly of the filter assembly 100, various techniques may be used to clean the components of the filter assembly 100 in an attempt to remove particles and provide a relatively "clean" filter assembly 100 for installation into an electronic device enclosure. For example, such cleaning techniques may include spray washing or air purging. Various cleaning or washing techniques may be used to remove at least a portion of particles that have settled on the exterior surfaces of the components that are assembled to form the filter assembly 100. For example, during manufacture and assembly, cleaning may be performed before the filter assembly 100 is fully manufactured. Additionally, for example, the exterior of the inner body 108 may be cleaned during manufacture, and then the exterior of the outer body 102 may be cleaned at a subsequent step.

[0064] Filter assemblies consistent with the technology disclosed herein can have a variety of different configurations, and Figure 3 and Figure 4 Another such configuration is depicted. Figure 3 An example exploded view of an example filter assembly 200 is depicted, and Figure 4 Depicted Figure 3 200 of the filter assembly. Figure 1 2 corresponds - also to similar elements, such as first filter media member 104 and first filter media member 204a. The differences between the exemplary embodiments will be discussed below.

[0065] The filter assembly 200 is configured to be disposed in an electronic device enclosure. The filter assembly 200 is generally configured to remove moisture and other chemical contaminants from the electronic device enclosure. The disclosed filter assembly 200 has an inner body 208, a cover 218, an outer body 202, a first filter media member 204a, and a sorbent member 206.

[0066] The housing, and each of the components of the housing, are discussed below, and any material or material properties discussed with respect to the housing 201 may apply to the components of the housing 201, such as the inner body 208 and the outer body 202. In some embodiments, the housing 201 is constructed of a material that is impermeable to air flow, such as with respect to Figure 1 As discussed in Figure 2.

[0067] like Figure 3 to Figure 4 As shown in , the shape of the filter assembly 200 is a cylindrical shape. In addition, the base 207 is defined with one or more openings, which are configured to be used during manufacturing and / or for installing the filter assembly 200 in the expected operating environment of the filter assembly 200.

[0068] The housing 201 can have a variety of configurations while remaining consistent with the technology disclosed herein. In the current example embodiment, the housing 201 defines a portion of a cylindrical member that defines a cavity 210. However, in some other embodiments, the housing 201 can be defined with alternative shapes (e.g., a partial sphere, a cube, a cuboid, a prism, a pyramid, a cone, etc.). In some embodiments, such as the embodiment currently depicted, the housing 201 defines more than one opening that provides fluid communication between an external environment (e.g., a disk drive enclosure) and the cavity 210. In various other embodiments, the housing 201 may be defined with only one opening that provides fluid communication between the external environment and the cavity 210.

[0069] Housing 201 may be constructed of a variety of materials and combinations of materials while remaining consistent with the technology disclosed herein, as described above with respect to Figure 1 As discussed in Figure 2.

[0070] The housing 201 includes an inner body 208, a cover 218, and an outer body 202. The inner body 208 has a first sidewall 209. The outer body 202 has a second sidewall 203. The cover 218 can be coupled to the base 207 to temporarily or permanently seal the one or more openings. In some embodiments, the cover 218 has an adhesive layer coupled to the cover 218. Figure 3 to Figure 4In the more specific embodiment shown in , the cover 218 has a double-sided adhesive layer 220 and a release liner 222. The double-sided adhesive layer 220 is configured to bond the filter assembly 200 to the operating environment. The release liner 222 is configured to be removed from the double-sided adhesive layer 220 before installing the filter assembly in the expected operating environment.

[0071] The inner body 208 has a first sidewall 209 with a peripheral surface portion 212. The inner body 208 may include a base 207 extending in a transverse direction. The inner body 208 may also include a first sidewall 209 extending axially outwardly from the base 207 in an axial direction by an axial length L, wherein possible axial lengths may be consistent with the above discussion. The transverse direction may be transverse to the axial direction. The inner body 208 may define a cavity 210 defined by the first sidewall 209 and the base 207. The first sidewall 209 may define a peripheral surface portion 212 surrounding the cavity 210.

[0072] In an exemplary embodiment, the base 207 may be defined with at least one diffusion channel 228. The at least one diffusion channel 228 may extend through the base 207 and form a through hole. The at least one diffusion channel 228 may allow, for example, air, vapor or other materials to diffuse through and enter the cavity 210. Therefore, the diffusion channel 228 allows fluid communication between the external environment and the filter, as described above. In this embodiment, the double-sided adhesive layer 220 may be defined with at least one vent port 230. The at least one vent port 230 may be aligned with the at least one diffusion channel 228 to allow the above-mentioned fluid communication. The at least one vent port 230 may abut the at least one diffusion channel 228. The release liner 222 as described above may extend across the vent port 230 to seal the vent port 230 until the filter assembly 200 is installed in the electronic device enclosure.

[0073] The peripheral surface portion 212 is generally configured to be coupled to the first filter media 204a so that the first filter media 204a extends across the cavity 210. The peripheral surface portion 212 can be transverse to the axial direction. The peripheral surface portion 212 can surround the cavity 210. The peripheral surface portion 212 can be located at an end relatively far from the base 207 of the inner body 208.

[0074] In some embodiments, such as the presently depicted embodiment, the inner body 208 may include a single chamber or multiple chambers located within the cavity 210, as described above with respect to Figure 1 As discussed in Figure 2.

[0075] The housing 201 (and in the example embodiment, more specifically the inner body 208) and the first filter media piece 204a collectively define a cavity 210 between the housing 201 (and in the example embodiment, more specifically the inner body 208) and the first filter media piece 204a. The first filter media piece 204a abuts the cavity 210 to allow fluid communication between the cavity 210 and the external environment of the filter assembly 200. In some embodiments, the first filter media piece 204a can be coupled to the inner body 208. The first filter media piece 204a can be coupled to the peripheral surface portion 212. In some embodiments, the first filter media piece 204a includes a peripheral area 215, which can be coupled to the peripheral surface portion 212. The first filter media piece 204a and the peripheral surface portion 212 can be coupled by an adhesive, welding such as ultrasonic welding or heat welding, and the like.

[0076] The first filter media 204a is configured to provide a fluid flow through the first filter media 204a, the fluid flow including water vapor and chemical contaminants. The first filter media 204a can be a variety of different materials and material combinations, as described above with respect to Figure 1 As discussed in Figure 2.

[0077] The cavity 210 is configured to receive the sorbent member 206. The first filter media member 204a is coupled to the inner body 208 across the cavity 210 to isolate the cavity, and thus the sorbent member 206, from the environment external to the filter assembly 200.

[0078] The sorbent member 206 is generally configured to absorb chemical contaminants from the cavity 210. The sorbent member 206 is disposed between the first filter medium member 204a and the inner body 208. In an exemplary embodiment, the sorbent member 206 is generally configured to absorb chemical contaminants that flow from the external environment into the cavity 210. The sorbent member 206 may be as described above with respect to Figure 1 2. In some specific embodiments, the adsorbent member 206 is silica gel or a molecular sieve. In embodiments where the chamber 210 has multiple chambers, a first adsorbent member can be placed in a first chamber and a different second adsorbent member can be placed in a second chamber.

[0079] The adsorbent member 206 may have various structures, including but not limited to beads, particles, sheets, etc. Figure 3 to Figure 4 In the exemplary embodiment shown in , the sorbent member 206 is in a bead-like structure. The sorbent member 206 is configured to be placed into the cavity 210 of the inner body 208. The dimensions of the cavity 210 and the sorbent member 206 are set so that the sorbent member 206 fits completely within the cavity 210.

[0080] The sorbent member 206 may not be bonded to both the inner body 208 and the first filter media member 204a. The filter assembly 200 may not have an adhesive between the sorbent member 206 and the first filter media member 204a. In other exemplary embodiments, an adhesive may be used to bond the sorbent member 206 to the inner body 208. Figure 1 2 discusses possible uses of this adhesive and possible advantages and disadvantages.

[0081] and Figure 1 2, the outer body 202 is generally configured to retain loose particles from the adsorbent member 206 that have settled on a portion of the outer surface 213 of the first side wall 209 of the inner body 208 during the manufacturing process so that these particles do not escape to the external environment. As described above, the first filter medium member 204a can be coupled to the peripheral surface portion 212, and in some embodiments, the first filter medium member 204a includes a peripheral area 215, and the peripheral area 215 can be coupled to the peripheral surface portion 212. In such an embodiment, the first filter medium member 204a can also be used to contain loose particles from the adsorbent member 206 that may have settled on the peripheral surface portion 212.

[0082] The outer body 202 generally has a second sidewall 203. The outer body 202 forms a portion of the housing 201 together with the inner body 208. The outer body 202 includes the second sidewall 203, which is positioned laterally outward of the first sidewall 209. Thus, the outer body 202 surrounds the first sidewall 209. In alternative embodiments, the second sidewall 203 can extend axially toward the base 207 to the proximal end of the base 207, so that the second sidewall 203 laterally surrounds the first sidewall 209 and the base 207. In some such embodiments, the second sidewall 203 is positioned laterally outward of the first sidewall 209 and the base 207. The base can include a lip 217, and in some such embodiments, the second sidewall 203 is positioned laterally outward of the first sidewall 209, the base 207, and the lip 217. In some embodiments, the material and material properties of the second sidewall 203 are generally consistent with the above description of the housing 201.

[0083] The second sidewall 203 may define an inner rim portion 223. The inner rim portion 223 is generally configured to be coupled to the second filter media member 204b such that the second filter media member 204b extends across the central opening 211. The inner rim portion 223 may extend transversely to the axial direction. In some embodiments, the second filter media member 204b includes a second peripheral region 216 that may be coupled to the inner rim portion 223 by adhesive, welding, etc. The inner rim portion 223 may surround the central opening 211. The inner rim portion 223 may be located at or near the distal end of the second sidewall 203. Unlike the previous examples, in the current example, the inner rim portion is slightly inset from the distal end of the outer body 203. The inner rim portion 223 extends laterally inward to define the central opening 211, which may have dimensions consistent with the inner rim portion discussion disclosed above. In some embodiments, the second peripheral region 216 of the second filter media member 204b can be positioned on an outer surface of the inner rim portion 223. In some other embodiments, the second peripheral region 216 of the second filter media member 204b can be positioned on an inner surface of the inner rim portion 223.

[0084] The outer body 202 has a second sidewall 203 that extends at least 50% of the axial length L of the first sidewall 209. The outer body 202 has a first axial end 202a and a second axial end 202b. The first axial end 202a is located at an end relatively far from the base 207 of the inner body 208. The second axial end 202b is located at an end relatively close to the base 207 of the inner body 208. In some embodiments, the second axial end 202b can abut the base 207 of the inner body 208, but other configurations are also possible, which will be discussed below. In the filter assembly 200 in which the outer body 202 is a discrete component separated from the inner body 208, the outer body 202 can be placed on the inner body 208 during the assembly process.

[0085] The inner body 208 and the outer body 202 are generally coupled to prevent the release of loose particles held between the inner body 208 and the outer body 202. In an example embodiment, the inner body 208 can be coupled to the outer body 202 by, for example, bonding the inner surface of the outer body 202 to the outer surface of the inner body 208 around the periphery of the inner body 208. In another example, the second axial end 202b of the second sidewall 203 is bonded to the base 207. In an example embodiment, an adhesive layer can be coupled to the lip 217 of the base 207 so that the second axial end 202b of the outer body 202 is bonded to the adhesive layer of the base 207. The outer body 202 and the inner body 208 can be bonded using adhesive layers as known to those of ordinary skill in the art and as described above with respect to Figure 1to the various methods discussed in connection with FIG. 2 .

[0086] In addition, as described above, the second sidewall 203 is generally configured to retain particles between the first sidewall and the second sidewall. Typically, the second sidewall 203 retains or covers at least a portion of the outer surface 213 of the first sidewall 209. In an exemplary embodiment, the second sidewall 203 completely surrounds the first sidewall 209. In an example embodiment, the second sidewall 203 can extend at least 50% of the axial length L of the first sidewall 209, but the second sidewall 203 can extend other axial lengths of the first sidewall 209 as described above. In the current example, the second sidewall 203 extends 85% to 100% of the axial length L of the first sidewall 209.

[0087] In the present example, the outer body has a retaining portion 214 having the above-mentioned Figure 1 2. More specifically, in the current example, the retaining portion 214 is the second filter medium member 204b and the inner edge portion 223. In an alternative embodiment, the retaining portion 214 is only the inner edge portion 223. The outer body, and in particular the second sidewall 203 and the inner edge portion 223, can advantageously retain particles that have fallen off from the first filter medium member 204a and the sorbent member 206 to prevent them from escaping to the external environment.

[0088] The retaining portion 214 can be positioned axially outside the first filter medium member 204a. In some embodiments, the retaining portion 214 is generally configured to retain particles within the outer body 202. The retaining portion 214 extends laterally inward from the first axial end 202a of the second side wall 203. The retaining portion 214 can allow diffuse fluid communication between the cavity 210 and the environment of the electronic device enclosure to be performed through the second filter medium member 204b. As described above, here, the retaining portion includes a second filter medium member 204b. The second filter medium member 204b can be connected to the second side wall 203 and can extend across the central opening 211. More particularly, the second filter medium member 204b is connected to the inner edge 223. The inner edge 223 is a flange defined by the first axial end 202a of the second side wall 203. The second filter medium member 204b can be bonded to the second side wall 203 and more particularly to the inner edge 223 of the outer body 202 by an adhesive, welding such as ultrasonic welding or heat welding, etc., as described above.

[0089] In some embodiments, the second filter media element 204b includes a second peripheral region 216 that can be coupled to the inner edge portion 223, as described above. The second filter media element 204b can be a variety of different materials and material combinations, as described above with respect to Figure 1As discussed above with respect to the first filter media member 104 of FIG. 2 .

[0090] The filter assembly 200 has a second adsorbent member 224. The second adsorbent member 224 is generally configured to adsorb chemical contaminants. The second adsorbent member 224 can be a material that is less likely to shed hard particles than the first adsorbent member (e.g., an activated carbon sheet). Therefore, the second adsorbent member 224 is less likely to produce particles that could escape from the filter and cause damage to other components in the electronic device enclosure. In an alternative embodiment, the second adsorbent member 224 can be as described above with respect to Figures 1 to 4 The material described in the adsorbent members 106 and 206.

[0091] The second sorbent member 224 may have various structures, not limited to beads, granules, sheets, etc., similar to the discussion above regarding the first sorbent member. The structure of the second sorbent member 224 may include one or more structures that promote air flow between the first filter medium member 204a and the second filter medium member 204b. As an example, the second sorbent member 224 may be perforated, may be a beaded structure, or may include a protrusion. In some exemplary embodiments, the second sorbent member 224 may include through holes to allow fluid communication between the first filter medium member 204a and the second filter medium member 204b.

[0092] In such Figure 3 to Figure 4 In the exemplary embodiment shown in , the second adsorbent member 224 has a plate-like structure. The second adsorbent member 224 is disposed between the first filter medium member 204a and the second filter medium member 204b. The second adsorbent member 224 is positioned axially outward from the first filter medium member. The second adsorbent member 224 abuts the first filter medium member 204a. In the current example, the second adsorbent member 224 is spaced apart from the second filter medium member 204b in the axial direction. In other embodiments, the second adsorbent member 224 may abut the second filter medium member 204b. The second adsorbent member 224 may be unbonded or bonded relative to the first filter medium member 204a and / or the second filter medium member 204b. In some examples, the second adsorbent member 224 is located between the peripheral surface portion 212 (and therefore, the first filter medium member 204a) and the inner edge portion 223. In some embodiments, the second adsorbent member 224 may be compressed between the peripheral surface portion 212 and the inner edge portion 223.

[0093] Figure 5 An example exploded view of yet another example filter assembly 300 is depicted, and Figure 6 Depicted Figure 52 is a cross-sectional view of a filter assembly 300. The filter assembly 300 is configured to be disposed in an electronic device enclosure. The filter assembly 300 is generally configured to remove moisture and other chemical contaminants from the electronic device enclosure. The disclosed filter assembly 300 has an inner body 308, an outer body 302, a first filter media member 304, and a sorbent member 306.

[0094] The housing 301 can have a variety of configurations while being consistent with the technology disclosed herein. In the current example embodiment, the housing 301 has an irregular shape, such as an asymmetric prism, that defines a cavity 310. The housing 301 can be defined with alternative shapes as described above. Although the housing 301 currently depicted defines a single cavity 310, in some other embodiments, the housing 301 defines two or more cavities. In some embodiments, such as the embodiment currently depicted, the housing 301 defines an opening 311 that provides fluid communication between an external environment (e.g., a disk drive enclosure) and the cavity 310. In various other embodiments, the housing 301 can be defined with more than one opening that provides fluid communication between the external environment and the cavity 310.

[0095] The housing 301 includes an inner body 308 and an outer body 302. The inner body 208 and the outer body 302 can be made of the materials discussed in relation to the above embodiments. The inner body 308 has a first sidewall 309 that encloses a cavity 310. The outer body 302 has a second sidewall 303 that surrounds the cavity 310. The inner body 308 can include a base 307 extending in a transverse direction. The inner body 308 can also include a first sidewall 309 that extends outwardly from the base 307 in an axial direction by an axial length L, wherein the axial length can be consistent with the above discussion. The inner body 308 can define a cavity 310 defined by the first sidewall 309 and the base 307.

[0096] The first sidewall 309 can have a peripheral surface portion 312 surrounding the cavity 310. The peripheral surface portion 312 is generally configured to be coupled to the peripheral region 315 of the first filter media member 304 such that the first filter media member 304 extends across the cavity 310. The peripheral surface portion 312 can be transverse to the axial direction. The peripheral surface portion 312 can surround the cavity 310. Unlike the above-mentioned embodiments in which the peripheral surface portion is located at the distal end of the inner body, here, the peripheral surface portion 312 is offset from the distal end of the inner body 308. However, the peripheral surface portion 312 is still located near the distal end of the inner body 308.

[0097] The housing 301 (and in the example embodiment, more specifically the inner body 308) and the first filter media member 304 collectively define a cavity 310 between the housing 301 (and in the example embodiment, more specifically the inner body 308) and the first filter media member 304. The first filter media member 304 abuts the cavity 310 to allow fluid communication between the cavity 310 and the external environment of the filter assembly 300. In some embodiments, the first filter media member 304 can be coupled to the inner body 308. The first filter media member 304 can be coupled to the peripheral surface portion 312. In some embodiments, the first filter media member 304 includes a peripheral region 315, which can be coupled to the peripheral surface portion 312. The first filter media member 304 and the peripheral surface portion 312 can be coupled by an adhesive, welding, such as ultrasonic welding or heat welding, etc.

[0098] The cavity 310 is configured to receive the sorbent member 306. The first filter media member 304 is coupled to the inner body 308 across the cavity 310 to isolate the cavity from the environment outside the filter assembly 300 and, therefore, the sorbent member 306 from the environment outside the filter assembly 300. The first filter media member 304 can be a variety of different materials and material combinations, as described above with respect to Figure 1 2. The sorbent member 306 is disposed between the first filter medium member 304 and the inner body 308. The sorbent member 306 may be as described above with respect to Figure 1 2. In embodiments where the cavity 310 has multiple chambers, a first sorbent member may be placed in a first chamber and a second, different sorbent member may be placed in a second chamber. The sorbent member 306 may be constructed in a manner consistent with the sorbent members described in detail above.

[0099] The outer body 302 includes a second sidewall 303 that is positioned laterally outward of the first sidewall 309. Thus, the outer body 302 laterally surrounds a portion of the first sidewall 309. In alternative embodiments, the second sidewall 303 laterally surrounds the first sidewall 309 and the base 307. In some such embodiments, the second sidewall 303 is positioned laterally outward of the first sidewall 309 and the base 307. The base may include a lip 317 that extends laterally outward from the base and extends laterally outward from the first sidewall. In some such embodiments, the second sidewall 303 is positioned laterally outward of the first sidewall 309, the base 307, and the lip 317.

[0100] The outer body 302 has a first axial end 302a and a second axial end 302b. The first axial end 302a is located at an end relatively far from the base 307 of the inner body 308. The second axial end 302b is located at an end relatively close to the base 307 of the inner body 308. In some embodiments, the second axial end 302b can abut the base 307 of the inner body 308, but other configurations are also possible, which will be discussed below. The inner body 308 and the outer body 302 can be coupled in a manner consistent with the discussion elsewhere in this document.

[0101] Typically, the second sidewall 303 retains or covers at least a portion of the outer surface 313 of the first sidewall 309. In an exemplary embodiment, the second sidewall 303 completely surrounds the first sidewall 309. In an exemplary embodiment, the second sidewall 303 can extend at least 50% of the axial length L of the first sidewall 309 or other ranges described above. In the depicted example, the second sidewall 303 extends 95% to 99% of the axial length L of the first sidewall 309. Although not shown, in some embodiments, the second sidewall 303 is positioned laterally outside the first sidewall 309, the base 307, and the lip 317, so that the second sidewall 303 extends 100% of the axial length L of the first sidewall 309.

[0102] The retaining portion 314 is generally consistent with the retaining portion discussed above, except for the differences noted herein or visible in the figures. The retaining portion 314 is positioned axially outward of the first filter medium member 304. The retaining portion 314 extends laterally inward from the first axial end 302a of the second sidewall 303. Unlike some previous examples, in the current example, the retaining portion 314 is not a filter medium member or inner edge portion as described in the previous examples. Instead, in this example, the retaining portion 314 is a laterally extending surface portion that extends across a majority of the lateral area of ​​the distal end of the cavity 310. The retaining portion 314 can extend across at least 70%, 75%, 80%, and up to 100% of the lateral area of ​​the distal end of the cavity 310. The retaining portion 314 can be a single integral component with the second sidewall 303, but in other embodiments, the retaining portion 314 can be a separate component coupled to the second sidewall 303.

[0103] The first filter medium element 304 is axially positioned between the retaining portion 314 and the peripheral surface portion 312. More particularly, the peripheral region 315 of the first filter medium element 304 is axially positioned between the retaining portion 314 and the peripheral surface portion 312. In the current example, the filter medium element 304 is directly connected to the peripheral surface portion 312 of the inner body 308 and is spaced apart from the retaining portion 314 in the axial direction. In the current example, the retaining portion 314 is defined by an opening 311. Unlike the above-mentioned embodiment in which the retaining portion is defined by a central opening, the present embodiment includes an opening 311 that is not necessarily located in the central portion of the retaining portion 314. The retaining portion 314 allows diffuse fluid communication between the cavity 310 and the environment of the electronic device enclosure to be carried out through the first filter medium element 304 and through the opening 311 of the outer body 302.

[0104] The filter assembly 300 currently depicted has an inlet filter 334, which can be used as an additional filter between the external environment and the disk drive, for example. The inlet filter 334 can operate as a filter during both the manufacture and assembly of the filter assembly 300 and during use after the filter assembly 300 is placed in the disk drive. The inlet filter 334 can be selectively in fluid communication with the opening 311. An example inlet filter 334 is described in U.S. Patent No. 10,134,447 B2.

[0105] Figure 7 An example cross-sectional view of yet another example filter assembly 400 during a manufacturing step is depicted and includes cross-sectional views of example molds and adsorption filter assemblies consistent with various embodiments.

[0106] The disclosed filter assembly 400 has an inner body 408, an outer body 402, a first filter medium member 404, and an adsorbent member 406. The shell 401 includes the inner body 408 and the outer body 402. The inner body 408 has a first sidewall 409. The outer body 402 has a second sidewall 403. The shell 401 can have various configurations consistent with the current example, such as a cylindrical shape, a prismatic shape, an irregular shape, or other shapes described above. The shell 401 defines a cavity 410. In this example, the shell 401 defines at least one diffusion channel 428, which provides fluid communication between the external environment and the cavity 410. The shell 401 can be constructed of various materials and material combinations while remaining consistent with the technology disclosed herein, as described above with respect to Figure 1 As described in Figure 2.

[0107] The inner body 408 has a first sidewall 409 with a peripheral surface portion 412. The inner body 408 has a base 407 extending in a transverse direction. The first sidewall 409 extends axially outward from the base 407 by an axial length L, wherein possible axial lengths can be consistent with the above discussion. The inner body 408 can define a cavity 410 defined by the first sidewall 409 and the base 407. The first sidewall 409 can define a peripheral surface portion 412 surrounding the cavity 410. The peripheral surface portion 412 surrounds the cavity 410. The peripheral surface portion 412 can be located at the distal end of the inner body 408. Although the inner body 408 has a visible single chamber of the cavity 410, in some embodiments, the cavity 410 can have multiple chambers, which have been described above.

[0108] Inner body 408 and first filter media piece 404 collectively define a cavity 410 between inner body 408 and first filter media piece 404. First filter media piece 404 abuts cavity 410 to allow fluid communication between cavity 410 and an environment external to filter assembly 400. First filter media piece 404 is coupled to inner body 408. First filter media piece 404 has a peripheral region 415 coupled to peripheral surface portion 412. First filter media piece 404 can be a variety of different materials and material combinations, as described above.

[0109] Cavity 410 is configured to receive sorbent member 406. First filter media member 404 is coupled to inner body 408 across cavity 410 to isolate the cavity and, therefore, sorbent member 406 from an environment external to filter assembly 400. Sorbent member 406 may be of the materials discussed elsewhere herein.

[0110] In the current example, the base 407 defines the at least one diffusion channel 428. The diffusion channel 428 extends through the base 407 and forms a tortuous flow path for fluid communication between the external environment and the cavity 410. The diffusion channel 428 can allow, for example, air, vapor, or other materials to move through the diffusion channel 428 and into the cavity 410.

[0111] The outer body 402 is generally configured to retain loose particles that have settled on a portion of the outer surface 413 of the first side wall 409 of the inner body 408 so that these particles do not escape to the external environment. The outer body 402 generally has a second side wall 403 and a retaining portion 414. The outer body 402 includes a second side wall 403 that is positioned laterally outside the first side wall 409. Thus, the outer body 402 surrounds at least a portion of the axial length of the first side wall 409. In alternative embodiments, the second side wall 403 laterally surrounds the first side wall 409 and the base 407. In some such embodiments, the second side wall 403 is positioned laterally outside the first side wall 409 and the base 407. In alternative embodiments such as those described above in which the base includes a lip, the second side wall 403 can be positioned laterally outside the first side wall 409, the base 407, and the lip, as described above. The material and material properties of the second side wall 403 are generally consistent with the above description.

[0112] The outer body 402 has a first axial end 402a and a second axial end 402b. The first axial end 402a is located at the distal end of the inner body 408. The second axial end 402b is located near the proximal end of the inner body 408.

[0113] As in the above-described embodiment, the second sidewall 403 retains or covers at least a portion of the outer surface 413 of the first sidewall 409. In an exemplary embodiment, the second sidewall 403 completely surrounds the first sidewall 409 in the lateral direction. The second sidewall 403 extends at least 50% of the axial length L of the first sidewall 409. In other exemplary embodiments, the second sidewall 403 may extend 100% of the axial length L of the first sidewall 409. In the current example, the second sidewall 403 extends at least 60%, 70%, or 80% of the axial length L of the first sidewall 409.

[0114] The outer body 402 has a retaining portion 414 that is positioned axially outside of the first filter medium member 404. In the current example, the retaining portion 414 is configured to retain the first filter medium member 404 on the inner body 408. The retaining portion 414 extends laterally inward from the first axial end 402a of the second side wall 403. The retaining portion 414 can be defined by a central opening 411 to allow diffuse fluid communication between the cavity 410 and the environment of the electronic device enclosure through the first filter medium member 404. In an example embodiment, the retaining portion 414 can extend laterally inward as described above. The retaining portion 414 is an inner edge portion that extends laterally over at least a portion of the peripheral surface portion 412. The peripheral region 415 of the first filter medium member 404 is axially positioned between the retaining portion 414 and the peripheral surface portion 412.

[0115] In some embodiments, the first filter media member 404 can be coupled to the retaining portion 414 so that the first filter media member 404 extends across the central opening 411. For example, the first filter media member 404 can be coupled to the retaining portion 414, or to the peripheral surface portion 412, or to both the retaining portion 414 and the peripheral surface portion 412. In the current example, the retaining portion 414 and the first filter media member 404 are coupled by an overmolding process. In some embodiments, as an example, the first filter media member 404 is also coupled to the peripheral surface portion 412 by an adhesive or welding.

[0116] In the present example, the second sidewall 403 is a coating formed over the first filter media member 404 and the inner body 408 by an overmolding process. Figure 7 Also shown are example molds that can be used to overmold the outer body 402 onto the inner body 408. The first mold 409a and the second mold 403a are generally configured to position the inner body 408, the sorbent member 406, and the first filter medium member 404 for the overmolding process. The first mold 409a and the second mold 403a are generally configured to define the size, shape, and position of the outer body 402 relative to the inner body and the first filter medium member 404. The first mold 409a and the second mold 403a can be any material suitable for use in the overmolding process, such as, for example, a metal (e.g., aluminum). The first mold 409a and the second mold 403a can form any mold shape suitable for the outer body 402. A third mold 446 can also be used to position the inner body 408, the sorbent member 406, and the first filter medium member 404. In the current example, the third mold 446 is configured to hinder contact between portions of the first filter medium member 404 and the molding material. For example, the third mold 446 can be spring loaded. The third mold 446 can be any material suitable for use in an overmolding process, such as the materials described above with respect to the first mold 409a and the second mold 403a. The third mold 446 can advantageously stabilize the first filter media element 404 of the filter assembly 400 on the first sidewall 409 for the overmolding process.

[0117] The material injection site 444 can provide a passage for injecting uncured or unset material into a cavity / cavities formed by the first mold, the second mold, and the third mold (409a, 403a, and 446, respectively). This can allow the material to fill the mold cavity to form the second sidewall 403 and the retaining portion 414, thereby ultimately forming the outer body 402. Then, the material can be cured or solidified to form the outer body 402 into a solid piece. The material used can be any material suitable for the overmolding process, such as, for example, a thermoplastic material, such as polycarbonate, polyethylene, acrylic acid, or resin. The material can also be any material as described above about the housing 401 (for example, the material can be impermeable for fluid communication). When the material is cured or solidified, the first mold 409a, the second mold 403a, and the third mold 446 can be removed, and the filter assembly 400 is retained.

[0118] Figure 8 An example exploded view of yet another example filter assembly 500 is depicted, and Fig. 9 Depicted Figure 8 500 is a cross-sectional view of a filter assembly 500. The filter assembly 500 is configured to be disposed in an electronic device enclosure. The filter assembly 500 is substantially consistent with the filter assemblies described above unless otherwise noted or visible in the figures. The filter assembly 500 has an inner body 508, an outer body 502, a first filter media member 504, and an adsorbent member 506, and the inner body 508, the outer body 502, the first filter media member 504, and the adsorbent member 506 are each substantially consistent with the above description unless otherwise noted herein and / or depicted in the figures.

[0119] The housing 501 has a cavity 510 and a sorbent member 506 disposed in the cavity. The housing 501 defines a central opening 511 that provides fluid communication between the external environment (e.g., a disk drive enclosure) and the cavity 510. In the current example, the inner body 508 has a base 507 and a first side wall 509 extending from the base 507 ( Fig. 9 ) extends axially outwardly by an axial length L. The inner body 508 defines a cavity 510 bounded by a first sidewall 509 and a base 507. In the current example, the cavity 510 is a single chamber, but in some other embodiments, the cavity 510 may have multiple chambers.

[0120] The first sidewall 509 defines a peripheral surface portion 512 surrounding the cavity 510. The peripheral surface portion 512 can be transverse to the axial direction. The peripheral surface portion 512 is located near the distal end of the inner body 508. Unlike some embodiments previously described, here, the peripheral surface portion 512 is defined by a flange on the distal end of the first sidewall.

[0121] The first filter media piece 504 is coupled to the peripheral surface portion 512 such that the first filter media piece 504 extends across the cavity 510. Thus, the inner body 508 and the first filter media piece 504 collectively define the cavity 510 between the inner body 508 and the first filter media piece 504. The first filter media piece 504 is coupled to the peripheral surface portion 512 and abuts the cavity 510. In particular, the first filter media piece 504 has a peripheral region 515 that is coupled to the peripheral surface portion 512. The first filter media piece 504 and the peripheral surface portion 512 may be coupled by the method described above.

[0122] Unlike some previous embodiments, in the current embodiment, the inner body 508 can be made of a non-rigid material such as a relatively thin film. For example, the inner body 508 can be a flexible bag-like member. In this example, the peripheral surface portion 512 can be a melting area, in which the first filter medium member 504 and the peripheral surface portion 512 are heat welded or ultrasonically welded together. In this example in which the inner body 508 is made of a relatively thin flexible film, the inner body 508 can adapt to the shape of the adsorbent member 506 contained in the inner body 508. The adsorbent member 506 can be consistent with the above-mentioned adsorbent member. In some embodiments of the current example, the adsorbent member 506 is a sheet member.

[0123] The outer body 502 has a first axial end and a second axial end and a second sidewall 503. The second sidewall 503 is positioned laterally outside the first sidewall 509. The second sidewall surrounds the first sidewall 509 and extends at least 50% of the axial length of the first sidewall 509. In the current example, the second sidewall 503 extends at least 95%, 97%, or 99% of the axial length L of the first sidewall 509. More specifically, the second sidewall 503 extends 100% of the axial length L of the first sidewall 509, so that the second sidewall 503 laterally surrounds the first sidewall 509 and the base 507. In some embodiments, the base may include the lip shown in the previous embodiment, and the second sidewall 503 may be positioned laterally outside the first sidewall 509, the base 507, and the lip.

[0124] The first axial end 502a is located at the distal end of the inner body 508. The second axial end 502b is located near the proximal end of the inner body 508. In the current example, the second axial end 502b of the outer body 502 does not abut the base 507 of the inner body 508. In the filter assembly 500 in which the outer body 502 is a discrete component separate from the inner body 508, the outer body 502 can be placed on the inner body 508 during the assembly process.

[0125] The retaining portion 514 may have a function consistent with the above description. The retaining portion 514 is positioned axially outward of the first filter medium 504. The retaining portion 514 extends laterally inward from the first axial end 502a of the second sidewall 503. In the current example, the retaining portion 514 is an inner edge portion, as described in the previous example.

[0126] The first filter medium 504 is axially positioned between the retaining portion 514 and the peripheral surface portion 512. More specifically, the peripheral region 515 of the first filter medium 504 may be axially positioned between the retaining portion 514 and the peripheral surface portion 512. In the current example, the filter medium 504 is directly coupled to the peripheral surface portion of the inner body 508, and the filter medium 504 is axially spaced apart from the retaining portion 514. However, in some other embodiments, the retaining portion 514 may compress the peripheral region 515 of the first filter medium 504.

[0127] In the present example, the filter assembly 500 has an intermediate body 520 disposed between the inner body 508 and the outer body 502. The intermediate body 520 has a transversely extending surface portion 522, and an intermediate sidewall 524 extending axially outward from the transversely extending surface portion 522. The intermediate sidewall 524 is positioned between the first sidewall 509 and the second sidewall 503 in the axial direction. The transversely extending surface portion 522 is positioned axially outward of the base 507, so that the base 507 is positioned axially between the adsorbent member 506 and the transversely extending surface portion 522. The intermediate sidewall 524 has an axial length A extending from the transversely extending surface portion 522 to a distal end portion 526. The second sidewall 503 surrounds the intermediate sidewall 524 in the transverse direction, and the second sidewall 503 extends at least a portion of the axial length A of the intermediate sidewall 524, wherein the axial length A of the intermediate sidewall 524 includes the axial height of the transversely extending surface portion 522.

[0128] In the current example, the outer body 502 is directly coupled to the middle body 520. In particular, the second end 502b of the second side wall 503 is welded to the transversely extending lip 528 of the middle body 520. The first filter medium member 504 is axially positioned between the retaining portion 514 and the first end 502a of the second side wall 503. More particularly, the peripheral region 515 of the first filter medium member 504 is axially positioned between the retaining portion 514 and the first end 502a of the second side wall 503. In some embodiments, the retaining portion 514 and the first end 502a of the second side wall 503 can compress the peripheral region 515 of the first filter medium member 504 and at least a portion of the peripheral surface portion 512 of the inner body 508.

[0129] In the current example, the laterally extending surface portion 522 defines a hole 532 for selective fluid communication between the external environment and the cavity 510. The cover 518 is connected to the laterally extending surface portion 522 to temporarily or permanently seal the hole 532. In some embodiments, the cover 518 has an adhesive layer 519, such as a double-sided adhesive layer, connected to the cover 518 to connect the filter assembly 500 to the enclosure. The cover 518 also has a release liner 517, which is configured to be removed from the double-sided adhesive layer 519 to install the filter assembly 500 in the expected operating environment. In the current example, the adhesive layer 519 collectively defines a hole 532.

[0130] Embodiments consistent with the current design can further limit the negative effects of particles on the electronic device enclosure by further containing any loose particles on the outer surface of the filter assembly 500. For assembly of the filter assembly 500, the adsorbent member 506 can be disposed in the inner body 508, and the first filter medium member 504 can be coupled to the inner body 508 to define a liquid seal around the adsorbent member 506. The inner body 508 can be cleaned with liquid or air pressure to remove at least a portion of the loose particles that may be present on the outer surface of the inner body 508. After cleaning, the inner body 508 having the adsorbent member 506 and the first filter medium member 504 can be inserted into the intermediate body 520. In some embodiments, the outer surface 513 of the intermediate body 520 can also be cleaned. The outer body 502 can then be disposed on the assembled inner body 508 and the intermediate body 520 and coupled to the intermediate body 520.

[0131] Fig.10 6 is a flow chart of an example method of forming an adsorbent filter assembly consistent with various embodiments. The flow chart can be consistent with a method 600 for constructing a filter assembly consistent with the technology disclosed herein. The method 600 of forming a filter assembly according to an exemplary embodiment can include: forming an inner body 650; disposing a sorbent member in a cavity 652; disposing a first filter media member across a peripheral surface portion and cavity 654; and coupling an outer body to an inner body 656.

[0132] In some exemplary embodiments, forming the internal body may include: forming the internal body as described above using any method generally known to a person of ordinary skill in the art. The internal body may have a base, a first sidewall, an axial length, a cavity, and a peripheral surface portion, as described above. Each of these features may have a configuration consistent with the embodiments described above. Forming the internal body may include: injection molding, machining, vacuum forming, engraving, etc. Method 600 may also include: bonding the first filter medium piece to the peripheral surface portion, as described above. Each of these features may have a configuration consistent with the embodiments described above.

[0133] In some exemplary embodiments, disposing the sorbent member in the cavity 652 may include disposing the sorbent member in the cavity using any method generally known to one of ordinary skill in the art. For example, sorbent beads may be poured into the cavity. In another example, a molded sorbent sheet may be manually or automatically positioned in the cavity. The sorbent member may be consistent with the sorbent members described elsewhere above.

[0134] The first filter media member is disposed across the peripheral surface portion and the cavity 654 using any method generally known to those skilled in the art. In some embodiments, the first filter media member is bonded to the peripheral surface portion using an adhesive or welding. In some embodiments, the first filter media member is disposed across the peripheral surface portion and the cavity in a molded component, such as a molded component in an overmolding system. The first filter media member, the peripheral surface portion, and the cavity can have configurations consistent with the corresponding components described above.

[0135] Some exemplary embodiments may include an outer body, a second sidewall, a first axial end, a second axial end, a retaining portion, an inner rim, and a central opening, each of which has been described in detail above. In some exemplary embodiments, coupling the outer body to the inner body 656 may include coupling the outer body to the inner body using any method generally known to those of ordinary skill in the art. For example, welding or an adhesive may be used to couple the outer body to the inner body 656. Method 600 may include bonding the inner surface of the outer body to the outer surface of the inner body, as described above. Method 600 may additionally or alternatively include bonding the second axial end of the second sidewall to the base, as described above. Such bonding may include the use of an adhesive layer as described above. In some exemplary embodiments, coupling the outer body to the inner body may be performed by overmolding the second sidewall onto the first filter medium and the inner body, as described above. In some such embodiments, the outer body is overmolded onto the first filter medium and the inner body. Method 600 may also include bonding the first filter medium to the retaining portion, as described above. Each of these features may have a configuration consistent with the above-described embodiments.

[0136] Some exemplary embodiments may include a second filter media member, as described above. Method 600 may also include: disposing the second filter media member on the first filter media member. In such embodiments, the second filter media member may be coupled to the second sidewall, as described above. The second filter media member may define a retaining portion of the outer body, as described above with respect to Figure 3 to Figure 4 described.

[0137] Description of each embodiment

[0138] Embodiment 1. A filter assembly, comprising:

[0139] a housing including an inner body and an outer body surrounding at least a portion of the inner body, the inner body having a base and a first sidewall, the base extending in a transverse direction, the first sidewall extending axially outwardly from the base an axial length, wherein the inner body defines a cavity and the first sidewall defines a peripheral surface portion surrounding the cavity;

[0140] a first piece of filter media extending over the peripheral surface portion and throughout the cavity; and

[0141] an adsorbent member disposed in the cavity,

[0142] wherein the outer body includes a second side wall located laterally outside of and surrounding the first side wall, wherein the second side wall extends at least 50% of the axial length of the first side wall, and wherein the outer body has a first axial end and a second axial end, and wherein the outer body also includes a retaining portion extending laterally inward from the first axial end of the second side wall, and wherein the retaining portion is positioned axially outside of the first filter medium component.

[0143] Embodiment 2. The filter assembly of any one of Embodiments 1 and 3 to 25, wherein the retaining portion includes a second piece of filter media coupled to the second sidewall and extending over the first piece of filter media.

[0144] Embodiment 3. The filter assembly of any one of Embodiments 1-2 and 4-25, wherein the retaining portion is an inner rim portion defining a central opening, wherein the inner rim portion extends transversely over at least a portion of the peripheral surface portion.

[0145] Embodiment 4. The filter assembly of any one of Embodiments 1 to 3 and 5 to 25, wherein the inner surface of the outer body is bonded to the outer surface of the inner body.

[0146] Embodiment 5. The filter assembly of any one of Embodiments 1-4 and 6-25, wherein the second axial end of the second sidewall is bonded to the base.

[0147] Embodiment 6. The filter assembly of any one of Embodiments 1-5 and 7-25, wherein the first filter media piece is bonded to the peripheral surface portion.

[0148] Embodiment 7. The filter assembly of any one of Embodiments 1-6 and 8-25, wherein the first piece of filter media is bonded to the retaining portion.

[0149] Embodiment 8. The filter assembly of any one of Embodiments 1 to 7 and 9 to 25, wherein the sorbent member comprises carbon.

[0150] Embodiment 9. The filter assembly of any one of Embodiments 1 to 8 and 10 to 25, wherein the first filter media element comprises a microporous membrane.

[0151] Embodiment 10. The filter assembly of any one of Embodiments 1-9 and 11-25, wherein the inner body is comprised of an impermeable material.

[0152] Embodiment 11. The filter assembly of any one of Embodiments 1 to 10 and 12 to 25, wherein the inner body is rigid.

[0153] Embodiment 12. The filter assembly of any one of Embodiments 1 to 11 and 13 to 25, wherein the second side wall is comprised of an impermeable material.

[0154] Embodiment 13. The filter assembly of any one of Embodiments 1 to 12 and 14 to 25, wherein the second sidewall is rigid.

[0155] Embodiment 14. The filter assembly of any one of Embodiments 1-13 and 15-25, wherein the second sidewall is a coating on the first filter media piece and the inner body.

[0156] Embodiment 15. The filter assembly of any one of Embodiments 1 to 14 and 16 to 25, further comprising an adhesive layer coupled to an outer surface of the base.

[0157] Embodiment 16. The filter assembly of any one of Embodiments 1 to 15 and 17 to 25, wherein the base defines a diffusion channel.

[0158] Embodiment 17. The filter assembly of any one of embodiments 1 to 16 and 18 to 25, further comprising an intermediate body disposed between the inner body and the outer body, wherein the intermediate body comprises:

[0159] a laterally extending surface portion, wherein the base portion is axially positioned between the sorbent member and the laterally extending surface portion; and

[0160] An intermediate sidewall extends axially outwardly from the laterally extending surface portion an axial length, wherein the intermediate sidewall is positioned between the first sidewall and the second sidewall.

[0161] Embodiment 18. The filter assembly of any one of Embodiments 1 to 17 and 19 to 25, wherein the inner body is non-rigid.

[0162] Embodiment 19. The filter assembly of any one of Embodiments 1 to 18 and 20 to 25, wherein the intermediate body is rigid.

[0163] Embodiment 20. The filter assembly of any one of Embodiments 1-19 and 21-25, wherein the second sidewall abuts the first sidewall along a length of the first sidewall.

[0164] Embodiment 21. The filter assembly of any of Embodiments 1-20 and 22-25, wherein the second sidewall extends at least 75% of the axial length of the first sidewall.

[0165] Embodiment 22. The filter assembly of any of Embodiments 1-21 and 23-25, wherein the second sidewall extends at least 85% of the axial length of the first sidewall.

[0166] Embodiment 23. The filter assembly of any of Embodiments 1-22 and 24-25, wherein the second sidewall extends at least 90% of the axial length of the first sidewall.

[0167] Embodiment 24. The filter assembly of any one of Embodiments 1-23 and 25, wherein the second sidewall extends at least 95% of the axial length of the first sidewall.

[0168] Embodiment 25. The filter assembly of any one of Embodiments 1 to 24, wherein the second sidewall extends 100% of the axial length of the first sidewall.

[0169] Embodiment 26. A method of forming a filter assembly, the method comprising:

[0170] forming an inner body having a base and a first sidewall, the base extending in a transverse direction, the first sidewall extending axially outwardly from the base an axial length, wherein the base and the first sidewall define a cavity, and the first sidewall has a peripheral surface portion surrounding the cavity;

[0171] disposing an adsorbent member in the cavity;

[0172] disposing a first member of filter media on the peripheral surface portion and throughout the cavity; and

[0173] An outer body is disposed on the inner body such that a second side wall of the outer body is positioned laterally outside of and surrounds the first side wall, wherein the second side wall extends at least 50% of the axial length of the first side wall, and wherein the outer body has a first axial end and a second axial end, and wherein the outer body further comprises a retaining portion, the retaining portion extending laterally inward from the first axial end of the second side wall, and the retaining portion is positioned axially outside of the first filter medium component.

[0174] Embodiment 27. The method of any of Embodiments 26 and 28 to 50, further comprising: disposing a second piece of filter media on the first piece of filter media, and coupling the second piece of filter media to the second sidewall to define the retaining portion.

[0175] Embodiment 28. The method of any one of Embodiments 26 to 21 and 29 to 50, wherein the retaining portion is an inner rim portion defining a central opening, wherein the inner rim portion extends laterally over at least a portion of the peripheral surface portion.

[0176] Embodiment 29. The method of any one of embodiments 26 to 22 and 30 to 50, further comprising: bonding the inner surface of the outer body to the inner surface of the inner body.

[0177] Embodiment 30. The method of any one of Embodiments 26 to 23 and 31 to 50, further comprising: bonding the second axial end of the second sidewall to the base.

[0178] Embodiment 31. The method of any one of Embodiments 26-24 and 32-50, further comprising: bonding the first filter media piece to the peripheral surface portion.

[0179] Embodiment 32. The method of any one of Embodiments 26-25 and 33-50, further comprising: bonding the first filter media piece to the retaining portion.

[0180] Embodiment 33. The method of any one of Embodiments 26 to 26 and 34 to 50, wherein the sorbent member comprises carbon.

[0181] Embodiment 34. The method of any one of Embodiments 26-27 and 35-50, wherein the first filter media element comprises a microporous membrane.

[0182] Embodiment 35. A method according to any one of embodiments 26 to 28 and 36 to 50, wherein the inner body is made of an impermeable material.

[0183] Embodiment 36. A method according to any one of embodiments 26 to 29 and 37 to 50, wherein the inner body is rigid.

[0184] Embodiment 37. A method according to any one of embodiments 26 to 50 and 38 to 50, wherein the second side wall is made of an impermeable material.

[0185] Embodiment 38. The method of any one of embodiments 26 to 31 and 39 to 50, wherein the second side wall is rigid.

[0186] Embodiment 39. The method of any of Embodiments 26-32 and 40-50, further comprising overmolding the second sidewall onto the first filter media piece and the inner body.

[0187] Embodiment 40. The method of any one of Embodiments 26 to 33 and 41 to 50, further comprising: coupling an adhesive layer to the outer surface of the base.

[0188] Embodiment 41. The method of any one of Embodiments 26 to 34 and 42 to 50, wherein the base defines a diffusion channel.

[0189] Embodiment 42. The method of any one of embodiments 26 to 35 and 43 to 50, further comprising: disposing the inner body in an intermediate body, wherein the intermediate body comprises:

[0190] a laterally extending surface portion, wherein the base portion is axially positioned between the sorbent member and the laterally extending surface portion; and

[0191] An intermediate sidewall extends axially outwardly from the transversely extending surface portion an axial length, wherein the intermediate sidewall is positioned between the first sidewall and the second sidewall.

[0192] Embodiment 43. A method according to any one of embodiments 26 to 36 and 44 to 50, wherein the inner body is non-rigid.

[0193] Embodiment 44. A method according to any one of embodiments 26 to 43 and 45 to 50, wherein the intermediate body is rigid.

[0194] Embodiment 45. The method of any one of Embodiments 26 to 44 and 46 to 50, wherein the second sidewall abuts the first sidewall along a length of the first sidewall.

[0195] Embodiment 46. The method of any one of Embodiments 26 to 45 and 47 to 50, wherein the second sidewall extends at least 75% of the axial length of the first sidewall.

[0196] Embodiment 47. The method of any one of Embodiments 26 to 46 and 48 to 50, wherein the second sidewall extends at least 85% of the axial length of the first sidewall.

[0197] Embodiment 48. The method of any one of Embodiments 26 to 47 and 49 to 50, wherein the second sidewall extends at least 90% of the axial length of the first sidewall.

[0198] Embodiment 49. The method of any one of embodiments 26 to 48 and 50, wherein the second sidewall extends at least 95% of the axial length of the first sidewall.

[0199] Embodiment 50. The method of any one of Embodiments 26 to 49, wherein the second sidewall extends 100% of the axial length of the first sidewall.

[0200] It should also be noted that, as used in this specification and the appended claims, the phrase "configured" describes a system, device or other structure that is configured to perform a specific task or adopt a specific configuration. The word "configured" can be used interchangeably with similar words such as "arranged", "composed", "made".

[0201] All disclosures and patent applications in this specification indicate the level of common technology in the field to which the technology belongs. All disclosures and patent applications are incorporated herein by reference, and the extent of reference is the same as that each individual disclosure or patent application is specifically and individually indicated by reference. In the event of any inconsistency between the disclosure of this application and the disclosure of any document incorporated herein by reference, the disclosure of this application shall be used for ruling.

[0202] This application is intended to cover modifications or variations of the subject matter.It is to be understood that the above description is intended to be illustrative and not restrictive, and that the claims are not limited to the illustrative embodiments as described herein.

Claims

1. A filter assembly, comprising: a housing including an inner body and an outer body surrounding at least a portion of the inner body, the inner body having a base and a first sidewall, the base extending in a transverse direction, the first sidewall extending axially outwardly from the base an axial length, wherein the inner body defines a cavity and the first sidewall defines a peripheral surface portion surrounding the cavity; a first piece of filter media extending over the peripheral surface portion and throughout the cavity; and an adsorbent member disposed in the cavity, wherein the outer body includes a second side wall located laterally outside of and surrounding the first side wall, wherein the second side wall extends at least 50% of the axial length of the first side wall, and wherein the outer body has a first axial end and a second axial end, and wherein the outer body also includes a retaining portion extending laterally inward from the first axial end of the second side wall, and wherein the retaining portion is positioned axially outside of the first filter medium component.

2. The filter assembly according to claim 1 and any one of claims 3 to 14, wherein: The retaining portion includes a second piece of filter media coupled to the second sidewall and extending over the first piece of filter media.

3. The filter assembly according to any one of claims 1 to 2 and claims 4 to 14, wherein: The retaining portion is an inner rim portion defining a central opening, wherein the inner rim portion extends transversely over at least a portion of the peripheral surface portion.

4. The filter assembly according to any one of claims 1 to 3 and claims 5 to 14, wherein: The first filter media piece is bonded to the peripheral surface portion.

5. The filter assembly according to any one of claims 1 to 4 and claims 6 to 14, wherein: The first piece of filter media is bonded to the retaining portion.

6. The filter assembly according to any one of claims 1 to 5 and claims 7 to 14, wherein: The inner body is constructed of an impermeable material.

7. The filter assembly according to any one of claims 1 to 6 and claims 8 to 14, wherein: The inner body is rigid.

8. The filter assembly according to any one of claims 1 to 7 and claims 9 to 14, wherein: The second side wall is formed of an impermeable material.

9. The filter assembly according to any one of claims 1 to 8 and claims 10 to 14, wherein: The second side wall is rigid.

10. The filter assembly according to any one of claims 1 to 9 and claims 11 to 14, wherein The second sidewall is a coating on the first filter media element and the inner body.

11. The filter assembly according to any one of claims 1 to 10 and claims 12 to 14, wherein: The base defines a diffusion channel.

12. The filter assembly according to any one of claims 1 to 11 and claims 13 to 14, further comprising an intermediate body disposed between the inner body and the outer body, wherein: The intermediate entity comprises: a laterally extending surface portion, wherein the base portion is axially positioned between the sorbent member and the laterally extending surface portion; and An intermediate sidewall extends axially outwardly from the laterally extending surface portion an axial length, wherein the intermediate sidewall is positioned between the first sidewall and the second sidewall.

13. The filter assembly according to any one of claims 1 to 12 and claim 14, wherein: The second side wall abuts the first side wall along a length of the first side wall.

14. The filter assembly according to any one of claims 1 to 13, wherein The second sidewall extends at least 75% of the axial length of the first sidewall.

15. A method of forming a filter assembly, the method comprising: forming an inner body having a base and a first sidewall, the base extending in a transverse direction, the first sidewall extending axially outwardly from the base an axial length, wherein the base and the first sidewall define a cavity, and the first sidewall has a peripheral surface portion surrounding the cavity; disposing an adsorbent member in the cavity; disposing a first member of filter media on the peripheral surface portion and throughout the cavity; and An outer body is disposed on the inner body such that a second side wall of the outer body is laterally outside of and surrounds the first side wall, wherein the second side wall extends at least 50% of the axial length of the first side wall, and wherein the outer body has a first axial end and a second axial end, and wherein the outer body further comprises a retaining portion, the retaining portion extending laterally inward from the first axial end of the second side wall, and the retaining portion is positioned axially outside of the first filter medium component.

16. The method according to claim 15 and any one of claims 17 to 20, further comprising: A second piece of filter media is disposed on the first piece of filter media and the second piece of filter media is coupled to the second sidewall to define the retaining portion.

17. The method according to any one of claims 15 to 16 and claims 18 to 20, wherein: The retaining portion is an inner rim portion defining a central opening, wherein the inner rim portion extends transversely over at least a portion of the peripheral surface portion.

18. The method according to any one of claims 15 to 17 and claims 19 to 20, further comprising: The second sidewall is overmolded onto the first piece of filter media and the inner body.

19. The method according to any one of claims 15 to 18 and claim 20, further comprising: The inner body is arranged in an intermediate body, wherein the intermediate body comprises: a laterally extending surface portion, wherein the base portion is axially positioned between the sorbent member and the laterally extending surface portion; and An intermediate sidewall extends axially outwardly from the laterally extending surface portion an axial length, wherein the intermediate sidewall is positioned between the first sidewall and the second sidewall.

20. The method according to any one of claims 15 to 19, wherein: The second sidewall extends at least 75% of the axial length of the first sidewall.

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