Filter system and filter element with variable geometry sealing member

Abstract

A filtration system comprises a housing, a cover, and a filter element having a variable geometry sealing member. The housing comprises a sealing surface disposed at a housing first end. The variable geometry sealing member is disposed at the sealing surface. A shape of the variable geometry sealing member is defined by a first curve having a first radius and a second curve having a second radius. The first curve and the second curve are non-concentric such that a thickness of the variable geometry sealing member is non-uniform. The cover is coupled to the housing such that a surface of the cover compresses the variable geometry sealing member against the sealing surface.

Description

FILTER SYSTEM AND FILTER ELEMENT WITH VARIABLEGEOMETRY SEALING MEMBERCROSS-REFERENCE TO RELATED APPLICATION[0001 | This PCT Application claims the benefit and priority to U.S. Provisional Application No. 63 / 449,423 filed March 2, 2023, the contents of which is incorporated herein by reference in its entirety.FIELD

[0002] The present invention generally relates to filtration systems for filtering fluids such as air.BACKGROUND

[0003] A filtration system may be used to remove contaminants from air. The filtration system may include a filter element disposed within a housing and a cover. In operation, the filtration system directs the air through the filter element, which includes a filter media or filter media pack that captures contaminants entrained in the air. The performance of the filtration system depends, among other factors, on the structure of the filter element, including a sealing member that prevents air from bypassing the filter element or filter media.SUMMARY OF THE INVENTION10004] One embodiment of the invention relates to a filtration system. The filtration system includes a housing, a cover, and a filter element. The housing includes a sealing surface disposed at a housing first end. The filter element includes a variable geometry sealing member that is disposed at the sealing surface. A shape of the variable geometry sealing member is defined by a first curve having a first radius and a second curve having a second radius. The first curve and the second curve are non-concentric such that a thickness of the variable geometry sealing member is non-uniform. The cover is coupled to the housing such that asurface of the cover compresses the variable geometry sealing member against the sealing surface.|0005] These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below.BRIEF DESCRIPTION OF THE DRAWINGS[0006| FIG. 1 is a perspective view of a filtration system, according to an example embodiment.10007] FIG. 2 is a cross-sectional view of the filtration system of FIG. 1.

[0008] FIG. 3 is a perspective view of a filter element usable in the filtration system of FIG. 1, according to an example embodiment.|0009] FIG. 4 is a perspective view of a filter media pack usable in the filtration system of FIG. 1.|0010] FIG. 5 is a diagram showing steps of assembling a portion of the filter element of FIG. 3, according to an example embodiment.[00111 FIG. 6 is a diagram showing steps of assembling a portion of the filter element of FIG. 3, according to another example embodiment.

[0012] FIG. 7 is a side view of a portion of the filter element of FIG. 3.

[0013] FIG. 8 is a side sectional view of a filtration system, shown at a first depth.

[0014] FIG. 9 is a side sectional view of the filtration system of FIG. 1, shown at a second depth.

[0015] FIG. 10 is a side sectional view of the filtration system of FIG. 1, shown at a third depth.|O016] FIG. 11 is a side sectional view of the filtration system of FIG. 1, shown at a fourth depth.

[0017] FIG. 12 is a side sectional view of the filtration system of FIG. 1, shown at a fifth depth.|0018] FIG. 13 is a side sectional view of the filtration system of FIG. 1, shown at a sixth depth.|0019] FIG. 14 is a side sectional view of the filtration system of FIG. 1, shown at a seventh depth.

[0020] FIG. 15 is a perspective view of a filter element usable in the filtration system of FIG. 1 , according to another example embodiment.

[0021] FIG. 16 is a diagram showing steps of assembling a portion of the filter element of FIG. 15, according to an example embodiment.

[0022] FIG. 17 is a perspective view of a frame usable with the filter element of FIG. 15.

[0023] FIG. 18 cross sectional view of the frame of FIG. 17.

[0024] FIG. 19 is a perspective view of a sealing member assembly usable with the filter element of FIG. 15.|0025] FIG. 20 is a cross sectional view of the sealing member assembly of FIG. 19.

[0026] FIG. 21 is a perspective view of a filter media pack usable with the filter element of FIG. 15, shown with the sealing member assembly of FIG. 19.

[0027] FIG. 22 is a cross sectional view of the filter media pack and sealing member assembly of FIG. 21.

[0028] FIG. 23 is a cross sectional view of the filter media pack of FIG. 21 shown with the sealing member assembly of FIG. 19.|0029] FIG. 24 is a cross sectional view of the filter element of FIG. 15 shown with an inlet frame.DETAILED DESCRIPTION|0030] Referring to the Figures generally, various embodiments disclosed herein relate to a fdtration system. More specifically, the various embodiments disclosed herein relate to a filtration system for filtering a fluid, such as air. The filtration system includes a filter housing, a filter media pack having a variable geometry sealing member, and a cover.

[0031] The various embodiments described herein provide an improved air filtration system that includes a filter element having a variable geometry sealing member that is non-uniformly compressed along a length of the filter element. In particular, the variable geometry sealing member has an increased percent compression at a central portion of the filtration system compared to an end portion of the filtration system. The non-uniform compression of the variable geometry sealing member mitigates against leakage / filter media bypass due to deflection of the filter housing. In some embodiments, the variable geometry sealing member has less variation in seal thickness than alternative seal designs, thereby improving moldability of the variable geometry sealing member. In some embodiments, the variable geometry sealing member is structured to self-align within the filter housing thereby improving ease of installation of the variable geometry sealing member.|0032] FIGS. 1 and 2 are a perspective view and a sectional view, respectively, of a filtration system 100, according to an example embodiment. The filtration system includes a housing 102, a filter element 104, and a cover 106. The cover 106 is coupled to the housing 102. As shown in FIG. 1, the filtration system 100 also includes a hinge member 110. The housing 102 and the cover 106 are coupled to each other by the hinge member 110. The cover 106 is movable relative to the housing 102 via the hinge member 110. The hinge member 110 is disposed at a first side of the housing 102. The housing 102 and the cover 106 cooperate todefine an internal volume 120. The housing 102 is configured to receive the filter element 104 within the internal volume 120. The housing 102 includes an outlet port 108 disposed at a downstream side of the filter element 104.

[0033] In an example embodiment, the filtration system 100 defines a first axis 122. One or more of the components of the filtration system 100 may be centered on the first axis 122. The filtration system 100 can be centered on the first axis 122. For example, the first axis 122 extends through a center point of the filtration system 100.

[0034] As used herein, the term “axis” describes a theoretical line extending through at least a portion of an object, such as a centroid (e.g., center of mass, geometric center, etc.) of an object. In some arrangements, the object is centered on the axis. The object is not necessarily cylindrical (e.g., a non-cylindrical shape may be centered on an axis, etc.). Furthermore, the object is not necessarily on the axis (e.g., a centroid of a hollow object may be on the axis, but no portion of the object needs to be on the axis).|0035] The relative positioning of the components of the filtration system 100 described herein may be described relative to the first axis 122. For example, an axial direction is along or substantially parallel to the axis first 122. In another example, the cover 106 is disposed at a first axial end of the housing 102. A lateral direction may be defined as a direction that is substantially perpendicular to the axial direction. For example, a lateral direction is along or substantially parallel to a second axis 124 (e.g., a lateral axis). The second axis 124 is substantially perpendicular to the first axis 122. A longitudinal direction may be defined as a direction that is substantially perpendicular to the axial direction and the lateral direction. For example, a lateral direction is along or substantially parallel to a third axis 126 (e.g., a longitudinal axis). The third axis 126 is substantially perpendicular to the first axis 122 and the second axis 126. An outward direction may be substantially away from the first axis 122 (e.g., in the lateral direction, the longitudinal direction, or both). An inward direction may be substantially towards the axis 122 (e.g., in the lateral direction, the longitudinal direction, or both). For example, the filter element 104 is disposed inward relative to the housing 102, and the housing 102 is disposed outward relative to the filter element 104.

[0036] The housing 102 includes a housing body 130. The housing body 130 at least partially defines the internal volume 120. The internal volume 120 is sized to receive the filter element 104. The housing body 130 includes a housing wall 132. The housing wall 132 extends in a substantially axial direction. The housing body 130 includes a housing sealing portion 134. The housing sealing portion 134 includes a lower wall portion 136 and an upper wall portion 138. The lower wall portion 136 extends outward from the housing wall 132, away from the filter element 104. The upper wall portion 138 extends axially away from the lower wall portion 136, towards the cover 106. In some embodiments, at least a portion of the housing wall 132 extends axially above the lower wall portion 136. The housing sealing portion 134 may include the portion of the housing wall 132 that extends axially above the lower wall portion 136.

[0037] The housing 102 includes a housing engagement member 139. The housing engagement member 139 may be part of the housing body 130. The housing engagement member 139 is disposed at a second side of the housing 102, opposite the first side. In some embodiments, the first side and the second side of the housing 102 disposed at lateral sides of the housing 102 (e.g., sides that are spaced away from the first axis 122 in the lateral direction). In other embodiments, the first side and the second side of the housing 102 disposed at longitudinal sides of the housing 102 (e.g., sides that are spaced away from the first axis 122 in the longitudinal direction). The housing engagement member 139 is configured to engage at least a portion of the cover 106.

[0038] The housing 102 includes a sealing surface 140 that is disposed around a top end of the housing. In the embodiment shown in FIGS. 1 and 2, the sealing surface 140 is a channel. In other embodiments, the sealing surface may be a ledge or other surface of the housing. The sealing surface 140 is defined by the housing sealing portion 134. More specifically, at least the lower wall portion 136 and the upper wall portion 138 cooperate to define the sealing surface 140. In some embodiments, the sealing surface 140 is further defined by the portion of the housing wall 132 that extends axially above the lower wall portion 136.[0039[ The sealing surface 140 is structured to engage a portion of the filter element 104. More specifically, the filter element 104 includes a variable geometry sealing member 200 that engages the sealing surface 140.

[0040] The cover 106 includes an end wall 150 that defines an inlet opening 152 disposed at an upstream side of the filter element 104. The cover 106 may include one or more ribs 154 extending across the inlet opening 106. The ribs 154 may be coupled to or contiguous with the end wall 150. The ribs 154 may include a first set of ribs that extend across the inlet opening 152 in a first direction (e.g., the lateral direction). The ribs 154 may include a second set of ribs that extend across the inlet opening 152 in a second direction, different than the first direction (e g., the longitudinal direction).[00411 In some embodiments, the cover 106 includes a skirt 156. The skirt 156 extends away from the end wall 150 towards the housing 102. For example, the skirt 156 extends towards the housing 102 in the axial direction.|0042[ In some embodiments, the cover 106 is coupled to the housing 102 by the housing engagement member 139. The housing engagement member 139 is structured to engage a cover engagement member 158. As shown in FIG. 1, the cover 106 is coupled to the housing 102 in a snap fit arrangement. For example, the housing 102 includes a housing snap fit engagement member 139 disposed at a second side of the housing 102, opposite the first side. The cover 106 includes a cover snap fit engagement member 158 disposed at the housing snap fit engagement member 139. The cover snap fit engagement member 158 is structured to engage the housing snap fit engagement member 139 thereby coupling the cover 106 to the housing 102. In an example embodiment, the housing engagement member 139 defines an opening that is sized to receive at least a portion of the cover engagement member 158. In other embodiments, the cover 106 is coupled to the housing 102 by a different engagement member, such as a spring clip, a latch, a fastener, etc.[0043[ The cover 106 includes a sealing portion 160. The sealing portion 160 provides a force on the variable geometry sealing member 200, thereby pressing the variable geometry sealing member 200 into the sealing surface 140 of the housing 102. In this way, the variable geometrysealing member 200 forms a seal between the cover 106 and the housing 102 at the sealing surface 140.|0044] In some embodiments, and as shown in FIG. 2, the sealing portion 160 is or includes an axial projection 162. The projection 162 extends away from the end wall 150 and towards the housing 102. The projection 162 is positioned to contact the variable geometry sealing member 200 when the cover 106 is coupled to the housing 102. In some embodiments, the sealing portion is or includes one or more projections 162. In some embodiments, the projections 162 are contiguous with each other. In other embodiments, the projections 162 are non-contiguous with each other.. The sealing portion 160 is structured to provide an axial force (e.g., a force in the axial direction) to the variable geometry sealing member 200 such that the variable geometry sealing member 200 forms an axial seal (e.g., a seal in the axial direction) between the cover 106 and the housing 102.|0045[ FIG. 3 is a perspective view of the fdter element 104 usable in the filtration system 100 of FIG. 1, according to an example embodiment. In some embodiments, the filter element 104 is a primary filter element of the filtration system 100. That is, the filtration system 100 may include the filter element 104 and one or more additional filter elements.[0046| The filter element 104 includes a filter media pack 112 and the variable geometry sealing member 200. The filter media pack 112 is configured to filter a fluid, such as air. The filter media pack 104 is described in greater detail herein with respect to FIG. 4.|0047[ The variable geometry sealing member 200 has variation in seal thickness along a perimeter thereof. In some embodiments, the variable geometry sealing member 200 is coupled to the filter media pack 104. The shape of the variable geometry sealing member 200 is described in greater detail herein with respect to FIG. 7.[00481 Now referring to FIG. 4, a perspective view of the filter media pack 112 usable in the filter element 104 of FIG. 3 is shown. As shown in FIG. 4, the filter media pack 112 has a rectangular cross-section. In other embodiments, the filter media pack 112 has a round, obround, or other irregular shaped cross-section.

[0049] In some embodiments, the filter media pack 112 is a layered filter media pack having one or more layers of filter media joined together to form the filter media pack 112. In some embodiments, the filter media pack 112 is a pleated filter media having one or more pleated filter media layers. In some embodiments, when the filter media pack 112 is a pleated filter media, the pleat ends of the filter media pack 112 are sealed by adhesive and / or a potting, molding, or encapsulating process.

[0050] In some embodiments, the filter media pack 112 includes embossed media spacers that space layers of the filter media pack 112 away from each other. In other embodiments, the layers of the filter media pack 112 are spaced by an adhesive.

[0051] In some embodiments, when the filter media pack 112 is round or obround in shape, the filter media pack 112 is a corrugated media, a formed media sheet bonded to a flat media sheet, or a continuously wound single pleat.

[0052] In some embodiments, the filter element 104 includes a protective outer wrap 114 that extends around the side(s) of the filter media pack 112. For example, when the media pack 112 has a rectangular cross section the outer wrap 114 extends around four sides of the filter media pack 112. In other embodiments, the outer wrap 114 is provided only on two sides of the filter media pack 112. In these embodiments when a pleated media pack is used, the outer wrap 114 is coupled to pleat ends of the filter media pack 112 in a potting process. In yet other embodiments, when the filter media pack 112 is round or obround in shape the outer wrap 114 is formed around a perimeter of the filter media pack 112. In any of the above-described embodiments, the outer wrap 114 may be formed by one or more side panels that may be folded or wrapped around the filter media pack 112.

[0053] The variable geometry sealing member 200 is coupled to the filter media pack 112. In some embodiments, the variable geometry sealing member 200 is molded onto the filter media pack 112. In some embodiments, when the filter element 104 includes the outer wrap 114, the variable geometry sealing member 200 is molded onto the outer wrap 114. In other embodiments, the variable geometry sealing member 200 is stretched around a perimeter of the filter media pack 112 such that the filter media pack 112 is compressed by the variablegeometry sealing member 200. In yet other embodiments, the variable geometry sealing member 200 is coupled to a frame, and the frame is coupled to the filter media pack 112. The frame 250 is described herein with respect to FIGS. 15-24.

[0054] Now referring to FIGS. 5 and 6, diagrams showing steps of assembling a portion of the filtration system 100 of FIG. 1 are shown, according to various example embodiments. More specifically, a potting process for sealing a portion of the filter media pack 112 shown in FIG. 3 is shown in FIGS. 5 and 6.

[0055] Referring first to FIG. 5, a method 500 of a potting process is shown. In the embodiment shown in FIG. 5, a portion of the outer wrap 114 (e g., a side panel) is used for the potting process. At process 502, at least one side panel or outer wrap 114, having a first segment 115, a second segment 116, and a third segment 117 is provided. At process 504, the first segment 114 and the third segment 117 of the outer wrap 114 are folded upwards, away from the second segment 116. At process 506, a potting adhesive 118 is provided on the second segment 116. At process 508, a first side of the filter media pack 112 is provided on the second segment 116 such that the ends and / or edges of the layers of the filter media pack 112 are joined together and encapsulated by the potting adhesive 118. The potting adhesive 118 also couples the first side of the filter media pack 112 to the outer wrap 114.]0056] In some embodiment, the potting adhesive 118 is a “hot-melt” adhesive. The hot-melt adhesive is provided on the second segment 116 of the side panel or outer wrap 114. In some embodiments, the density of the hot-melt adhesive is approximately 0.92 grams per cubic centimeter (g / cc). In other embodiments, the density of the hot-melt adhesive is approximately 1.03 grams per cubic centimeter (g / cc). The hot-melt adhesive may possess other densities as well. In other embodiments, the potting adhesive 118 is a urethane based adhesive and / or another suitable type of adhesive compound.|0057] Referring now to FIG. 6, a method 600 of a potting process is shown. As shown, a mold 610 is used for the potting process. At process 602, the filter media pack 112 is provided. At process 604, the mold 610 is provided. At process 606, the potting adhesive 118 is provided in a cavity 612 of the mold 610. At process 608, the filter media pack 112 is provided, at leastpartially, within the cavity 612 such that the potting adhesive 118 joins and seals the ends / edges of the layers of the filter media pack 112.

[0058] FIG. 7 is a side view of a portion of the filter element 104 of FIG. 3. More specifically, a side view of the variable geometry sealing member 200 is shown. The sealing surface 140 is configured to have a shape that is substantially similar to or the same as the variable geometry sealing member 200.[0059| The sealing member 200 includes a sealing member wall, shown as a wall 202, and a sealing member projection, shown as a sealing member body 206. A connecting portion 204 extends between the wall 202 and the sealing member body 206. The wall 202 and the connecting portion 204 are described in greater detail herein with respect to FIGS. 15-24.

[0060] The wall 202 extends in an axial direction, substantially parallel to the housing wall 132. The wall 202 may contact an outer surface of the fdter media pack 1 12. In some embodiments, the outer surface of the filter media pack 112 is defined by the outer wrap 114 and / or one or more endcaps, such as the endcaps 119, shown in FIG. 15.[006.1 ] The sealing member body 206 is disposed on a side of the sealing member 200. The sealing member body 206 extends outward, away from the filter element 104, towards the housing 102. The sealing member body 206 extends away from the wall 202. The sealing member body 206 is received by the housing sealing portion 134, such that the sealing member body 206 contacts the sealing surface 140.

[0062] In some embodiments, the sealing member 200 includes one or more projections 206. For example, the sealing member 200 may include a corresponding sealing member body 206 disposed on each side of the sealing member 200. In some embodiments, the sealing member 200 has a substantially rectangular cross-sectional shape, such that the sealing member 200 has four sides. In these embodiments, the sealing member 200 includes four projections 206. In some embodiments, adjacent projections 206 are contiguous with each other. In other embodiments, adjacent projections are coupled to each other. For example, a first sealing member body 206 disposed at a first side of the sealing member 200 and a second sealingmember body 206 disposed at a second side of the sealing member 200, adjacent to the first side may be coupled to each other at or proximate a corner defined by the first and second sides of the sealing member 200. In another example, the first sealing member body 206 and the second sealing member body 206 are contiguous with each other such that a corner is defined where the first sealing member body 206 and the second sealing member body 206 coincide.[0O63| A thickness (e.g., in the axial direction) of the sealing member body 206 (e.g., each sealing member body 206) is defined by a first curve 210 having a first radius 212 and a second curve 220 having a second radius 222, larger than the first radius 212. In some embodiments, the first curve 210 and the second curve 220 are not concentric such that a distance between the first curve 210 and the second curve 220 is not uniform. More specifically, and as shown in FIG. 7, a first distance 214 between the first curve 210 and the second curve 220 at a sealing member first end 214 is less than a second distance 216 between the first curve 210 and the second curve 220 at a sealing member central portion. A third distance 218 between the first curve 210 and the second curve 220 at a sealing member second end is substantially similar to or the same as the first distance 214 between the first curve 210 and the second curve 220 at the sealing member first end. As such, an axial thickness (e.g., the thickness in the axial direction)of the sealing member 200 is non-uniform.|<>064] In an example embodiment, and as shown in FIG. 7, the first distance 214 is defined between the first curve 210 and the second curve 220 at a sealing member first end 214. The second distance 216 is defined between the first curve 210 and the second curve 220 at a sealing member central portion. The third distance 218 is defined between the first curve 210 and the second curve 220 at a sealing member second end. The second distance 216 is greater than the first distance 214. The second distance 216 is greater than the third distance 218. In some embodiments, the first distance 214 and the third distance 218 are equal.

[0065] Each sealing member body 206 may have the same or substantially similar axial thickness. For example, each sealing member body 206 may have a corresponding first curve 210 and second curve 220, where each first curve 210 has the same radius 212, and eachsecond curve 220 has the same second radius 222. Thus, adjacent projections 206 may have the same axial thickness at a location where the adjacent projections 206 coincide.|0066] A central portion of the variable geometry sealing member 200 defines a first thickness or first depth 216. A first end of the variable geometry sealing member 200 defines a second thickness or a second depth 214 that is smaller than the first depth 216. A second end of the variable geometry sealing member 200, opposite the first end, defines a third depth 218 that is substantially similar to or the same as the second depth.

[0067] In the embodiment shown in FIG. 7, both the first curve 210 and the second curve 220 are concave curves relative to the housing 102. In other embodiments, both the first curve 210 and the second curve 220 may be convex curves relative to the housing 102. In still other embodiments, one of the first curve 210 or the second curve 220 is substantially straight (e.g., having an infinite radius), and the other is concave. In yet other embodiments, one of the first curve 210 or the second curve 220 is substantially straight (e g., having an infinite radius), and the other is convex. In yet another embodiment, the variable geometry sealing member 200 has a uniform thickness along the center portion of the variable geometry sealing member 200 and a tapered or decreasing thickness at the first end of the variable geometry sealing member 200 and / or at the second end of the variable geometry sealing member.(0068] Now referring to FIGS. 8-14 various side sectional views of the filtration system 100 of FIG. 1 are shown at varying depths. The non-uniform thickness of the variable geometry sealing member 200, or more specifically, the sealing member body 206, along the length of the variable geometry sealing member 200 (e.g., in the longitudinal direction for a sealing member body 206 on a lateral side of the filtration system 100 and / or in the lateral direction for a sealing member body 206 on a longitudinal side of the filtration system 100) results in a different percent compression of the sealing member body 206 along the length of the variable geometry sealing member 200. More specifically, because a central portion of the sealing member body 206 is thicker than the end portions of the sealing member body 206, the compression of the sealing member body 206 is non-uniform. Variables that cause the non- uniform compression of the sealing member body 206 include the thickness of the sealingmember body 206, the geometry of the sealing surface 140 of the housing 102 relative to the geometry of the sealing member body 206, and a distance between the sealing surface 140 and the sealing portion 160 of the cover 106 relative to the thickness of the sealing member body 206. Accordingly, adjusting any of these variables may change the compression of the sealing member body 206.

[0069] The sectional view shown in FIG. 8 is shown at a first depth, proximate the central portion of the variable geometry sealing member 200. In the arrangement shown, the central portion of the sealing member body 206 is compressed approximately 12% to 20% of the thickness of the sealing member body 206.

[0070] The sectional view shown in FIG. 9 is shown at a second depth between the first depth and the first end portion of the variable geometry sealing member 200. In the arrangement shown, the sealing member body 206 proximate the second depth is compressed approximately 12% to 20% of the thickness of the sealing member body 206.|007l] The sectional view shown in FIG. 10 is shown at a third depth between the second depth and the first end portion of the variable geometry sealing member 200. In the arrangement shown, the sealing member body 206 proximate the third depth is compressed approximately 12% to 20% of the thickness of the sealing member body 206.[00721 The sectional view shown in FIG. 11 is shown at a fourth depth between the third depth and the first end portion of the variable geometry sealing member 200. In the arrangement shown, the sealing member body 206 proximate the fourth depth is compressed approximately 10% to 20% of the thickness of the sealing member body 206.

[0073] The sectional view shown in FIG. 12 is shown at a fifth depth between the fourth depth and the first end portion of the variable geometry sealing member 200. In the arrangement shown, the sealing member body 206 proximate the fifth depth is compressed approximately 9% to 19% of the thickness of the sealing member body 206.

[0074] The sectional view shown in FIG. 13 is shown at a sixth depth between the fifth depth and the first end portion of the variable geometry sealing member 200. In the arrangementshown, the sealing member body 206 proximate the sixth depth is compressed approximately 8% to 18% of the thickness of the sealing member body 206.|0075] The sectional view shown in FIG. 14 is shown at a seventh depth between the sixth depth and the first end portion of the variable geometry sealing member 200. In the arrangement shown, the sealing member body 206 proximate the seventh depth is compressed approximately 7% to 17% of the thickness of the sealing member body 206.[O076| It should be noted that the compression levels identified with respect to FIGS. 8-14 are examples only, and the compression amounts can vary in different system arrangements.

[0077] Now referring to FIG. 15, a perspective view of the filter element 104 usable in the filtration system 100 of FIG. 1 is shown, according to another example embodiment. The filter element 104 shown in FIG. 15 includes the filter media pack 112, the variable geometry sealing member 200, and the frame 250. The frame 250 is disposed around a perimeter of the filter media pack 112. In some embodiments, the frame 250 is disposed at a first end of the filter media pack 112, proximate the cover 106. In some embodiments, the frame 250 is disposed between the filter media pack and the variable geometry sealing member 200.|0078] In some embodiments, the frame 250 is a contiguous part extends around the perimeter of the filter media pack 112. In other embodiments the frame 250 is not contiguous such that the frame 250 includes one or more frame segments disposed around the perimeter of the filter media pack 112. In some embodiments, the frame 250 is made from plastic material. In some embodiments, the variable geometry sealing member 200 is molded to frame 250. The frame 250 includes a portion, such as a flange 158 (shown in FIG. 18), that the variable geometry sealing member 200 is molded around. In some embodiments, the portion of the frame 250 enables the variable compression of the sealing member body 206 (e.g., between the cover 106 and the sealing surface 140). In other embodiments, the variable geometry sealing member 200 is stretched around a perimeter of the frame 250 such that the frame 250 is compressed by the variable geometry sealing member.

[0079] In some embodiments, the frame 250 and the variable geometry sealing member 200 cooperate to form a sealing member assembly 260. The sealing member assembly 260 is coupled to the filter media pack 112. In some embodiments, the sealing member assembly 260 is coupled to the filter media pack 112 with an adhesive.[0080| The variable geometry sealing member 200 is substantially similar to the variable geometry sealing member described herein with respect to FIGS. 1-14. The variable geometry sealing member 200 includes an opening, such as a cavity 210 (shown in FIG. 20) that is sized to receive a portion of the frame 250, such as the flange 158.|O081] The filter media pack 112 is substantially similar to the filter media pack 112 described herein with respect to FIGS. 1-14. The filter media pack 112 includes one or more endcaps 119. At least one side of the filter media pack 112 is potted in the endcap 119. For example, the filter media pack 112 may include four endcaps 119 disposed on the sides (e.g., the lateral and longitudinal sides) of the filter media pack 1 12.|O082] FIG. 16 is a diagram showing a method 700 of assembling a portion of the filter element 104 of FIG. 15, according to another example embodiment. More specifically, the method 700 includes a potting process for sealing a portion of the filter media pack 112 with the endcap 119 is shown in FIG. 16.[00831 At process 702 the filter media pack 112 is provided. At process 704 at least one endcap is provided. At process 706, an adhesive 128 is applied to at least a portion of the endcap 128. At process 708, a first side of the filter media pack 112 is provided on the endcap 119 such that the ends / edges of the layers of the filter media pack 112 are joined together and encapsulated by the adhesive. At process 710, the adhesive is cured, and the endcap 119 is coupled to the filter media pack 112 by the adhesive. The process shown in FIG. 16 may be repeated for each endcap 119 of the filter media pack 112.

[0084] FIG. 17 is a perspective view of the frame 250 usable with the filter element 104 of FIG. 15. FIG. 18 is cross sectional view of the frame of FIG. 17. As shown in FIGS. 17 and 18, the frame 250 includes a frame wall 251. The frame wall 251 has a first wall portion 252, asecond wall portion 254, and a third wall portion 256. The first wall portion 252 extends in an axial direction. The second wall portion 254 extend away from the first wall portion 252 and towards the filter media pack 112. The second wall portion 254 is contiguous with the first wall portion 252. The second wall portion 254 extends in a direction perpendicular to the axial direction (e.g., the lateral direction, the longitudinal direction, or both). The third wall portion 256 extends away from the second wall portion 254 and away from the cover 106. The third wall portion 256 is contiguous with the second wall portion 254. The third wall portion 256 extends in the axial direction such that the third wall portion 256 is substantially parallel to the first wall portion 252. As briefly described above, the frame 250 also includes the flange 158. The flange 258 extends away from the first wall portion 102 and away from the filter media pack 112. The flange 108 is substantially perpendicular to the first wall portion 102 (e.g., in the lateral direction, the longitudinal direction, or both). The flange 258 is disposed axially between the second wall portion 254 and a top of the frame 250. The flange 258 is disposed axially between the second wall portion 254 and the cover 106.[0085| FIG. 19 is a perspective view of the sealing member assembly 260 usable with the filter element 104 of FIG. 15. FIG. 20 is a cross sectional view of the sealing member assembly 260 of FIG. 19. As shown, the sealing member assembly 260 includes the variable geometry sealing member 200 and the frame 250. As described above, the variable geometry sealing member 200 may be coupled to the frame 250 by a molding process. In other embodiments, the variable geometry sealing member 200 may be coupled to the frame 250 by stretching the variable geometry sealing member 200 around the frame. In any of the above-described embodiments, the cavity 258 defined by the variable geometry sealing member 200 is sized to receive the flange 258 of the frame 250.

[0086] FIG. 21 is a perspective view of the filter element 104, shown with the sealing member assembly 160 of FIG. 19. FIG. 22 is a cross sectional view of the filter media pack 112 and sealing member assembly 160 of FIG. 21. In some embodiments, the sealing member assembly 160 is coupled to the filter media pack with an adhesive. More specifically, an inner portion of the frame wall 251 of the frame 250 of the sealing member assembly 260 is coupled to the at least one endcap 119 of the filter media pack 112 by the adhesive.

[0087] FIG. 23 is a cross sectional view of the filter element 104. The filter element 104 includes the filter media pack 112 of FIG. 21 shown with the sealing member assembly 160 of FIG. 19. The filter element 104 includes an adhesive compound 262 disposed between the frame 250 and the filter media pack 112. The frame 250 and the filter media pack 112 cooperate to define a cavity 264 that is sized to receive the adhesive compound 262. More specifically, the frame wall 251, or a portion thereof, such as the first wall portion 252 and the second wall portion 254, and an outer surface of the filter media pack 112 define the cavity 264. The adhesive compound 262 is configured to couple the frame 250 to the filter media pack 112. In some embodiments, the outer surface of the filter media pack 112 is or includes the endcap 119.

[0088] FIG. 24 is a cross sectional view of the filter element 104 of FIG. 25 shown with an inlet frame 270. The inlet frame 270 is disposed at an inlet side of the filter media pack 112. The inlet frame 270 contacts the filter media pack 112 at an inlet side of the filter media pack 112. The inlet frame 270 includes one or more ribs 272. A first set of the ribs 727 extend across the inlet side of the filter media pack 112 in a first direction (e.g., a lateral direction). A second set of the ribs 272 extend across the inlet side of the filter media pack 112 in a second direction (e.g., a longitudinal direction), substantially perpendicular to the first direction. The ribs 272 define a plurality of openings 274 in the inlet frame 270 that allow a fluid to pass therethrough.

[0089] In some embodiments, the inlet frame 270 is coupled to the filter media pack 112. In some embodiments, the inlet frame 270 is retained at the inlet side of the filter media pack 112 by one or more of the endcaps 119. For example, the endcaps 119 may include a flange 174 that extends inward, towards the filter media pack 112. The flange 174 may be disposed between the inlet frame 270 and the cover 106. The flange 174 may be disposed axially above the inlet frame 270. The inlet frame 270 is disposed between the flange 174 and the inlet side of the filter media pack 112. In this way, the inlet frame 270 is retained against the inlet side of the filter media pack 112 by the flange 174.

[0090] It should be noted that the term “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples,representations, and / or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).|00 1 ] As utilized herein, the term “substantially” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. The term “substantially” as used herein refers to ±10% of the referenced measurement, position, or dimension. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0092] The terms “coupled,” “attached,” and the like as used herein mean the joining of two members directly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable).

[0093] References herein to the positions of elements (e.g., “top,” “bottom,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.]0094] It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, various parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied in particular implementations, and the nature ornumber of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various example embodiments without departing from the scope of the concepts presented herein.[00951 While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

Claims

WHAT IS CLAIMED IS:

1. A filtration system comprising: a housing comprising a sealing surface disposed at a housing first end; a filter element comprising a variable geometry sealing member, the variable geometry sealing member disposed at the sealing surface wherein a shape of the variable geometry sealing member is defined by a first curve having a first radius and a second curve having a second radius, wherein the first curve and the second curve are non-concentric such that a thickness of the variable geometry sealing member is non-uniform; and a cover coupled to the housing such that a surface of the cover compresses the variable geometry sealing member against the sealing surface.

2. The filtration system of claim 1, wherein the housing comprises a housing body, the housing body defining an internal volume sized to receive the filter element, the housing body comprising: a housing wall, and a housing sealing portion, the housing sealing portion including a lower wall portion and an upper wall portion.

3. The filtration system of claim 2, wherein at least the lower wall portion and the upper wall portion cooperate to define the sealing surface.

4. The filtration system of claim 2, wherein the lower wall portion extends outward from the housing wall, away from the filter element, and the upper wall portion extends axially away from the lower wall portion, towards the cover.

5. The filtration system of claim 1, wherein: a first distance is defined between the first curve and the second curve at a sealing member first end of the variable geometry sealing member;a second distance is defined between the first curve and the second curve at a sealing member central portion of the variable geometry sealing member; and the second distance is greater than the first distance.

6. The filtration system of claim 1, wherein the variable geometry sealing member comprises a sealing member body, the sealing member body extending away from the filter element, towards the housing, the sealing member body contacting the sealing surface.

7. The filtration system of claim 1, wherein the variable geometry sealing member comprises: a sealing member wall; and a connecting portion extending between the sealing member wall and the sealing member body.

8. The filtration system of claim 1, wherein the cover comprises: an end wall, the end wall defining an inlet opening disposed at an upstream side of the filter element; a plurality of ribs extending across the inlet opening, the plurality of ribs including: a first set of ribs that extend across the inlet opening in a first direction, and a second set of ribs that extend across the inlet opening 152 in a second direction, different than the first direction.

9. The filtration system of claim 8, wherein the cover comprises a cover sealing portion, the cover sealing portion positioned to provide a force on the variable geometry sealing member, thereby pressing the variable geometry sealing member into the sealing surface of the housing.

10. The filtration system of claim 9, wherein the sealing portion includes a projection, the projection extending away from the end wall and towards the housing such that the projection contacts the variable geometry sealing member when the cover is coupled to the housing.

11. The filtration system of claim 1, wherein the filter element comprises: a filter media pack; and an outer wrap that extends around the filter media pack, wherein the variable geometry sealing member is coupled to at least one of the filter media pack or the outer wrap.

12. The filtration system of claim 1, wherein the filter element comprises: a filter media pack; and a frame disposed between the variable geometry sealing member, the frame comprising a frame wall and a flange, the flange extending outward from the frame wall, away from the filter media pack and towards the variable geometry sealing member.

13. The filtration system of claim 1, wherein the variable geometry sealing member defines a cavity, the cavity receiving the flange of the frame.

14. A filter element comprising: a filter media pack; and a variable geometry sealing member, the variable geometry sealing member disposed around a perimeter of the filter media pack, wherein a shape of the variable geometry sealing member is defined by a first curve having a first radius and a second curve having a second radius, wherein the first curve and the second curve are non-concentric such that a thickness of the variable geometry sealing member is non-uniform.

15. The filter element of claim 14, wherein one of the first radius or the second radius is infinite, such that one of the first curve or the second curve is substantially straight.

16. The filter element of claim 14, wherein the first radius is equal to the second radius.

17. The filter element of claim 14, wherein the first radius is different than the second radius.

18. The filter element of claim 14, further comprising an endcap, wherein at least one side of the filter media pack is potted in the endcap.

19. The filter element of claim 18, further comprising an inlet frame disposed at an inlet side of the filter media pack, the inlet frame contacting the filter media pack at the inlet side of the filter media pack, and the inlet frame comprising one or more ribs, a first set of the one or more ribs extending across the inlet side of the filter media pack in a first direction, and a second set of the one or more ribs extending across the inlet side of the filter media pack in a second direction different than the first direction, the one or more first ribs defining a plurality of openings in the inlet frame that allow a fluid to pass therethrough.

20. A sealing member assembly comprising: a frame including a frame wall and a flange; and a variable geometry sealing member, the variable geometry sealing member disposed around a perimeter of the frame, wherein a shape of the variable geometry sealing member is defined by a first curve having a first radius and a second curve having a second radius, wherein the first curve and the second curve are non-concentric such that a thickness of the variable geometry sealing member is non-uniform, the variable geometry sealing member defining a cavity, wherein the flange extends into the cavity.

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