Inertial separator, inertial separator panel, method for manufacturing an inertial separator panel, and a method for separating particulates and / or water from gas

Abstract

An inertial separator includes: (a) an air inlet member comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (ii) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl; (iii) the plurality of vanes are non-overlapping vanes; and (b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member: (i) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming an region for collection of particulates and / or water droplets. Inertial separator panels and methods of making and using are included.

Description

[0001] INERTIAL SEPARATOR, INERTIAL SEPARATOR PANEL, METHOD FOR MANUFACTURING AN INERTIAL SEPARATOR PANEL, AND A METHOD FOR SEPARATING PARTICULATES AND / OR WATER FROM GAS CROSS REFERENCE TO RELATED APPLICATION

[0002] This application is being filed on July 9, 2024, as a PCT International Patent Application and claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 525,893, filed on July 10, 2023, the disclosure of which is incorporated herein by reference in its entirety.

[0003] FIELD OF THE DISCLOSURE

[0004] The present disclosure relates to an inertial separator, an inertial separator panel, a method for manufacturing an inertial separator panel, and a method for separating particulates and / or water from gas. More particularly, the inertial separator panel includes a plurality of inertial separators, and the inertial separator panel can be used for removing particulates and / or water from an air feed stream for flowing into an air cleaner or into another device that would benefit from having particulates and / or water removed from an air feed stream. The air feed stream can be provided as environmental air that has or has not been subjected to cleaning or filtering, and the separator panel can be referred to as a precleaner when the air exiting the separator panel is fed to another device for downstream cleaning in, for example, an air cleaner. The method for manufacturing an inertial separator panel can include molding wherein the inertial separators are molded in place. BACKGROUND

[0005] It is desirable to remove particulates and / or water from a gas stream such as air prior to introducing the gas stream into an internal combustion engine in order to prolong the useful life of the internal combustion engine. Vehicles are often used in environments where there is dust or other particulates, and it may be beneficial to remove at least some of that dust or other contaminants prior to feeding the air to a main filter cartridge in an air cleaner for cleaning the air. Vehicles used in off road and in agricultural applications are often subject to high dust conditions. Even vehicles used as over the highway trucks may experience high dust conditions at times. In such situations, it is generally helpful to provide a precleaner upstream of the primary filter cartridge used for cleaning the air in an air cleaner to help prolong the useful life of the primary filter cartridge.

[0006] If there is water in the air, for example, in the form of water droplets, it is also desirable to remove the water droplets prior to introducing the air into the air cleaner. Thus, removing water droplets and larger size particulates from an air stream fed to an air cleaner has a tendency to help prolong the life of the main or primary filter element inside the air cleaner. Precleaners are often provided as part of an air cleaner. Exemplary disclosures of air cleaners containing a precleaner include U.S. Patent No. 8,177,872, U.S. Patent 7,008,467, U.S. Patent No. 7,905,936, U.S. Patent No. 6,350,291, European Patent No. EP 1 364 695, and PCT Publication No. W02007 / 000397. Because air cleaners for engines are often located in the engine compartment of a motor vehicle, the available space for the precleaner may be limited thereby placing a priority on a compact size of the precleaner.

[0007] Exemplary precleaners that are referred to as inertial separators or centrifugal separators are manufactured by Donaldson Company Inc and are available under the name Donaldson Strata™ Tubes and Panels. Exemplary inertial separators are disclosed by U.S. Patent No. 4,242,115 and U.S. Patent No. 4,746,340.

[0008] SUMMARY An inertial separator is provided according to the present disclosure. The inertial separator can be characterized in several alternative ways.

[0009] One characterization of an inertial separator includes: (a) an air inlet member comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (ii) a central hub and a plurality7of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality' of vanes are configured to cause air entering the air inlet to swirl; (iii) the plurality of vanes are non-overlapping vanes; and (b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member: (i) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming an region for collection of particulates and / or water droplets.

[0010] Another characterization of an inertial separator includes: (a) an air inlet member comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (ii) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl; (iii) the outer surface of the contaminant outlet wall is radially recessed relative to the outer surface of the air inlet member wall; and (b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member: (i) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming an region for collection of particulates and / or water droplets. Another characterization of an inertial separator includes: (a) an air inlet member comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (ii) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl; (iii) the central hub having a first surface perpendicular to the axis, a second surface that extends toward the second end of the air inlet construction, and an edge between the first surface and the second surface, wherein the first surface is located extending along the edge; and (b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member: (i) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming a region for collection of particulates and / or water droplets.

[0011] An inertial separator panel is provided according to the present disclosure. The inertial separator panel can be provided wi th a plurality of inertial separators wherein the plurality of inertial separators are according to any of the inertial separators described herein. For example, one characterization of an inertial separator panel includes: (a) a first panel construction comprising a first panel wall and a plurality of inertial separator air inlet members, wherein: (i) the plurality of inertial separator air inlet members comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, and the air inlet member second end comprising an end opposite the air inlet, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (A) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (B) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet construction peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl; (C) the plurality of vanes are non-overlapping vanes; and (b) a second panel construction comprising a second panel wall and a plurality of inertial separator air outlet members. wherein: (i) the plurality of inertial separator air outlet members comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface; wherein, when the air outlet construction engages the air inlet construction, wherein: (A) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming a region for collection of particulates and / or water droplets.

[0012] Other characterizations of the inertial separator panel can be made in a manner different from the previously characterized plurality of inertial separators. For example, another characterization of an inertial separator panel includes: (a) a first panel construction comprising a first panel wall and a plurality of inertial separator air inlet members, wherein: (i) the plurality of inertial separator air inlet members comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, and the air inlet member second end comprising an end opposite the air inlet, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (A) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (B) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet construction peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl; (b)a second panel construction comprising a second panel w all and a plurality of inertial separator air outlet members, wherein: (i) the plurality of inertial separator air outlet members comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface; wherein, when the air outlet construction engages the air inlet construction, wherein: (A) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming a region for collection of particulates and / or w ater droplets; and (c) the first panel wall and the plurality7of inertial separator air inlet members are molded together, and the second panel wall and the plurality of inertial separator air outlet members are molded together. Another characterization of an inertial separator panel includes: (a) a first panel construction comprising a first panel wall and a plurality of inertial separator air inlet members, wherein: (i) the plurality of inertial separator air inlet members each comprising an air inlet member first end and an air inlet member second end. the air inlet member first end comprising an air inlet, and the air inlet member second end comprising an end opposite the air inlet, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein: (A) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough; (B) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet construction peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl; (b)a second panel construction comprising a second panel wall and a plurality of inertial separator air outlet members, wherein: (i) the plurality of inertial separator air outlet members comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface; wherein, when the air outlet construction engages the air inlet construction, wherein: (A) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming a region for collection of particulates and / or water droplets; and (c) a plurality of inertial separators being formed by joining the first panel and the second panel, wherein: (i) the plurality' of inertial separators each having a contaminant outlet formed from the contaminant opening, and wherein the contaminant outlets do not all point in a same direction.

[0013] A method for manufacturing an inertial separator panel is provided according to the present disclosure. The method can include molding the first panel construction and molding the second panel construction, and assembling the first panel construction and the second panel construction to form an inertial separator panel having a plurality of inertial separators. The plurality of inertial separators can each include a first member and a second member wherein the first member is molded integral with the first panel construction and the second member is molded integral with the second panel construction. The molding can be done by injection molding, and the injection molding can be done by molding each of the first panel construction and the second panel construction using a two part mold.

[0014] A method for separating particulates and / or water from a gas such as air is provided. The method includes introducing a gas such as air into any of the described characterizations of inertial separator and / or inertial separator panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a perspective view of a prior art air cleaner assembly that includes a precleaner upstream of a main filter cartridge and a secondary or safety filter cartridge, and being viewed toward the inlet flow end of the assembly. Figure 2A is a perspective view of the air inlet side of an inertial separator panel according to the present disclosure;

[0016] Figure 2B is an exploded perspective view of the air inlet side of the inertial separator panel according to Figure 2 A;

[0017] Figure 3A is a perspective view of the air outlet side of an inertial separator panel according to the present disclosure.

[0018] Figure 3B is an exploded perspective view of the air outlet side of the inertial separator panel according to Figure 3A.

[0019] Figure 4 is an isolated perspective view of an inertial separator according to the present disclosure showing the air flow inlet. Figure 5 is a perspective view of the inertial separator of Figure 4 showing the air flow outlet.

[0020] Figure 6 is a side view of the inertial separator of Figure 4.

[0021] Figure 7 is an alternative side view of the inertial separator of Figure 4.

[0022] Figure 8 is a section view of the inertial separator of Figure 4 taken along lines 8-8.

[0023] Figure 9 is top view of the inertial separator of Figure 4.

[0024] Figure 9A is a similar view of the inertial separator provided in Figure 9 but more clearly indicating the arcs used to define the vane angles and the gap angles.

[0025] Figure 10 is a bottom view of the inertial separator of Figure 4. Figure 11 is a perspective of the inside of the inertial separator air inlet member of Figure 10.

[0026] Figure 12 is a plan view of the air inlet side of the inertial separator panel depicted in Figure 2A.

[0027] Figure 13 is a perspective view showing the contaminant outlet arrangement 124 of the air inlet side 52 of the inertial separator panel 50 of Figure 2A.

[0028] Figure 14 is a perspective view of an inertial separator air inlet member according to the present disclosure.

[0029] Figure 15 is a side view of the inertial separator air inlet member according to Figure 14. Figure 16 is a side view of the inertial separator air inlet member according to Figure 14.

[0030] Figure 17 is a top view of the inertial separator air inlet member according to Figure 14. Figure 18 is a bottom view of the inertial separator air inlet member according to Figure 14.

[0031] DETAILED DESCRIPTION Now referring to Figure 1, a representative prior art air cleaner assembly (or more commonly referred to as an air cleaner) is illustrated at reference number 10. The air cleaner assembly includes an air inlet arrangement 12, an air outlet arrangement 14, a contaminant ejection port 16, and an air cleaner body 18. Environmental air which may contain particulates and / or water droplets, or which may be relatively clean in certain circumstances, flows into the air inlet arrangement 12, and filtered or clean air flows out through the air outlet arrangement 14 and, in particular, the outlet 14x. The type of air cleaner depicted can be referred to as a two stage air cleaner. Located within the air cleaner body 18 is a main filter cartridge and, optionally, a secondary or safety filter cartridge. The air inlet arrangement 12 is illustrated as an access cover 20 for entry into the air cleaner body 18, and can be removed for servicing the air cleaner assembly 10 by, for example, replacing or refurbishing the main filter cartridge and / or the secondary or safety' filter cartridge. As illustrated, the access cover 20 includes an inertial separator panel 22 that includes a plurality of inertial separators 24 arranged to receive inlet air which may be environmental air and process the air for the removal of particulates and / or water droplets. Latches 26, such as over center latches, can be used to fasten the access cover 20 to the air cleaner body 18. The air cleaner arrangement 10 is depicted in US 10,532,310, the disclosure of which is incorporated herein byreference in its entirety. Although the air inlet arrangement 12 is illustrated as an access cover 20, it should be appreciated that the air inlet arrangement can be provided as a non-access cover portion of the air cleaner arrangement. One example is depicted in, for example, U.S. Patent No. 7,9056,936, where the air inlet arrangement is part of the air cleaner assembly but is not part of the access cover. Another example is where the precleaner or air inlet arrangement is located spaced or separate from the portion of the air cleaner arrangement that includes the main filter cartridge as illustrated in, for example, US 8,177,872. The entire disclosures of U.S. Patent No. 7,905.936 and U.S.

[0032] Patent No. 8.177,872 are incorporated herein by reference in their entireties.

[0033] Additional examples of precleaners having a panel of inertial separators as part of an air cleaner assembly are depicted in, for example, U.S. Patent No. 7,008,467, U.S. Patent No. 6,350,291, U.S. Patent No. 8,177,872, European Patent No. EP 1 364695, and PCT Publication No. WO 2007 / 000397.

[0034] Typically, in prior art precleaners that include inertial separators, the individual inertial separators are inserted or snap fit into a panel or multiple panels to form an array of inertial separators. The fit of each inertial separator is often not perfect and there may be some leakage at the locations between the inertial separators and a wall of the panel holding the inertial separators in place, and this leakage results in a loss of air flow through the inertial separators. In addition, the assembly of such precleaners typically requires labor in correctly placing each inertial separators in a correct orientation in the precleaner. Incorrectly oriented inertial separators can have a negative effect on air flow and particulate buildup and clogging in the precleaner. The present disclosure provides for inertial separator panels (i. e. , precleaners) that can be molded with the inertial separators in place thereby avoiding air leakage and loss of flow through the inertial separators, and decreasing the labor required to assemble the precleaner and also ensuring that the inertial separators are correctly oriented. In the context of the present disclosure, it should be understood that the reference to environmental air, dirty air, inlet air, clean air, and outlet air is relative. According to the disclosure, a gas is processed for the removal of contaminants. The gas may be air and the air may be referred to as environmental air, dirty air, or inlet air. Such air may or may not be particularly dirty or dusty or may or may not contain water droplets. The gas from the precleaner may be referred to as clean air or outlet air, and it may or may not be sufficiently clean for certain uses, such as a feed stream to an internal combustion engine, but the air is typically cleaner that the air that was fed for processing in the precleaner. Of course, in a particular situation, this depends on how clean or dirty the air was going into the precleaner. The inlet air may be fairly clean and there is no requirement that the inlet air is dirty prior to being fed to the precleaner, and the processing is done to remove contaminants that may be present in certain situations, for example, in a dusty environment, so that the air processed by the precleaner can be further processed by a further air cleaning device so that the resulting air can be used when cleaner air is required. Accordingly, as used herein, air fed to the precleaner can be referred to as dirty air even if it is not that dirty, and air recovered from the precleaner can be referred to as clean air even though it may require further cleaning or filtering for the removal of particulates before it can safely be used, for example, in an internal combustion engine. In the following discussion, reference will be made to contaminant or contaminants, interchangeably. It should be understood that the term “contaminants” is meant to include any type of matter that is found in air that can be separated from the air by use of centrifugal separation. The term contaminants can include dust and particulates and any other type of organic or inorganic matter that is held by air and should be separated from the air to provide clean air that can be processed through an internal combustion engine without damaging the internal combustion engine. Also, in the context of the present disclosure, and for convenience, the term contaminants includes water droplets unless explicitly excluded. The Inertial Separator Panel

[0035] Figures 2A and 3A show an inertial separator panel 50 having an air inlet side 52 and an air outlet side 54, and a plurality of inertial separators 100 extending therebetween according to the present disclosure. The inertial separator panel 50 can be provided as part of an air cleaner assembly or it can be provided separate from an air cleaner assembly. When provided as part of an air cleaner assembly, the inertial separator panel 50 can be provided as part of an air inlet arrangement and access cover of an air cleaner assembly or the inertial separator panel 50 can be provided as part of an air inlet arrangement and non-access cover component of an air cleaner assembly. In addition, the inertial separator panel 50 can be provided as part of an air inlet arrangement located remote or spaced away from an air cleaner assembly and where, for example, the outlet air from the inertial separator panel 50 flows via tube or conduit to an inlet of an air cleaner assembly where there is, for example, a primary fdter cartridge for filtering the air.

[0036] The reference to an air inlet side 52 of the inertial separator panel 50 does not preclude the processing of air prior to entry into the air inlet side 52. For example, it may be advantageous that the air flowing toward the air inlet side 52 is processed, for example, by being passed through a screen for the removal of large items such as bugs and leaves, and / or that it has been processed by turning via a bend to remove water therefrom that may be part of the air stream as a result of, for example, periods of precipitation or water spray that may occur when driving or moving from one location to another.

[0037] The inertial separator panel 50 includes a plurality of inertial separators 100 which are described in more detail below. As illustrated in Figures 2B and 3B, the inertial separator panel 50 includes a first panel construction or air inlet construction 56 and a second panel construction or air outlet construction 58. As illustrated the first panel construction 56 and the second panel construction 58 attach together and are illustrated nesting with each other when assembled. Each of the inertial separators 100 includes a first member or inertial separator air inlet member 102 and a second member or inertial separator air outlet member 104. As air enters the first member 102. it is processed for removal of contaminants therefrom, and air with at least some of the contaminants removed therefrom exits the second member 104. The air enters the first member 102 via an air inlet 106, and the air is caused to spin or rotate as a result of flowing over the plurality of vanes 108. In the embodiment illustrated, the plurality7of vanes 108 provide for a clockwise rotation, or a right hand rotation, based on the flow being viewed from above the air inlet 106. Of course, the direction of flow can be adjusted to provide for counter clockwise flow by designing the vanes to cause flow in the opposition direction. As a result of the rotational flow, the contaminants, such as, particulates and / or water droplets, have a tendency to move in a direction away from a center of the inertial separator. As a result, cleaner air flows through the inlet 110 of the second member 104 and then flows through the outlet 1 12 of the second member 104. The contaminants that are spun outwardly collect and flow through the contaminant outlet 114. While the general concept of using inertial separators is known in the art, there are several features of the inertial separators 100 that provides for enhanced performance. Many of these features are discussed in more detail. In addition to enhanced performance, the inertial separator panel 50 can be more cost effectively manufactured by molding each of the first panel construction or air inlet construction 56 and the second panel construction or air outlet construction 58.

[0038] The first panel construction 56 includes a first panel wall 60 that contains or holds onto the first member 102 of the plurality of inertial separators 100. The second panel construction 58 includes a second panel wall 62 that contains or holds onto the second member 104 of the plurality of inertial separators 100. By combining the first panel construction 56 and the second panel construction 58, the inertial separator panel 50 can be assembled. In addition, the first member 102 of the plurality of inertial separators 100 and the second member 104 of the plurality of inertial separators 100 are arranged in the first panel construction 56 and the second panel construction 58, respectively, so that when the first panel construction 56 and the second pane construction 58 are assembled, the plurality of first members 102 and the plurality of second members 104 assemble together to form the plurality7of inertial separators 100. Advantageously and preferably, the first panel wall 60 and the plurality of first members 102 are integral with each other as a result of molding, and the second panel wall 62 and the plurality of second members 104 are integral with each other as a result of molding. It should be appreciated that the term “integral” indicates, when used, that the components are formed from a continuous polymer or plastic material by molding.

[0039] The type of molding used to form the first panel construction 56 and the second panel construction 58 can include injection molding. Because the first panel wall 60 and the plurality of first members 102 are preferably integral, and because the second panel wall 62 and the plurality of second members 104 are preferably integral, air leakage around the plurality of inertial separators can be reduced or eliminated. In certain prior art inertial separator panels, the plurality of inertial separators are separately prepared and then inserted otherwise introduced into an opening in a wall thereby forming a panel. The insertion can be a result of a snap fit arrangement. This type of arrangement in the prior art may be susceptible to air leakage between the inertial separators and the wall, and that leakage would have the effect of decreasing the energy flowing through the inertial separators thereby reducing the efficiency of the inertial separators. Furthermore, the amount of labor required by had fitting the inertial separators into a wall can be significantly reduced by forming integral constructions as described. While the present disclosure identifies a preferred embodiment where the first panel wall 60 and the plurality of first members 102 are integral, and where the second panel wall 62 and the second members 104 are integral, it should be appreciated that an integral formation is not required. That is, the first panel wall and the first members need not be integral and / or the second panel wall and the second members need not be integral. The combination of the first panel wall 60 and second panel wall 62 forms a contaminant collection area 64 therebetween. The contaminant collection area 64 can be referred to as the baffle chamber. The contaminant collection area 64 receives the particulates from the contaminant outlets 114 of the plurality of inertial separators 100. The particulates collected in the contaminant collection area 64 are removed therefrom via the inertial separator panel contaminant outlet 66.

[0040] The first panel construction 56 includes a first side wall 68, and the second panel construction 58 includes a second side wall 70. As illustrated, the first panel construction 56 and the second panel construction 58 attach together so that the first side wall 68 and the second side wall 70 thereby form the contaminant collection area 64. As further illustrated, fasteners 72 can be used to hold the first panel construction 56 and the second panel construction 58 together. The fasteners 72 are shown having a bolt 74 that extends through the first panel wall 60 and engages a receiver 76 attached to the second panel wall 62. Of course, this arrangement can be reversed, if desired. In this manner, the inertial separator panel 50 can be disassembled and the contaminant collection area 64 can be cleaned, if desired.

[0041] In the embodiment illustrated, the first side wall 68 fits or nests within the second side wall 70. This arrangement could be reversed, if desired. That is, it would be possible to configure the inertial separator panel so that the first side wall of the panel containing the first member or the inertial separator inlet member 102 is outside of the second side wall of the second panel construction that contains the second member or inertial separator outlet member 104. The purpose of the walls 68 and 70 is to create that contaminant collection area 64 and the inertial separator panel contaminant outlet 66.

[0042] The inertial separator panel 50 is designed so that the inertial separator panel contaminant outlet 66 is generally facing downwardly during normal operations. This is so that the contaminants (i.e., the particulates and / or water droplets) can fall generally downwardly as result of gravity and then out through the inertial separator panel contaminant outlet 66. Of course, the actual flow within the contaminant collection area 64 located between the first panel w all 60 and the second panel wall 62 can be fairly complex. That is, during normal operations, the flow within each of the plurality of inertial separators 100 causes a flow pattern within the contaminant collection area 64. The inventors discovered that the contaminant outlet 114 of each of the plurality of inertial separator 100 can be arranged in a particular direction or orientation to take advantage of the flow' pattern or regime within the contaminant collection area 64 in order to enhance removal of the particulates from the contaminant collection area 64 via the inertial separator panel contaminant outlet 66. This arrangement can also advantageously provide a non-vacuum or non-scavenge flow' from the inertial separator panel contaminant outlet 66. If desired, however, a vacuum or scavenge flow can be provided through the inertial separator panel contaminant outlet 66.

[0043] An advantage of the inertial separator panel 50 is that the first panel 56 (including the plurality of first members 102) and the second panel 58 (including the plurality of second members 104) can each be conveniently manufactured by forming or molding, such as, by injection molding. As a result, the plurality’ of first members 102 are integral with the first panel wall 60, and the plurality of second members 104 are integral with the second panel wall 62. This construction reduces the risk of air leakage caused by gaps that may otherwise be present when an inertial separator is snap fit or inserted into a previously formed precleaner assembly. The ability to mold each of the first panel 56 and the second panel 58 is at least in part because of the design of the vanes 108 of the plurality of inertial separators 100 described below. The ease of moldability is reflected in the ability to mold each of the first panel 56 and the second panel 58 using a two part mold assembly thereby avoiding the complexity and expense of using a multipart (more than two part) mold. Of course, more than two part molds can be used to form the first and second panels 56 and 58, and a greater convenience of molding and assembly can still be provided. Inertial Separators 100

[0044] Now referring to Figures 4-8, an exemplary inertial separator 100 is illustrated in isolation from the remainder of the inertial separator panel 50. The inertial separator 100 includes a first member or inertial separator inlet member 102 and a second member or inertial separator outlet member 104. The second member 104 can also be referred to as the cone. The first member 102 and the second member 104 engage each other to form the inertial separator 100.

[0045] A plurality of first members 102 can be molded integral with the first panel wall 60 of the first panel construction 56. and a plurality of second members 104 can be molded integral with the second panel wall 62 of the second panel construction 58. In the inertial separator 100 illustrated in, for example. Figures 4-8, the second panel wall 62 is partially shown illustrating how the second member 104 extends from the second panel wall 62, and the first panel wall 60, although not shown attached to the first member 102. can extend from the first member 102 at the location 67. Accordingly. the space between the location 67 and the second panel wall 62 forms the contaminant collection area 64.

[0046] The first member 102 includes an air inlet 106, a plurality of vanes 108, a hub 116, and a contaminant outlet arrangement 124. The first member 102 includes a first end 120 and a second end 122. Located at the first end 120 are the air inlet 106, the plurality of vanes 108, and the hub 116. Extending axially from the second end 122 is the contaminant outlet arrangement 124 that includes a contaminant outlet side wall 138 and a contaminant outlet opening 140 that forms the contaminant outlet 114. Extending in an axial direction from the first end 120 to the second end 122 is a first member side wall 150.

[0047] The second member 104 includes an air inlet 110 and an air outlet 112. The second member 104 extends from a first end 126 to a second end 128. The first end 126 includes the air inlet 110 of the second member 104, and the second end 128 includes the air outlet 112 of the second member 104. Extending in an axial direction from the first end 126 to the second end 128 is a second member side wall 160.

[0048] A swirling motion of the air within the inertial separator 100 causes the contaminants in the air entering through the air inlet 106 to move toward the first member wall 150 and away from the central axis 118. As the air rotates, the contaminants have a tendency to move away from the central axis 118 of the inertial separator 100, and relatively clean air (air with less particulates and / or water droplets) passes into the air inlet 110 of the second member 104 and then out through the air outlet 112. It is noted that the air inlet 110 is arranged within the first member 102 so that the air inlet 110 is within the central axis 118 and separate from the first member side wall 150. The particulates and / or water droplets collect in the area between the first member 102 and the second member 104, at a location below the air inlet 110, and pass out through the contaminant outlet 114. In the embodiment illustrated, the contaminant outlet 114 is formed as part of the contaminant outlet arrangement 124. As illustrated, the contaminant side wall or skirt 138 surrounds a portion of the second member side wall 160 and engages the second panel wall 62. and a remainder of the second panel wall 62 and the skirt 138 forms the contaminant opening 140. In the embodiment shown, the skirt 138 engages the first member side wall 150 around the entire axis 118, although that is not necessary. That is, the skirt 138 need only engage a portion of the first side wall 150 so that a remaining portion of the first side wall 150 forms part of the contaminant opening 140. Furthermore, the skirt 138 can be formed so that it extends completely around the axis 118 and engages the second panel wall 62 in which case the contaminant opening is located above the second panel wall 62 by a portion of the skirt 138. For example, the portion of the skirt 138 illustrated in Figure 6 located above the contaminant opening 140 can be formed below the contaminant opening 140 and engaging the second panel wall 62. In the embodiment shown, however, the contaminant outlet 114 is formed by the contaminant opening 140 surrounded by the contaminant side wall 138 on top and the second panel wall 62 on bottom.

[0049] In the exemplary7illustrated embodiment, the contaminant outlet 114 for the inertial separator 100 extends about 180 degrees of perimeter around the central axis 118. Alternatively stated, the contaminant side wall or skirt 138 extends about 180 degrees around the central axis 118. In general, the size of the contaminant outlet 114 is selected to maximize the amount of particulates and / or w ater droplets that are released from the inertial separator 100 into the contaminant collection area 64. If the contaminant outlet 114 is too large in a radial direction, then it is expected that the particulates and / or water droplets may get sucked back into the inertial separator 100, and if the contaminant outlet 114 is too small in a radial direction, then it is expected that the particulates and / or w ater may not sufficiently be released from the inertial separator 100. Preferably, contaminant outlet 114 extends about 170 degrees to about 190 degrees, and the skirt extends about 170 degrees to about 190 degrees, although alternatives are possible.

[0050] The first member or inertial separator inlet member 102 includes a side w all 150. The side wall 150 is illustrated extending from the first end 120 to the second end 122, and is illustrated having a cylindrical configuration. The first member side wall 150 includes an outer surface 152 and an inner surface 154. A cylindrical configuration indicates that the radius from the central axis 118 to the inner surface 154 is constant along the length of the side w all 150 from the first end 120 to the second end. At any point axially along the inner surface 154, the side wall 150 can be considered circular. In this particular embodiment, although alternatives are possible, the inner surface 154 is cylindrical in shape meaning that the perimeter of the inner surface 154 is constant from the first end 120 to the second end 122. If desired, the side wall 150 can be altered so that it is not cylindrical. That is, it can be provided as conical or partly conical, for example. In a conical or partly conical configuration, the perimeter of the inner surface 154 at any location between the first end 120 and the second end 122 can be different. For example, the perimeter of the inner surface 154 at the first end 120 can be less than the perimeter of the inner surface 154 at the second end 122. Also, if desired, the reverse can be provided where the perimeter of the inner surface 154 at the first end is larger than the perimeter of the inner surface 154 at the second end 122. In general, the thickness of the side wall 150 extending from the first end 120 to the second end 122 can be generally constant except that a slight change due to molding and the existence of, for example, a draft angle may alter the thickness. As further illustrated, the contaminant side wall or skirt 138 extends axially from the first member side wall 150 at the second end 122. The contaminant side wall 138 includes an outer surface 156 and an inner surface 158. As shown, the radius, from the central axis 118. of the contaminant side wall outer surface 156 is less than the radius of the first member side outer surface 152. By recessing the radius of the contaminant side wall outer surface 156 relative to the first member side wall outer surface 152, it is possible to enhance particulate flow within the contaminant collection area 64. As previously explained, a plurality of inertial separators 100 are arranged within the inertial separator panel 50. The particulate collected in the contaminant collection area 64, as a result of flow from the contaminant outlet 114 of the plurality of inertial separators 100, needs to flow by other inertial separators 100 in the inertial separator panel 50 before reaching the contaminant outlet opening 140. Accordingly, by providing a recess in the radius of the contaminant side wall outer surface 156. relative to the radius of the side wall outer surface 152, more room is available between adjacent inertial separators 100 to allow the contaminants to flow within the contaminant collect area 64 without becoming clogged. This has the effect of enhancing flow through the contaminant collection area 64 without requiring a vacuum or scavenge outlet, although a vacuum or scavenge outlet can be utilized.

[0051] In the embodiment illustrated, the radius, from the central axis 118, of the contaminant side wall inner surface 158 is generally constant with the radius of the first member side wall surface 154. This helps provide that the flow within the first member 102 is maintained and uninterrupted as the flow descends below the second end 122 and into the location of the contaminant side wall 138. Of course, alternatives are available.

[0052] The second member or inertial separator outlet member 104 includes a side wall

[0053] 160. The side wall 160 extends from the first end 126 to the second end 128, and the first end 126 is located within the interior of the first member 102. As illustrated, the second member side wall 160 is generally conical, at least in the area extending above the contaminant outlet 114, although alternatives are possible. As shown, the radius at the first end 126 is smaller than at other locations toward the second end 128. The second member 104 may be provided as cylindrical at the location about the contaminant outlet 114, but it is expected that a conical shape at this location helps enhance particulate flow toward the contaminant outlet 114. In the embodiment illustrated, the air inlet 110 at the first end 126 has a smaller area than the air outlet 112 at the second end 128. Furthermore, as illustrated, the second member side wall 160 is not continuously conical. That is, from the first end 126 toward the second end 128, there is a gradual increase in circumference or perimeter thereby decreasing the distance between the second member 104 and first member 102 followed by a more aggressive (less gradual) increase in the area of the contaminant outlet 114. This helps provide a desired fit between the first member 102 and the second member 104, and also helps with the separation and removal of contaminant through the outlet contaminant outlet 114. The second member side wall 160 includes an inner surface 164 and an outer surface 166.

[0054] The Plurality7of Vanes 108 of the Inertial Separators 100

[0055] Now referring to Figures 4 and 8-11, the plurality of vanes 108 of the inertial separator 100 are illustrated. The plurality of vanes 108 extend from the hub 116 to the first member side wall 150 and cause the air entering the air inlet 106 to rotate. The plurality of vanes 108 can be characterized as non-overlapping which means that the plurality of vanes 108 do not completely overlap when viewed in an axial direction (i.e. , along the axis 118). In the embodiment depicted, there are radially extending gaps 170 between the plurality of vanes or blades 108. The phrase “radial gap” refers to a separation between radially extending vanes. For example, if one can see an object through the plurality of vanes 108 (in an axial direction), when the object is located behind the plurality of vanes 108, then the blades can be characterized as nonoverlapping because of the existence of at least one radial gap. Thus, even if there is some overlap between parts of the vanes 108, if there is an axial line through the plurality of vanes 108 that is unobstructed, then the blades can be characterized as nonoverlapping. If the object is completely obscured, then the blades are considered overlapping. In the embodiment depicted in Figure 9, the existence of the gaps 170 permits a viewer to see portions of the second member or inertial separator air outlet member 104. and the plurality of vanes or blades 108 can be referred to as nonoverlapping. The plurality of vanes 108 shown in Figure 9 are fully non-overlapping because the gaps 170 extend along the entire length of each blade relative to an adjacent blade. The phrase “radial gap” should be distinguished from another type of gap between the vanes 108 that simply allow air to pass between the vanes 108.

[0056] Clearly the blades are separate or spaced from each other and that separation can be referred to a gap even though it may not be a radial gap as defined above. That is, each vane or blade extends at a pitch or slope to help turn air passing thereby, and the air would clearly pass through a gap between the vanes even though the gap is not a radial gap.

[0057] One advantage of providing non-overlapping vanes is that the molds needed to injection mold the first member or inertial separator air inlet 102 or for molding the first panel 50 can be relatively uncomplicated. For example, a two part mold can be used where the two parts pinch together at the gaps 170 between the vanes 108. In addition, it has been found that the performance of the resulting panel with nonoverlapping blades can be improved relative to prior art inertial separators having overlapping blades. In the embodiment shown, there are six vanes 108a-108f with a gap 170 betw een each of the vanes 108a-108f. The number of vanes can be provided as 4 to 7, and preferably 5 to 6. As illustrated, the plurality of vanes 108 have a pitch sufficient to turn the air entering through the air inlet 106. The pitch or slope of the vanes 108 can vary over the length of each vane from the leading edge 172 to the trailing edge 174, or the pitch can be constant. In general, it is expected that the pitch or slope will by variable. For example, it is pitch at the hub 116 would be different from the pitch at the first member side wall 150. The pitch or slope should be sufficient to turn the air a desired amount for a selected flow rate.

[0058] The plurality of vanes 108 each occupy a vane angle. The vane angle is the circumferential angle that a vane occupies. The vane angle can be determined at the vane root 175 which is where each vane 108 contacts the hub 116 along, for example, the hub side wall 119. Alternatively, vane angle can be determined at the vane tip 177 which is where each vane contacts the first member side wall 150 along the inner surface 154. The root vane angle and the tip vane angle can be the same or different. As illustrated in Figure 9, the root vane angle and the tip vane angle are slightly different because the vane leading edge 172 and the vane trailing edge 174 do not extend along a radius to the central axis 118. The vane angles can be measured as an arc, at the indicated location, based on a center of the inertial separator 100 through which extends the central axis 118 even though the leading edge 172 and / or the trailing edge 174 may not align with the central axis 118. Furthermore, the vane angle can be determined at any point along the leading edge 172 or trailing edge 174. For example, the six vanes 108a-108f each have a vane angle of about 51 degrees, and that angle can be measured anywhere from the vane root 175 to the vane tip 177, and the total or cumulative vane angle is about 306 degrees, and the total or cumulative gap angle is about 54 degrees. That means between each vane 108 is a gap angle of about 9 degrees. Defining the plurality7of blades as non-overlapping means that the cumulative vane angle is less than 360 degrees and the cumulative gap is greater than zero at any location along the leading edge 172 or the trailing edge 174 from the vane root 175 to the vane tip 177. Preferably, the cumulative vane angle is less than 354 degrees and the cumulative gap is greater than 6 degrees. A vane gap of at least 1 degree may be sufficient to allow a two part mold to pinch off flow of polymer between blades when molding. In addition, the cumulative vane angle can be less than about 339 degrees and the cumulative gap can be greater than about 21 degrees. Preferably, the cumulative vane angle can be greater than about 265 degrees, and the cumulative gap can be less than about 95 degrees. Now referring to Figure 9A, exemplary' vane angles are illustrated at the vane root 175, and at the vane tip 177. The vane angle can also be provided for at a location therebetween. As illustrated, for a given vane 108. the vane angle at the vane edge 174 and the vane angle at the vane root 175 may be different, but it is expected that they may be pretty7close. Furthermore, they can be provided as identical in the situation where the vane leading edge 172 and the vane trailing edge 174 are along a line extending from the central axis 118. The plurality of vanes 108 can be provided so that they occupy an axially facing surface area at the air inlet 106 that is less than then the axially facing surface area of the air inlet 106 minus the axially facing surface area of the hub 116. This is illustrated in Figure 9 by the gaps 170 between adjacent vanes 108. In the case of vane 108f, there is a leading edge 172 and a trailing edge 174. The leading edge 172 comes into contact with the air flowing into the air inlet 106 and the trailing edge 174 contacts the same air as it exits the plurality7of vanes 108. The existence of the gaps 170 means that one looking into the air inlet 106 can see the second member 104 including the inlet 110 and the second member side wall outer surface 166. While an individual gap 170 between blades is illustrated as greater than zero degrees, it should be appreciated that an individual gap 170 is preferably at least 1 degree. By providing the existence of a gap 170 that is greater than zero, the inertial separator 100 can be characterized as an open inertial separator as opposed to a closed inertial separator having no gap 170.

[0059] It should be apparent from Figure 9 that the existence of the gaps 170 means that a portion of the axially facing area of the inlet 110 is exposed to direct flow via air inlet 106. This area of direct flow from the air inlet 106 to the inlet 110 can be referred to as the direct pass through area 123. Accordingly, unless caused to move, the particulates and / or water droplets entering the pass through area 123 will enter the inlet 110. The air entering the pass through area 123 can be caused to move in at least a couple of ways. One way is rotation caused by the mass flow of the air over the plurality of vanes 108. This rotation can cause the particulates and / or water to move outwardly toward the first member side wall 150. Another way is to create a disruptive flow over the hub 116. This disruptive flow may be turbulent flow. In many prior art inertial separators, a hub may be found having an outwardly axial facing surface that is rounded or bull nosed in order to provide a less disruptive flow into the inertial separator. In general, the prior art theory may one or a combination of the following rationales: that the hub is for securing the blades or vanes, and that it should be small is cross section to permit air to more easily enter into the inertial separator; that the hub should minimize disturbance of air at the air inlet and thereby permit the blades or vanes to more easily turn the air and as result of flow; and / or that the outwardly facing surface of the hub should be curved and or bull nose shaped to better accommodate air flow into the air inlet and not disrupt air flow over the blades or vanes. Instead, it has been surprising found that both increasing the surface area of the hub 116 relative to the cross section of the air inlet and flattening the hub surface 117 is beneficial for reducing the amount of particulates and / or water droplets that might enter the inlet 1 10.

[0060] As illustrated in Figure 9, the hub 116 includes an axially facing surface 117 and an arrow 179 that extends proud of the axially facing surface 117. The arrow 179 is optional and it can be omitted. Nevertheless, the existence of the arrow 179 does not significantly affect the desired flow over the axially facing surface 117 because at least 20% of the axially facing surface 117 is adj acent the hub facing edge 181 where the surface 117 has the desired level of flatness. Preferably, at least 50% of the axially facing surface 117 is adjacent the hub facing edge 181 and exhibits the flatness. In general, the reference to flatness means that the flatness is sufficient to cause disruptive or turbulent flow. Preferably, flat means about 90 degrees relative to the central axis 118. It should be appreciated that molding may cause the flatness to be different than exactly 90 degrees in order to assist with demolding.

[0061] Another feature, illustrated in Figure 8, that helps provide for removal of particulates and / or water droplets from the air entering the air inlet is selecting the axial distance between the vane trailing edge 174 and the air inlet 110 of the second member 104. This distance can sometimes be referred to as a dwell distance 189. A longer dwell distance 189 creates more opportunity for the particulates and / or water in the rotating air to move away from the central axis 118 toward the fist member side wall 150. Of course, the amount of dwell distance 189 may be constrained by the dimensions required for the inertial separator panel 50.

[0062] Figure 10 illustrates the inertial separator 100 through the air outlet 112, and Figure 11 illustrates a perspective bottom view of the inertial separator air inlet member 102. As shown, the second member side wall inner surface 164 extends from the second end 128 to the first end 126 where there is located the air inlet 110. The plurality of vanes 108 extend from the trailing edge 174 to the leading edge 172, and also extend from the hub 1 16 to the wall 150. The trailing edge 174 is shown somewhat flattened. The hub side wall 175 is where the vanes engage the hub 116, and the hub side wall 175 is shown having a draft angle that assists with molding.

[0063] In addition to performance advantages, the inertial separator 100 allows for a significantly less complicated generally easier and less expensive molding operation for molding the first member 102. This is at least partly a result of the “open” characterization of the inertial separator 100.

[0064] There are several characterizations that can be relied upon for defining the inertial separators, alone or in combination with each other or with other characterization. It is also pointed out that the plurality of inertial separators 100 may have the same or different characterization, as provide. A first exemplary characterization is a ratio between the hub outer diameter defined at the hub side wall 175 to the diameter of the second member side wall inner surface 164 which can be a range of about 25% to 35%. For example, when the hub side w all 175 has an outer diameter of 10 mm and the second member side wall 164 has an inner diameter of 33 mm, the ratio is 10:33 or about 30%. This is a w ay of expressing the ratio betw een the surface area of the hub surface 117 and the surface area of the air inlet 106. A second exemplary characterization is a ratio of the outer diameter of the hub at the hub side wall 175 to the inner diameter at the air inlet 110 which can be about 55% to about 66%. In the case where the outer diameter of the hub at the hub side wall 175 is 10 mm and the inner diameter of the air inlet 110 is 16.5, the ratio is 10: 16.5 which is about 61%. Of course, this can also be expressed as the ratio of the area of the hub surface 117 to the area of the air inlet 110. A third characterization is a ratio of the outer diameter of the hub at the hub side wall 175 to the dwell distance 189 which can be about 17% to about 38%, and more preferably about 22% to about 33%. In the case where the outer diameter of the hub at the hub side wall is 10 mm and the dwell distance 189 is 36.2, the ratio is 10:36.2 or about 28%. This can also be considered as the ratio of the area of the hub surface 117 to the dwell distance 189.

[0065] Flow in the Contaminant Collection Area 64

[0066] Now referring to Figures 12 and 13, the direction of the contaminant outlet 1 14 of each of the plurality of inertial separators 100 are illustrated the inertial separator panel 50 by reference to the arrows 179. As illustrated, each of the plurality of inertial separators 100 includes an arrow 179 that points in a particular direction. The indicated direction corresponds to the center of the contaminant outlet 114 of the corresponding inertial separator 100. The arrows 179 are optional and are not needed although they show the direction of the corresponding contaminant outlet 114.

[0067] As illustrated in Figure 12. the arrows 179 (and the corresponding contaminant outlets 114) point in different directions to enhance particulate flow through the contaminant collection area 64 and toward the inertial separator panel contaminant outlet 66. A panel axis 200 is show n extending vertically through a center of the inertial separator panel 50 and through a center located inertial separator panel contaminant outlet 66. It is pointed out that the location of the inertial separator panel contaminant outlet 66 is optional and can be located at other locations, but it is advantageous to have it pointing downwardly in order to provide gravity assist when removing particulates from the panel 50. As shown, several of the contaminant outlets 114 point in different directions. Several contaminant outlets 114 point in a downward direction or in a direction toward inertial separator panel contaminant outlet 66, several of the contaminant outlets 114 point in a direction to the left of the panel axis 200, and several of the contaminant outlets 114 point in a direction to the right of the panel axis 200. The applicants learned that the mass flow through the contaminant collection area 64 of the inertial separator panel 50 is complicated. Because the illustrated inertial separators 100 provide right hand flow (flow in a clockwise direction viewed from the inlets 106 based on the orientation of Figure 12), the mass flow within the contaminant collection area 64 can be considered to be generally clockwise but there are exceptions. By providing multiple different directions for the contaminant outlets 1 14 of the plurality of inertial separators 100, it is found that particulate flow inside the contaminant collection area 64 is improved in order to deliver particulates to the inertial separator panel contaminant outlet 66. By directing some of the contaminant outlets 1 14 in an outward direction, away from the panel axis 200. flow inside the contaminant collection area 64 can improved thereby assisting the movement of particulates toward the separator panel contaminant outlet 66. By way of example, at least 10% of the contaminant outlets 114 can be directed to one side of the panel axis 200, and at least 10% of the contaminant outlets 114 can be directed to the other side of the panel axis 200. Alternatively, at least 20% of the contaminant outlets 114 can be directed to one side of the panel axis 200, and at least 20% of the contaminant outlets 114 can be directed to the other side of the panel axis 200, or at least 30% of the contaminant outlets 114 can be directed to one side of the panel axis 200, and at least 30% of the contaminant outlets 114 can be directed to the other side of the panel axis 200. It is pointed out that a contaminant outlet is not directed to either side of the panel axis 200 when the contaminant outlet is directed parallel to the panel axis 200. Figures 14-18

[0068] Now referring to Figures 14-18, several views of the first member or inertial separator air inlet member 102 of the inertial separator 100 are shown in isolation or separate from the second member or inertial separator air outlet member 104 of the inertial separator 100. As illustrated, the hub 116 includes an arrow 179 pointing in a direction of the center of the contaminant outlet 114. The arrow is shown extending proud of the hub top surface 117. It is pointed out the arrow 179 is an optional feature and can be removed from the hub 116. The arrow 179 can be drawn in broken lines indicating that it is not a required feature. For example, the hub can be provided without such an arrow, or the hub can be provided with some indicia of where the center of the contaminant outlet 114 is but where the indicia does not extent proud of the hub top surface.

[0069] The above represents example principles. Many embodiments can be made using these principles.

Claims

We claim:1 . An inertial separator comprising:(a) an air inlet member comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein:(i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough;(ii) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl;(lii) the plurality of vanes are non-overlapping vanes; and(b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member:(i) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming a region for collection of particulates and / or water droplets.

2. An inertial separator according to claim 1, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

3. An inertial separator according to claim 1, wherein:(a) the contaminant outlet wall extends about 170 degrees to about 190 degrees about the axis.

4. An inertial separator according to claim 1, wherein:(a) the plurality’ of vanes comprises 4 to 7 vanes.

5. An inertial separator according to claim 1, wherein:(a) the plurality of vanes comprises 5 to 6 vanes.

6. An inertial separator according to claim 1. wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

7. An inertial separator according to claim 1. wherein:(a) the plurality of vanes have a cumulative vane angle of less than 354 degrees.

8. An inertial separator according to claim 1, wherein:(a) the plurality’ of vanes have a cumulative vane angle of greater than 265 degrees and less than 339 degrees.

9. An inertial separator according to claim 1, wherein:(a) the plurality of vanes have a cumulative gap of at least 6 degrees.

10. An inertial separator according to claim 1, wherein:(a) the plurality of vanes have a cumulative gap of greater than 21 degrees and less than 95 degrees.1 1. An inertial separator according to claim 1, wherein:(a) the central hub has an axially facing surface directed toyvard the air inlet member first end, and at least 55% of the axially facing surface exhibits a flatness sufficient to cause turbulent flow.

12. An inertial separator according to claim 1, wherein:(a) a ratio between a diameter of the central hub and a diameter of the air inlet of the air outlet member is about 55% to about 66%.

13. An inertial separator according to claim 1, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 17% to about 38%.

14. An inertial separator according to claim 1, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 22% to about 33%.

15. An inertial separator comprising:(a) an air inlet member comprising an air inlet member first end and an air inlet member second end. the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein:(i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough;(ii) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl;(iii) the outer surface of the contaminant outlet wall is radially recessed relative to the outer surface of the air inlet member wall; and(b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member:(i) the outer surface of the air outlet member and the inner surface of the air inlet member wall forming an region for collection of particulates and / or water droplets.

16. An inertial separator according to claim 15, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

17. An inertial separator according to claim 15, wherein:(a) the contaminant outlet wall extends about 170 degrees to about 190 degrees about the axis.

18. An inertial separator according to claim 15, wherein:(a) the plurality of vanes comprises 4 to 7 vanes.

19. An inertial separator according to claim 15, wherein:(a) the plurality of vanes comprises 5 to 6 vanes.

20. An inertial separator according to claim 15, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

21. An inertial separator according to claim 15, wherein:(a) the plurality of vanes have a cumulative vane angle of less than 354 degrees.

22. An inertial separator according to claim 15, wherein:(a) the plurality of vanes have a cumulative vane angle of greater than 265 degrees and less than 339 degrees.

23. An inertial separator according to claim 15, wherein:(a) the plurality of vanes have a cumulative gap of at least 6 degrees.

24. An inertial separator according to claim 15, wherein:(a) the plurality of vanes have a cumulative gap of greater than 21 degrees and less than 95 degrees.

25. An inertial separator according to claim 15, wherein:(a) the central hub has an axially facing surface directed toward the air inlet member first end, and at least 55% of the axially facing surface exhibits a flatness sufficient to cause turbulent flow.

26. An inertial separator according to claim 15, wherein:(a) a ratio between a diameter of the central hub and a diameter of the air inlet of the air outlet member is about 55% to about 66%.

27. An inertial separator according to claim 15, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 17% to about 38%.

28. An inertial separator according to claim 15, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 22% to about 33%.

29. An inertial separator comprising:(a) an air inlet member comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, the air inlet member second end being located at an end opposite the air inlet member first end, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein:(i) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough;(ii) a central hub and a plurality7of vanes extending from the central hub to the inner surface of the air inlet member peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl;(iii) the central hub having a first surface perpendicular to the axis, a second surface that extends toward the second end of the air inlet construction, and an edge between the first surface and the second surface, wherein the first surface is located extending along the edge; and(b) an air outlet member comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface, wherein, when the air outlet member engages the air inlet member:(i) the outer surface of the air outlet member and the inner surface of the air inlet member w all forming a region for collection of particulates and / or water droplets.

30. An inertial separator according to claim 29, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

31. An inertial separator according to claim 29, wherein:(a) the contaminant outlet wall extends about 170 degrees to about 190 degrees about the axis.

32. An inertial separator according to claim 29, wherein:(a) the plurality of vanes comprises 4 to 7 vanes.

33. An inertial separator according to claim 29, wherein:(a) the plurality of vanes comprises 5 to 6 vanes.

34. An inertial separator according to claim 29, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

35. An inertial separator according to claim 29, wherein:(a) the plurality of vanes have a cumulative vane angle of less than 354 degrees.

36. An inertial separator according to claim 29, wherein:(a) the plurality of vanes have a cumulative vane angle of greater than 265 degrees and less than 339 degrees.

37. An inertial separator according to claim 29, wherein:(a) the plurality of vanes have a cumulative gap of at least 6 degrees.

38. An inertial separator according to claim 29, wherein:(a) the plurality of vanes have a cumulative gap of greater than 21 degrees and less than 95 degrees.

39. An inertial separator according to claim 29, wherein:(a) the central hub has an axially facing surface directed toward the air inlet member first end, and at least 55% of the axially facing surface exhibits a flatness sufficient to cause turbulent flow.

40. An inertial separator according to claim 29, wherein:(a) a ratio between a diameter of the central hub and a diameter of the air inlet of the air outlet member is about 55% to about 66%.

41. An inertial separator according to claim 29, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 17% to about 38%.

42. An inertial separator according to claim 29, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 22% to about 33%.

43. An inertial separator panel comprising:(a) a first panel construction comprising a first panel wall and a plurality7of inertial separator air inlet members, wherein:(i) the plurality of inertial separator air inlet members comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, and the air inlet member second end comprising an end opposite the air inlet, and an air inlet member wall extending peripherally around an axis extending fromthe air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein:(A) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough;(B) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet construction peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl;(C) the plurality of vanes are non-overlapping vanes; and(b) a second panel construction comprising a second panel wall and a plurality of inertial separator air outlet members, wherein:(i) the plurality7of inertial separator air outlet members comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface; wherein, when the air outlet construction engages the air inlet construction, wherein:(A) the outer surface of the air outlet member and the inner surface of the air inlet member wall form a region for collection of particulates and / or water droplets.

44. An inertial separator panel according to claim 43, wherein:(a) the first panel wall and the plurality' of inertial separator air inlet members are molded together, and the second panel wall and the plurality of inertial separator air outlet members are molded together.

45. An inertial separator panel according to claim 43, wherein:(a) the first panel wall and the plurality’ of inertial separator air inlet members are integrally molded, and the second panel wall and the plurality of inertial separator air outlet members are integrally molded.

46. An inertial separator panel according to claim 43, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

47. An inertial separator panel according to claim 43, wherein:(a) the contaminant outlet wall extends about 170 degrees to about 190 degrees about the axis.

48. An inertial separator panel according to claim 43, wherein:(a) the plurality of vanes comprises 4 to 7 vanes.

49. An inertial separator panel according to claim 43, wherein:(a) the plurality of vanes comprises 5 to 6 vanes.

50. An inertial separator panel according to claim 43, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

51. An inertial separator panel according to claim 43, wherein:(a) the plurality of vanes have a cumulative vane angle of less than 354 degrees.52 An inertial separator panel according to claim 43, wherein:(a) the plurality of vanes have a cumulative vane angle of greater than 265 degrees and less than 339 degrees.

53. An inertial separator panel according to claim 43, wherein:(a) the plurality of vanes have a cumulative gap of at least 6 degrees.

54. An inertial separator panel according to claim 43, wherein:(a) the plurality of vanes have a cumulative gap of greater than 21 degrees and less than 95 degrees.

55. An inertial separator panel according to claim 43, wherein:(a) the central hub has an axially facing surface directed toward the air inlet member first end, and at least 55% of the axially facing surface exhibits a flatness sufficient to cause turbulent flow.

56. An inertial separator panel according to claim 43, wherein:(a) a ratio between a diameter of the central hub and a diameter of the air inlet of the air outlet member is about 55% to about 66%.

57. An inertial separator panel according to claim 43, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 17% to about 38%.

58. An inertial separator panel according to claim 43, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 22% to about 33%.

59. An inertial separator panel comprising:(a) a first panel construction comprising a first panel wall and a plurality of inertial separator air inlet members, wherein:(i) the plurality of inertial separator air inlet members comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, and the air inlet member second end comprising an end opposite the air inlet, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein:(A) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough;(B) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet construction peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl;(b) a second panel construction comprising a second panel wall and a plurality of inertial separator air outlet members, wherein:(i) the plurality of inertial separator air outlet members comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface; wherein, when the air outlet construction engages the air inlet construction, wherein:(A) outer surface of the air outlet member and the inner surface of the air inlet member wall forming a region for collection of particulates and / or water droplets; and(c) the first panel wall and the plurality of inertial separator air inlet members are molded together, and the second panel wall and the plurality of inertial separator air outlet members are molded together.

60. An inertial separator panel according to claim 59, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

61. An inertial separator panel according to claim 59, wherein:(a) the contaminant outlet wall extends about 170 degrees to about 190 degrees about the axis.

62. An inertial separator panel according to claim 59, wherein:(a) the plurality’ of vanes comprises 4 to 7 vanes.

63. An inertial separator panel according to claim 59, wherein:(a) the plurality' of vanes comprises 5 to 6 vanes.

64. An inertial separator panel according to claim 59, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

65. An inertial separator panel according to claim 59, wherein:(a) the plurality of vanes have a cumulative vane angle of less than 354 degrees.

66. An inertial separator panel according to claim 59, wherein:(a) the plurality of vanes have a cumulative vane angle of greater than 265 degrees and less than 339 degrees.

67. An inertial separator panel according to claim 59, wherein:(a) the plurality of vanes have a cumulative gap of at least 6 degrees.

68. An inertial separator panel according to claim 59, wherein:(a) the plurality of vanes have a cumulative gap of greater than 21 degrees and less than 95 degrees.

70. An inertial separator panel according to claim 59, wherein:(a) the central hub has an axially facing surface directed toward the air inlet member first end, and at least 55% of the axially facing surface exhibits a flatness sufficient to cause turbulent flow.

71. An inertial separator panel according to claim 59, wherein:(a) a ratio between a diameter of the central hub and a diameter of the air inlet of the air outlet member is about 55% to about 66%.

72. An inertial separator panel according to claim 59, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 17% to about 38%.

73. An inertial separator panel according to claim 59, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 22% to about 33%.

74. An inertial separator panel comprising:(a) a first panel construction comprising a first panel wall and a plurality of inertial separator air inlet members, wherein:(i) the plurality of inertial separator air inlet members each comprising an air inlet member first end and an air inlet member second end, the air inlet member first end comprising an air inlet, and the air inlet member second end comprising an end opposite the air inlet, and an air inlet member wall extending peripherally around an axis extending from the air inlet member first end to the air inlet member second end and having an inner surface and an outer surface, wherein:(A) the air inlet member second end comprises a contaminant outlet arrangement comprising a contaminant outlet wall extending from the air inlet member wall, and a contaminant opening for flow of particulate therethrough;(B) a central hub and a plurality of vanes extending from the central hub to the inner surface of the air inlet construction peripherally extending wall, wherein the plurality of vanes are configured to cause air entering the air inlet to swirl;(b) a second panel construction comprising a second panel wall and a plurality7of inertial separator air outlet members, wherein:(i) the plurality of inertial separator air outlet members comprising a first end and a second end, the first end comprising an air inlet, and the second end comprising an air outlet, and an air outlet member wall extending peripherally around the axis, the air outlet member wall having an inner surface and an outer surface; wherein, when the air outlet construction engages the air inlet construction, wherein:(A) the outer surface of the air outlet member and the inner surface of the air inlet member wall form a region for collection of particulates and / or water droplets; and(c) a plurality7of inertial separators being formed by joining the first panel and the second panel, wherein:(i) the plurality7of inertial separators each having a contaminant outlet formed from the contaminant opening, and wherein the contaminant outlets do not all point in a same direction.

75. An inertial separator panel according to claim 74, wherein:(a) the contaminant outlets of at least some of the plurality7of inertial separators point in a direction toward a left of a panel axis, and the contaminant outlets of at least some of the plurality of inertial separators point in a direction toward a right of the panel axis.

76. An inertial separator panel according to claim 74, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

77. An inertial separator panel according to claim 74, wherein:(a) the contaminant outlet wall extends about 170 degrees to about 190 degrees about the axis.

78. An inertial separator panel according to claim 74, wherein:(a) the plurality of vanes comprises 4 to 7 vanes.

79. An inertial separator panel according to claim 74, wherein:(a) the plurality’ of vanes comprises 5 to 6 vanes.

80. An inertial separator panel according to claim 74, wherein:(a) the contaminant opening extends about 170 degrees to about 190 degrees about the axis.

81. An inertial separator panel according to claim 74, wherein:(a) the plurality' of vanes have a cumulative vane angle of less than 354 degrees.

82. An inertial separator panel according to claim 74, wherein:(a) the plurality' of vanes have a cumulative vane angle of greater than 265 degrees and less than 339 degrees.

83. An inertial separator panel according to claim 74, wherein:(a) the plurality' of vanes have a cumulative gap of at least 6 degrees.

84. An inertial separator panel according to claim 74, wherein:(a) the plurality' of vanes have a cumulative gap of greater than 21 degrees and less than 95 degrees.

85. An inertial separator panel according to claim 74, wherein:(a) the central hub has an axially facing surface directed toward the air inlet member first end, and at least 55% of the axially facing surface e.xhi bits a flatness sufficient to cause turbulent flow.

86. An inertial separator panel according to claim 74, wherein:(a) a ratio between a diameter of the central hub and a diameter of the air inlet of the air outlet member is about 55% to about 66%.

87. An inertial separator panel according to claim 74, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 17% to about 38%.

88. An inertial separator panel according to claim 74, wherein:(a) a ratio between a diameter of the central hub and a distance from the plurality of vanes to the air inlet of the air outlet member is about 22% to about 33%.

89. A method for manufacturing an inertial separator panel according to claims 43-88 comprising:(a) molding the first panel construction comprising the first panel wall and the plurality of inertial separator air inlet members, and molding the second panel construction comprising the second panel wall and the plurality of inertial separator outlet members; and(b) assembling the first panel construction and the second panel construction to form the inertial separator panel.

90. A method according to claim 89, wherein:(a) the molding comprises injection molding.

91. A method according to claim 90. wherein:(a) the injection molding comprises molding each of the first panel construction and the second panel construction using a two part mold.

92. A method for separating particulates and / or water from a gas such as air comprising:(a) introducing a gas into an inertial separator panel according to any of claims 43-88.

93. A method according to claim 92, wherein: (a) the gas comprises air.

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