Filter cartridge and air cleaner assembly

Abstract

To provide an air filter cartridge used in an air cleaner assembly.SOLUTION: An air filter cartridge 600 is installed in a housing, and comprises: a media pack 602 defining an outer perimeter and including media extending between opposed first and second ends; a radial seal arrangement 630 that is arranged along an outer periphery of the media pack and directed outward so as to provide a radial seal surface, and that includes first seal segments and second seal segments arranged on the second end side of the media pack with respect to the first seal segment; and a second member 608 of a projection-receiver arrangement that extends radially outwardly separating away from the outer periphery of the media pack and that is aligned circumferentially at least partially with the first seal segments. The air filter cartridge is removably installed in the openable / closable cleaner housing.SELECTED DRAWING: Figure 26

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application was filed as a PCT International Patent Application on December 16, 2016, and claims priority to U.S. Provisional Patent Application Nos. 62 / 269,761, filed December 18, 2015, and 62 / 316,713, filed April 1, 2016, both of which are incorporated herein by reference in their entireties.

[0002] This disclosure relates to a filter device for filtering air, typically for example, the intake air of an internal combustion engine. This disclosure particularly relates to a filter device that uses a cartridge having opposing intake and exhaust ends. The air cleaning device and its features, as well as methods of assembly and manufacture, are also described. [Background technology]

[0003] Air flows may carry contaminants, such as dust or liquid particles, therein. In many instances, it is desirable to filter some or all of the contaminants from the air flow. For example, air flows to engines (e.g., combustion air flows) for automobiles or power plants, gas flows to gas turbine systems, and air flows to various combustion furnaces carry particulate contaminants therein that must be filtered. For such systems, it is desirable to remove selected contaminants from the air (or reduce their levels in the air). Various air filter devices have been developed for contaminant removal. Improvements are needed. Summary of the Invention [Means for solving the problem]

[0004] According to the present disclosure, air cleaning device assemblies, housings, replaceable filter cartridges, and related features, components, and methods are disclosed. Generally, these features relate to systems configured to ensure the correct orientation and sealing of filter cartridges within the housing of an air cleaning device assembly. Various approaches are described herein that can be used individually or together to achieve desired results. [Brief explanation of the drawings]

[0005] [Figure 1] 1 is a partial schematic perspective view of a first type of exemplary filter medium usable in a device according to the present disclosure; FIG. [Figure 2] 2 is an enlarged schematic cross-sectional view of a portion of a filter medium of the type shown in FIG. 1. [Figure 3] Included are schematic diagrams of examples of various fluted filter media definitions for the filter media types of FIGS. [Figure 4] FIG. 4 is a schematic diagram of an exemplary process for manufacturing filter media of the type of FIGS. [Figure 5] FIG. 5 is a schematic cross-sectional view of an optional end fold for flutes of a filter medium of the type of FIGS. [Figure 6] 2 is a schematic perspective view of a roll-type filter device, for example made with strips of filter media according to FIG. 1, that can be used in a filter cartridge having features according to the present disclosure. FIG. [Figure 7] 2 is a schematic perspective view of a stacked filter media pack device, for example made with strips of filter media according to FIG. 1, that can be used in a filter device having features according to the present disclosure. FIG. [Figure 8] 2 is a schematic diagram of the inlet and outlet ends of a filter media pack that uses an alternative filter media to that of FIG. 1 and that can alternatively be used in selected filter cartridges according to the present disclosure. [Figure 8A] FIG. 9 is a schematic view of the intake and exhaust end opposite to the view in FIG. 8. [Figure 8B] FIG. 8B is a schematic cross-sectional view of the filter media pack of FIGS. 8 and 8A. [Figure 9]10 is a schematic partial cross-sectional view of another alternative type of filter media that can be used in a filter media pack of a filter cartridge having features according to the present disclosure. [Figure 10] 10 is a schematic partial cross-sectional view of a first modified filter medium of the type of FIG. 9; FIG. [Figure 11A] 10 is a schematic diagram of another usable fluted sheet and liner sheet combination according to the present disclosure. [Figure 11B] FIG. 11B is a second schematic diagram of a filter medium of the type of FIG. 11A. [Figure 11C] FIG. 10 is a schematic partial plan view of yet another modified filter medium. [Figure 12] 10 is a schematic diagram of another variation of a filter medium that can be used in accordance with the present disclosure. [Figure 13] 1 is a schematic top perspective view of an air cleaning device assembly including features and components according to the present disclosure; [Figure 14] FIG. 14 is a schematic side view of the air cleaning device assembly of FIG. 13. [Figure 15] FIG. 14 is a schematic top view of the air cleaning device assembly of FIG. 13. [Figure 16] 16 is a schematic cross-sectional view of the air cleaning device assembly of FIG. 13 taken along line 16-16 shown in FIG. 15. [Figure 16A] 16A is an enlarged schematic cross-sectional view of a portion of the air cleaning device assembly shown in FIG. 16 indicated by the circled portion labeled FIG. 16A in FIG. 16. [Figure 16B] 16B is an enlarged schematic cross-sectional view of the portion of the air cleaning device assembly shown in FIG. 16 indicated by the circled portion labeled FIG. 16B in FIG. 16. [Figure 16C] 16C is an enlarged schematic cross-sectional view of the portion of the air cleaning device assembly shown in FIG. 16 indicated by the circled portion labeled FIG. 16C in FIG. 16. [Figure 17] 17 is a schematic cross-sectional view of the air cleaning device assembly of FIG. 13 taken along line 17-17 shown in FIG. 15. [Figure 18]18 is a schematic cross-sectional view of the air cleaning device assembly of FIG. 13 taken along line 18-18 shown in FIG. 15. [Figure 19] 14 is a schematic exploded perspective view of the air cleaning device assembly of FIG. 13, viewed from above. [Figure 20] FIG. 14 is a schematic perspective view of a housing body of the air purification device assembly of FIG. 13. [Figure 21] FIG. 21 is a schematic side view of the housing body shown in FIG. 20. [Figure 22] FIG. 22 is a schematic top view of the housing main body portion shown in FIG. 21. [Figure 23] 14 is a schematic perspective view of the inner portion of the precleaner of the air cleaning device assembly of FIG. 13, viewed from below. FIG. [Figure 24] 14 is a schematic bottom view of the cover portion of the air cleaning device assembly of FIG. 13. FIG. [Figure 25] 14 is a schematic side view of a cover portion of the air cleaning device assembly of FIG. 13. FIG. [Figure 26] FIG. 14 is a schematic perspective view of an attachable filter cartridge component in the air cleaning device assembly of FIG. 13. [Figure 27] FIG. 27 is a second schematic perspective view of the filter cartridge shown in FIG. 26. [Figure 28] FIG. 27 is a schematic side view of the filter cartridge shown in FIG. 26. [Figure 28A] FIG. 27 is a schematic side view of the filter cartridge shown in FIG. 26, but in which only one lip seal is provided for the sealing arrangement. [Figure 29] FIG. 27 is a second schematic side view of the filter cartridge shown in FIG. 26. [Figure 30] FIG. 27 is a schematic top view of the filter cartridge shown in FIG. 26. [Figure 31] FIG. 27 is a schematic perspective view of the shell of the filter cartridge shown in FIG. 26. [Figure 32] FIG. 32 is a second schematic perspective view of the shell shown in FIG. 31. [Figure 33] FIG. 32 is a schematic side view of the shell shown in FIG. 31. [Figure 34] FIG. 32 is a second schematic side view of the shell shown in FIG. 31. [Figure 35] FIG. 32 is a schematic top view of the shell shown in FIG. 31. [Figure 36] FIG. 27 is a schematic perspective view of the sealing arrangement of the filter cartridge shown in FIG. 26. [Figure 37] FIG. 37 is a schematic side view of the seal arrangement shown in FIG. 36. [Figure 38] 38 is a schematic cross-sectional view of the seal arrangement shown in FIG. 36 taken along line 38-38 in FIG. 37. [Figure 39] FIG. 37 is a second schematic side view of the seal arrangement shown in FIG. 36. [Figure 40] FIG. 37 is a schematic top view of the seal arrangement shown in FIG. 36. [Figure 41] 14 is a schematic perspective view of a second or safety filter cartridge component that can be installed in the air cleaning device assembly of FIG. 13. FIG. [Figure 42] FIG. 42 is a second schematic perspective view of the filter cartridge shown in FIG. 41. [Figure 43] FIG. 42 is a schematic side view of the filter cartridge shown in FIG. 41. [Figure 44] FIG. 42 is a schematic top view of the filter cartridge shown in FIG. 41. [Figure 45] FIG. 42 is a schematic perspective view of the shell of the filter cartridge shown in FIG. 41 with the filter media installed. [Figure 46] FIG. 46 is a second schematic perspective view of the shell shown in FIG. 45. [Figure 47] FIG. 46 is a schematic side view of the shell shown in FIG. 45. [Figure 48] FIG. 46 is a schematic top view of the shell shown in FIG. 45. [Figure 49] FIG. 42 is a schematic perspective view of the sealing arrangement of the filter cartridge shown in FIG. 41. [Figure 50] FIG. 50 is a schematic side view of the seal arrangement shown in FIG. 49. [Figure 51]51 is a schematic cross-sectional view of the seal arrangement shown in FIG. 49 taken along line 51-51 of FIG. 50. [Figure 52] FIG. 50 is a schematic top view of the seal arrangement shown in FIG. 49. [Figure 53] 14 is a schematic perspective view of a filter cartridge component with the cover removed that can be installed in the air cleaning device assembly of FIG. 13. FIG. [Figure 54] FIG. 54 is a schematic perspective view of the filter cartridge shown in FIG. 53. [Figure 55] FIG. 54 is a schematic, partially exploded view of the air filter cartridge shown in FIG. 53. [Figure 56] 54 is a schematic partial perspective view of the air filter cartridge shown in FIG. 53 installed within the housing shown in FIG. 13. FIG. [Figure 57] 54 is a schematic cross-sectional view of the air filter cartridge shown in FIG. 53 in a fully installed position within the bulkhead shown in FIG. 13. [Figure 58] 14 is a schematic perspective view of a filter cartridge component that can be installed in the air cleaning device assembly of FIG. 13. FIG. [Figure 59] FIG. 59 is a schematic side view of the filter cartridge shown in FIG. 58. [Figure 60] FIG. 27 is a schematic perspective view of the sealing arrangement of the filter cartridge shown in FIG. 26. [Figure 61] FIG. 61 is a schematic side view of the seal arrangement shown in FIG. 60. [Figure 62] 62 is a schematic cross-sectional view of the seal arrangement shown in FIG. 60 taken along line 62-62 of FIG. 61. [Figure 63] FIG. 61 is a second schematic side view of the seal arrangement shown in FIG. 60. [Figure 64] 16 is a schematic cross-sectional view of the air cleaning device assembly of FIG. 13 taken along line 16-16 shown in FIG. 16, but with the filter cartridge of FIGS. 58 and 65 installed. [Figure 64A]64A is an enlarged schematic cross-sectional view of a portion of the air cleaning device assembly shown in FIG. 64 indicated by the circled portion labeled FIG. 64A in FIG. 64. [Figure 64B] 64B is an enlarged schematic cross-sectional view of a portion of the air cleaning device assembly shown in FIG. 64 indicated by the circled portion labeled FIG. 64B in FIG. 64. [Figure 64C] 64C is an enlarged schematic cross-sectional view of a portion of the air cleaning device assembly shown in FIG. 64, indicated by the circled portion labeled FIG. 64C in FIG. 64. [Figure 65] 65 is a schematic perspective view from above of the second or safety filter cartridge shown in FIG. 64 that can be installed in the air cleaning device assembly of FIG. 13. FIG. [Figure 66] FIG. 66 is a schematic perspective view of the filter cartridge shown in FIG. 65, viewed from below. [Figure 67] FIG. 66 is a schematic side view of the filter cartridge shown in FIG. 65. [Figure 68] FIG. 66 is a schematic top view of the filter cartridge shown in FIG. 65. [Figure 69a] 59A-59C are schematic cross-sectional and perspective views of an alternative filter cartridge component that can be installed in an air cleaning device assembly, similar to the component described with respect to FIG. 58. [Figure 69b] 59A-59C are schematic cross-sectional and perspective views of an alternative filter cartridge component that can be installed in an air cleaning device assembly, similar to the component described with respect to FIG. 58. [Figure 70] By way of illustration of the process of the disclosed embodiment with respect to Figures 58 and 60, a manufacturing process and manufacturing tools for manufacturing a generic 3D gasket structure are shown. [Figure 71] By way of illustration of the process of the disclosed embodiment with respect to Figures 58 and 60, a manufacturing process and manufacturing tools for manufacturing a generic 3D gasket structure are shown. [Figure 72]By way of illustration of the process of the disclosed embodiment with respect to Figures 58 and 60, a manufacturing process and manufacturing tools for manufacturing a generic 3D gasket structure are shown. [Figure 73] 1 is a schematic cross-sectional side view of an air cleaning device assembly including features and components according to the present disclosure. [Figure 74] FIG. 74 is a schematic perspective cross-sectional view of the housing of the air cleaning device assembly shown in FIG. 73. [Figure 75] FIG. 74 is a schematic perspective view of the filter cartridge of the air cleaning device assembly shown in FIG. 73. [Figure 76] 76 is a schematic cross-sectional view of the filter cartridge shown in FIG. 75 taken along line 76-76. [Figure 76a] FIG. 77 is a schematic cross-sectional view of an enlarged portion of the filter cartridge shown in FIG. 76. [Figure 77] FIG. 74 is a schematic perspective view of the filter cartridge of the air cleaning device assembly shown in FIG. 73 with the sealing arrangement removed. [Figure 78] 1 is a schematic side view of an air cleaning device assembly according to the present disclosure. [Figure 79] FIG. 79 is a schematic side view of the air cleaning device assembly shown in FIG. 78. [Figure 80] FIG. 79 is a schematic cross-sectional view of a portion of the air cleaning device assembly shown in FIG. 78. [Figure 81] 1 is a schematic perspective view of an air cleaning device assembly according to the present disclosure; [Figure 82] FIG. 82 is a schematic perspective view of a first housing part of the air purification device assembly shown in FIG. 81. [Figure 83] FIG. 82 is a schematic side view of the air cleaning device assembly shown in FIG. 81 with the filter cartridge fully installed and in a secured position. [Figure 84] 82 is a schematic side view of the air cleaner assembly shown in FIG. 81 with the filter cartridge partially installed in the housing. FIG. [Figure 85]FIG. 82 is a schematic side view of the air cleaner assembly shown in FIG. 81 with the filter cartridge in a partially installed position. DETAILED DESCRIPTION OF THE INVENTION

[0006] I. Exemplary Filter Media Configurations General Principles according to the present disclosure relate to the interaction between a filter cartridge and an air purification device system in an advantageous manner to achieve a particular selected desired result, as described below. A filter cartridge generally contains a filter media therein through which air and other gases pass during filtering. The filter media can be of various types and configurations and can be made from a variety of materials. For example, a cartridge according to principles of the present disclosure can utilize a pleated filter media device, as described below.

[0007] This principle is particularly well adapted for use in situations where the filter media is fairly deep between the inlet and outlet ends of the cartridge, although other options are possible. This principle is also commonly used in cartridges with relatively large cross-sectional dimensions. In such devices, alternative types of filter media to pleated media are often desirable.

[0008] This section provides examples of some filter media devices that can be used with the technology described herein. However, it will be appreciated that a variety of alternative types of filter media can be used. The choice of filter media type is generally one of preference, such as availability, functionality in a given application, ease of manufacture, etc., and the choice does not necessarily relate to the overall functionality of the selection among the various features of the interaction between the filter cartridge and the air cleaning device characterized herein.

[0009] A. A filter pack device using a filter medium with fluted filter medium fixed to a liner filter medium. Fluted filter media (filter media having ridges) can be used to provide fluid filter structures in a variety of ways. One well-known method is characterized herein as a Z-filter structure. The term "Z-filter structure," as used herein, is intended to include, but is not limited to, a type of filter structure in which stacked, folded, or otherwise formed filter flutes are used to define a longitudinal, typically parallel, collection of intake and exhaust filter flutes (typically combined with a liner media) for fluid flow through the filter media. Some examples of Z-filter media are provided in U.S. Pat. Nos. 5,820,646, 5,772,883, 5,902,364, 5,792,247, 5,895,574, 6,210,469, 6,190,432, 6,350,296, 6,179,890, 6,235,195, U.S. Design Patent No. 399,944, U.S. Design Patent No. 428,128, U.S. Design Patent No. 396,098, U.S. Design Patent No. 398,046, and U.S. Design Patent No. 437,401, each of which is incorporated herein by reference.

[0010] One type of Z-filter media utilizes two specific filter media components that are bonded together to form the filter media structure: (1) a fluted (typically corrugated) filter media sheet or sheet segment, and (2) a liner filter media sheet or sheet segment. While the line filter media sheet is typically not corrugated, it can also be corrugated, for example, perpendicular to the flute direction, as described in U.S. Provisional Patent Application No. 60 / 543,804, filed February 11, 2004, and published August 25, 2005, as PCT Publication WO 05 / 077487, which is incorporated herein by reference.

[0011] The fluted and liner media sections can include additional material between them, but they can also be sections of a single sheet of media folded over so that the liner media material is properly adjacent to the fluted media portion of the media.

[0012] Fluted (typically corrugated) filter media sheets and liner media sheets or combined sheet segments are typically used to define a filter media with parallel flutes. In some instances, the fluted and liner sheets are separate, then secured together, and then wound into a filter media strip to form a Z-shaped filter media structure. Such devices are described, for example, in U.S. Patent Nos. 6,235,195 and 6,179,890, each of which is incorporated herein by reference. In certain other devices, the filter structure is constructed by stacking several unwound segments or strips of fluted (typically corrugated) filter media secured to a liner media. An example of this is shown in Figure 11 of U.S. Patent No. 5,820,646, which is incorporated herein by reference.

[0013] Here, strips of material, including fluted sheets (ridged filter media sheets) secured to corrugated sheets, are then assembled into a stack to form a media pack, which may be referred to as a "single facer strip," "single face strip," or "single facer" or "single face" filter media. These terms and variations refer to each strip having a liner sheet attached to one side, or single face, of the fluted (typically corrugated) sheet.

[0014] Typically, the fluted sheet and liner sheet (i.e., single facer) combination strip is wound to construct a roll-type filter media pack with the liner sheet facing outward. Some winding methods are described in U.S. Provisional Patent Application No. 60 / 467,521, filed May 2, 2003, and PCT Application No. 04 / 07927, filed March 17, 2004, now published as International Publication No. WO 04 / 082795, each of which is incorporated herein by reference. The resulting roll-type device generally has a portion of the liner sheet as the outer surface of the filter media pack.

[0015] The term "corrugated," as used herein to refer to a structure within a filter medium, refers to a corrugated structure resulting from passing the filter medium between two corrugating rollers, i.e., through the nip or jaws of the two rollers, each having surface features suitable for imparting corrugations to the final filter medium. However, the term "corrugated" is not limited to flutes formed by a method that involves passing the medium through the jaws between the corrugating rollers, unless the term is specifically defined as such. The term "corrugated" also applies when the filter medium is corrugated and then further modified or transformed by a folding method, such as that described in PCT Publication WO 04 / 007054, published January 22, 2004, which is incorporated herein by reference.

[0016] Corrugated filter media is a specific form of fluted filter media, which is filter media that has individual flutes or ridges (formed, for example, by corrugating or folding) across it.

[0017] A replaceable filter element or filter cartridge configuration utilizing Z-shaped filter media is sometimes referred to as a "linear flow configuration" or variations thereof. Generally, this refers to a replaceable filter element or cartridge having an inlet end (or face) and an opposite outlet end (or face), with flow into and out of the filter cartridge generally in the same linear direction. In this context, the term "replaceable" refers to a filter media-containing filter cartridge that is periodically removed and replaced from a corresponding fluid (e.g., air) purification device. In some instances, the inlet end (or face) and outlet end (or face) are each generally flat or planar, and both are parallel to one another. However, variations thereof, such as non-flat faces, are also possible.

[0018] A straight-flow configuration (especially for rolled or stacked filter media packs) contrasts with serviceable filter cartridges, in which the flow generally changes direction when entering and exiting the filter media, such as the cylindrical pleated filter cartridge of the type shown in U.S. Pat. No. 6,039,778, which is incorporated herein by reference. That is, in the filter of U.S. Pat. No. 6,039,778, the flow enters the cylindrical filter cartridge through the side of the cylinder, then changes direction and exits through the open end of the filter media (a forward flow system). In a typical reverse flow system, the flow enters a serviceable cylindrical cartridge through the open end of the filter media, then changes direction and exits through the side of the cylindrical filter media. An example of such a reverse flow system is shown in U.S. Pat. No. 5,613,992, which is incorporated herein by reference.

[0019] The term "Z-media configuration" and variations thereof, as used herein, without further elaboration, shall include any or all of, but are not necessarily limited to, a web of corrugated or otherwise fluted filter media (filter media having ridges) secured to a (liner) filter media, whether separate sheets or part of a single web, with suitable sealing (closures) to define intake and exhaust flutes, and / or a filter media pack configured or formed from such filter media into a three-dimensional network of intake and exhaust flutes, and / or a filter cartridge or structure containing such a filter media pack.

[0020] In Figure 1, an example of a filter media 1 that can be used in a Z-media structure is shown. The filter media 1 is formed from a fluted, in this case corrugated, sheet 3 and a liner sheet 4. Structures such as filter media 1 are referred to herein as single facers or single-face strips.

[0021] At times, the corrugated fluted or ribbed sheet 3 of FIG. 1 is of a type generally characterized herein as having a regular, curved wave pattern of flutes, ridges, or corrugations 7. The term "wave pattern" in this context refers to a flute, ridge, or wave pattern of alternating valleys 7b and ridges 7a. In this context, the term "regular" refers to alternating valley-ridge pairs (7b, 7a) that are generally of the same repeating corrugation (flute or ridge) shape and size. (Also, typically in a regular configuration, each valley 7b is a substantially inverted ridge for each ridge 7a.) The term "regular," therefore, refers to a corrugation (or flute) pattern that includes valleys (inverted ridges) and ridges, with each pair (including adjacent valleys and ridges) repeating without substantial variation in corrugation size and shape over at least 70% of the length of the flute. In this context, the term "substantially" refers to variations resulting from changes in the process or geometry used to fabricate the corrugated or fluted sheet, as opposed to slight variations due to the flexibility of the filter media sheet 3. Regarding repeating pattern features, the number of ridges and grooves may not necessarily be equal in any filter configuration. The ends of the filter media 1 may, for example, be between pairs of ridges and valleys, or partially along pairs of ridges and valleys. (For example, in FIG. 1, the partially shown filter media 1 has eight complete ridges 7a and seven complete valleys 7b.) Also, the opposite ends of the flutes (valley and ridge ends) may differ from one another. Such variations in the ends are ignored in these definitions unless otherwise noted. That is, variations in the ends of the flutes are intended to be covered by the above definitions.

[0022] Regarding the "curved" wave pattern characteristic of the corrugations, in certain instances, the wave pattern is not the result of folds or creases imposed on the filter media, but rather the peaks 7a of each ridge and the bottoms 7b of each valley are formed along radiused curves. Typical radii for such Z-shaped filter media are at least 0.25 mm and typically no greater than 3 mm.

[0023] With respect to corrugated sheet 3, another feature of the particular regular curved wave pattern shown in FIG. 1 is that along most of the length of flutes 7, at approximately the midpoint 30 between each valley and each adjacent ridge, there is a transition region where the curvature reverses. For example, when looking at back side or face 3a of FIG. 1, valleys 7b are recessed regions and ridges a are protruding regions. Of course, when looking at front side or face 3b, valleys 7b on face 3a form ridges, and ridges 7a on face 3a form valleys. (In some examples, region 30 can be a straight segment rather than a point, with the curvature reversed at the end of segment 30.)

[0024] A characteristic of the particular regular wave-pattern fluted (in this case, corrugated) sheet 3 shown in FIG. 1 is that the individual corrugations, ridges, or flutes are generally straight, although other options are possible. In this context, "straight" means that the ridges 7a and valleys (or inverted ridges) 7b do not substantially change in cross-sectional shape over at least 70%, typically at least 80%, of their length. The term "straight" with respect to the corrugation pattern shown in FIG. 1 distinguishes it, in part, from the tapered flutes of the corrugated filter media shown in FIG. 1 of WO 97 / 40918, incorporated herein by reference, and in PCT application WO 03 / 47722, published June 12, 2003. For example, the tapered flutes of WO 97 / 40918 are curved wave patterns, not "regular" or straight flute patterns, as that term is used herein.

[0025] 1 of the present application, as previously mentioned, filter media 1 has first and second opposed edges 8 and 9. When filter media 1 is formed into a media pack, edge 9 generally forms the inlet end or face and edge 8 forms the outlet end or face for the media pack, although the opposite orientation is also possible.

[0026] In the illustrated example, the various flutes 7 extend completely between the opposing edges 8, 9, although other options are possible. For example, they can extend to a position near or near the edges, but not completely between them. They can also terminate and begin partway through the filter medium, such as in the filter medium of U.S. Patent Application Publication No. 2014 / 0208705 A1, which is incorporated herein by reference.

[0027] 1, a sealant bead 10 may be provided near the edge 8 to seal the corrugated sheet 3 and the liner sheet 4 together. The bead 10 is sometimes referred to as a "single facer" or "single-face" bead, or variations thereof, because it is between the corrugated sheet 3 and the liner sheet 4, forming a single-facer (single-face) filter media strip 1. The sealant bead 10 closes the individual flutes 11 near the edge 8 to the passage of air out of them (or into them in the opposite direction of flow).

[0028] In the filter media shown in FIG. 1 , a sealing bead 14 is provided near the edge 9. The sealing bead 14 generally closes the flutes 15 near the edge 9 against unfiltered fluid passing therethrough (or, in the opposite direction, flowing therethrough). The bead 14 will typically be applied when the filter media 1 is assembled into a media pack. If the media pack is fabricated from a stack of strips 1, the bead 14 forms a seal between the back surface 17 of the liner sheet 4 and the side surface 18 of the adjacent next corrugated sheet 3. If the filter media 1 is cut into strips and stacked rather than rolled up, the bead 14 is called a "stack bead." (If the bead 14 is used in a roll-type configuration formed from long strips of filter media 1, it is called a "rolled bead.")

[0029] For other types of through-flow filter media, the sealing material can be in other locations, and even no additional sealant or adhesive can be used. For example, in some instances, the filter media can be folded to form an edge or marginal seam, or the filter media can be sealed by another technique, such as ultrasonic irradiation. Furthermore, if a sealant material is used, it need not be near both ends.

[0030] Referring to Figure 1, once filter media 1 has been incorporated into a media pack, for example by stacking or winding, it can operate as follows: First, air in the direction of arrow 12 enters open flutes 11 near end 9. Because end 8 is closed by bead 10, air passes through filter media 1 as shown by arrow 13. It can then exit the filter media or media pack by passing through open ends 15a of flutes 15 near end 8 of the media pack. Of course, operation can also be performed with air flowing in the opposite direction.

[0031] For the particular configuration shown herein in FIG. 1, the parallel corrugations 7a, 7b are generally straight throughout the filter media, from edge 8 to edge 9. The straight flutes, ridges, or corrugations may be deformed or folded at selected locations, particularly at the ends. Modifications made to the ends of the flutes to effect closure are generally not considered in the foregoing definitions of "regular," "curved," and "wave pattern."

[0032] Z-shaped filters that do not utilize a corrugation shape with a straight, regularly curved wave pattern are also known. For example, U.S. Patent No. 5,562,825 to Yamada et al. shows a corrugation pattern that utilizes approximately semicircular (in cross section) inlet flutes adjacent to narrow V-shaped (with curved sides) outlet flutes (see Figures 1 and 3 of 5,562,825). U.S. Patent No. 5,049,326 to Matsumoto et al. shows circular or tubular (in cross section) flutes defined by one sheet with half tubes attached to another sheet with half tubes, resulting in parallel, straight flutes with flat areas between them (see Figure 2 of Matsumoto's '326 patent). U.S. Patent No. 4,925,561 to Ishii et al. (Figure 1) shows flutes folded to form a rectangular cross section, in which the flutes are tapered along their length. WO 97 / 40918 (FIG. 1) shows flutes or parallel corrugations that have a curved wave pattern (with contiguous curved convex and concave valleys) but are tapered (and therefore not straight) along their length. WO 97 / 40918 also shows flutes that have a curved wave pattern but with ridges and valleys of varying sizes. Flutes with different shapes containing varying ridges are also known.

[0033] Generally, filter media is a relatively flexible material, typically a nonwoven fibrous material (cellulose, synthetic, or both), often containing resins and sometimes treated with additional materials. This allows it to be easily formed into and incorporated into various corrugation patterns without unacceptable damage to the filter media. It can also be easily rolled up or otherwise configured for use, again without unacceptable damage to the filter media. Of course, it must be of such a nature that it will maintain the required corrugation during use.

[0034] Typically, the corrugating process imposes inelastic deformation on the media, preventing it from returning to its original shape. However, when the tension is released, the flutes or corrugations tend to spring back, recovering only a portion of the stretch and bending that had occurred previously. To prevent this springback of the corrugated sheet, a liner media sheet is sometimes connected to the fluted media sheet. Such a connection is shown in 20.

[0035] Typically, the filter media also contains a resin. During the corrugation process, the filter media can be heated to a temperature above the glass transition temperature of the resin. The resin is then cooled, which helps it retain its shape.

[0036] The corrugated (fluted) sheet 3, the liner sheet 4, or both filter media may be provided with fine fiber material on one or both sides thereof, e.g., according to U.S. Patent No. 6,673,136, incorporated herein by reference. In some instances, when such fine fiber material is used, it may be desirable to provide the fine fibers on the upstream side of the material and within the flutes. In this case, airflow during filtration typically enters the edge containing the stacked beads.

[0037] A problem with Z-filter structures relates to the closure of the ends of the individual flutes. While other options exist, a sealant or adhesive is typically provided to achieve this closure. As is evident from the above disclosure, typical Z-filter media, especially those that use straight flutes rather than tapered flutes and a sealant to seal the flutes, require a large sealant surface area (and volume) at both the upstream and downstream ends. A high-quality seal at these locations is critical to the proper operation of the resulting filter media structure. Large sealant volumes and areas can cause problems in this regard.

[0038] Turning now to FIG. 2, a schematic diagram of a Z-shaped filter media, or Z-shaped filter media structure 40, is shown, utilizing a corrugated sheet 43 with a regular curved wave pattern and an uncorrugated flat sheet 44, i.e., a single facer strip. The distance D1 between points 50 and 51 defines the extent of the flat filter media 44 within the area 52 under a given corrugated flute 53. The length D2 of the arcuate filter media for a given corrugated flute 53 over the same distance D1 is, of course, greater than D1, depending on the shape of the corrugated flute 53. For typical regularly shaped filter media required for fluted filter applications, the linear length D2 of the filter media 53 between points 50 and 51 is often at least 1.2 times D1. Typically, D2 will be 1.2 to 2.0 times D1, inclusive. One particularly conventional device for air filtration has a configuration in which D2 is approximately 1.25 to 1.35 times D1. Such media are used commercially, for example, in Donaldson Powercore™ Z-filter devices. Another potentially advantageous size is one in which D2 is about 1.4 to 1.6 times D1, where the ratio D2 / D1 is sometimes characterized as the flute / flat ratio for corrugated media, i.e., the media's aperture.

[0039] Various flutes are defined in the corrugated packaging industry, such as standard flute E, standard flute X, standard flute B, standard flute C, and standard flute A. Attached Figure 3, along with Table A below, provides definitions of these flutes.

[0040] Donaldson Company, Inc. (hereinafter DCI), the assignee of the present application, uses various standard flutes A and B in various Z-filter devices. These flutes are also defined in Table A and FIG. 3.

[0041] [Table 1]

[0042] Of course, other standards and flute definitions from the corrugated box industry are also known.

[0043] Generally, standard flute configurations from the corrugated box industry can be used to define the corrugation diameter or approximate corrugation shape for corrugated filter media. The above comparison of DCI A flutes and DCI B flutes with the corrugated box industry standard flutes A and standard flutes B shows some advantageous variations.

[0044] It should be noted that alternative flute definitions, such as those characterized in U.S. Patent Application No. 12 / 215,718, filed June 26, 2008, published as U.S. Patent Application Publication No. 2009 / 0127211, U.S. Patent Application No. 12 / 012,785, filed February 4, 2008, published as U.S. Patent Application Publication No. 2008 / 0282890, and / or U.S. Patent Application No. 12 / 537,069, published as U.S. Patent Application Publication No. 2010 / 0032365, may be used with the air cleaning device features characterized below. The entire disclosures of each of U.S. Patent Application Nos. 2009 / 0127211, 2008 / 0282890, and 2010 / 0032365 are incorporated herein by reference.

[0045] Another modified filter medium, including a fluted filter medium and a liner filter medium secured thereto, either in stacked or rolled form, can be used in devices according to the present disclosure, as described in U.S. Patent Application Publication No. 2014 / 0208705 A1, published July 31, 2014, owned by Baldwin Filters, Inc., which is incorporated herein by reference.

[0046] B. Manufacturing of a filter media pack configuration containing the filter media of Figures 1-3. See Figures 4-7. FIG. 4 shows an example of a manufacturing process for producing a filter media strip (single facer) corresponding to strip 1 of FIG. 1. Generally, a liner sheet 64 and a fluted (corrugated) sheet 66 having flutes 68 are joined together with an adhesive bead 70 positioned therebetween to form a filter media web 69. The adhesive bead 70 forms the single facer bead 10 of FIG. 1. An optional folding process is performed at station 71 to form a central fold 72 in the center of the web. The Z-shaped filter media or Z-shaped filter media strip 74 is cut or slit at 75 along the bead 70 to create two small pieces or strips 76, 77 of Z-shaped filter media 74, each with a linear sealant (single facer bead) extending between the corrugations and the liner sheet. Of course, if the optional tucking process is used, the edge with the flushing sealant (single facer bead) will also have a set of tucking flutes at this location.

[0047] Methods for carrying out the process characterized with respect to FIG. 4 are described in PCT Publication No. WO 04 / 007054, published January 22, 2004, which is incorporated herein by reference.

[0048] Continuing with reference to FIG. 4, Z-shaped filter media 74 must be formed before passing through folding station 71 and ultimately being slit at 75. In the schematic shown in FIG. 4, this is accomplished by passing a sheet of filter media 92 between a pair of corrugating rollers 94, 95. In the schematic shown in FIG. 4, the sheet of filter media 92 is unwound from a roll 96, wound around a tension roller 98, and then passes through a nip or jaw 102 between corrugating rollers 94, 95. Corrugating rollers 94, 95 have teeth 104 that impart the generally desired corrugated shape to the flat sheet 92 after it passes through nip 102. After passing through nip 102, sheet 92 is corrugated in the machine direction and referred to as a corrugated sheet at 66. Corrugated sheet 66 is then secured to a liner sheet 64. (The corrugating process may optionally include a step of heating the filter media.)

[0049] 4, the process also advances liner sheet 64 to folding process station 71. Liner sheet 64 is stored on roll 106 and then directed toward corrugated sheet 66 to form Z-filter media 74. Corrugated sheet 66 and liner sheet 64 will typically be secured together by adhesive or other means (e.g., by sonic welding).

[0050] 4, there is shown an adhesive line 70 used as a sealant bead to secure the corrugated sheet 66 and the liner sheet 64 together. Alternatively, a sealant bead to form a liner bead can be applied as shown at 70a. If a sealant bead is applied at 70a, it may be desirable to provide a gap in the corrugating roller 95, and possibly in both corrugating rollers 94, 95, to receive the bead 70a.

[0051] Of course, the apparatus of FIG. 4 can be adapted to use the tack bead 20 of FIG. 1, if desired.

[0052] The type of corrugation provided to the corrugated filter media is selectable and is determined by the corrugation or corrugation teeth of the corrugating rollers 94, 95. One useful corrugation pattern would be a regular curved wave pattern with straight flutes or ridges, as defined above. A typical basic curved wave pattern used is one in which the distance D2, as defined above, within the corrugation pattern is at least 1.2 times the distance D1, as defined above. In some exemplary applications, D2 = 1.25-1.35 x D1, although other options are possible. In some instances, this technique may also be applied to curved wave patterns that are not "regular," including, for example, those that do not use straight flutes. Modifications to the curved wave patterns shown are also possible.

[0053] As previously mentioned, the process shown in Figure 4 can be used to make the center fold 72. Figure 5 shows a cross section of one of the flutes 68 shown in Figure 4 after folding and scoring.

[0054] Folded configuration 118 can be seen to form tucked flutes 120 having four creases 121a, 121b, 121c, and 121d. Folded configuration 118 includes a flat first layer or portion 122, which is secured to liner sheet 64. A second layer or portion 124 is shown pressed against first layer or portion 122. Second layer or portion 124 is preferably formed by folding opposite outer edges 126, 127 of first layer or portion 122.

[0055] 5, two of the folds or creases 121a, 121b are generally referred to herein as "upper inward" folds or creases. The term "upper" in this context means that the folds are at the top of the entire folded body 120 when the folded body 120 is viewed in the orientation of FIG. 5. The term "inward" refers to the fold or crease lines of each fold 121a, 121b being oriented toward one another.

[0056] In Figure 5, folds 121c, 121d are generally referred to herein as "lower, outward" folds. The term "lower" in this regard refers to the fact that folds 121c, 121d are not positioned higher in the orientation of Figure 5, as are folds 121a, 121b. The term "outward" refers to the fact that the fold lines of folds 121c, 121d face away from one another.

[0057] The terms "upper" and "lower," when used in this context, refer specifically to fold peak 120 when viewed in the orientation of Figure 5, i.e., they do not otherwise indicate the orientation that fold peak 120 may have in the actual product in use.

[0058] Based on these characterizations and reference to Figure 5, the present disclosure defines a regular fold configuration 118 according to Figure 5 as including at least two "upper inward folds." These inward folds are unique and do not significantly encroach on adjacent flutes upon folding.

[0059] A third layer or portion 128 can also be seen pressed against the second layer or portion 124. The third layer or portion 128 is formed by folding from opposite inner edges 130, 131 of the third layer 128.

[0060] Another way to look at the folded configuration 118 is with respect to the shape of the alternating ridges and valleys of the corrugated sheet 66. A first layer or portion 122 is formed from the inverted ridges. A second layer or portion 124 corresponds to two peaks (after the ridges are inverted) folded toward, and in a preferred configuration against, the inverted ridges.

[0061] Techniques for providing the optional tucking described with respect to Figure 5 in a preferred manner are described in PCT Publication No. WO 04 / 007054, which is incorporated herein by reference. Methods for applying roll-up beads and rolling up filter media are described in PCT Application No. 04 / 07927, filed March 17, 2004, published as WO 04 / 082795, which is incorporated herein by reference.

[0062] Alternative methods for folding the fluted end closed are possible. Such methods can include, for example, folding other than at the center of each flute and performing rolling, pressing, or folding on the various flutes. Generally, folding involves folding or otherwise manipulating the filter media near the fluted end to compress it closed.

[0063] The techniques described herein are particularly well suited for use with filter media packs obtained from rolling up a single sheet or "single facer" strip comprising a combination of corrugated and liner sheets, although they can also be in a laminated configuration.

[0064] A roll-type filter medium or filter medium pack configuration can be provided with various perimeter definitions. In this regard, the term "perimeter definition" or variations thereof refers to the defined perimeter shape when viewed at either the inlet end or outlet end of the filter medium or filter medium pack. A typical shape is a circle, as described in PCT Publication No. WO 04 / 007054. Another usable shape is an oval, and some examples of ovals are ellipses. Generally, an oval has opposing curved ends connected by a pair of opposing sides. In some ellipses, the opposing sides are also curved. In other ellipses, also known as track shapes, the opposing sides are generally straight. Track shapes are described, for example, in PCT Publication No. WO 04 / 007054 and PCT Application No. 04 / 07927, published as WO 04 / 082795, each of which is incorporated herein by reference.

[0065] Another way to describe the perimeter or outer perimeter shape is by defining the perimeter that would result from cutting the media pack in a direction perpendicular to the unwound end of the roll.

[0066] The opposing inlet and outlet ends or faces of a filter media or media pack can be provided with a variety of different definitions. In many configurations, the ends or end faces are generally flat (planar) and perpendicular to each other. In other configurations, one or both end faces include a tapered, e.g., stepped, portion that can be defined as either projecting axially outward from the axial end of the side wall of the media pack or projecting axially inward from the end of the side wall of the media pack.

[0067] Fluted seals (e.g., from single facer beads, rolled beads, or laminated beads) can be formed from a variety of materials. Various cited and incorporated references describe hot melt or polyurethane seals as being usable for a variety of applications.

[0068] FIG. 6 generally depicts a roll media pack (or rolled filter media) 130 constructed by rolling up a single strip of single-face filter media. The particular roll media pack depicted is an elliptical media pack 130a, specifically a track-shaped media pack 131. The rear end of the media is located on the outside of the media pack 130 and is designated 131x. For convenience and sealing, the end typically terminates along a straight portion of the media pack 130. Typically, a hot-melt seal bead or seal bead is positioned along this end to ensure a secure seal. Opposite inlet and outlet (end) faces of the media pack 130 are designated 132 and 133. One is the inlet inlet face, and the other is the outlet outlet face.

[0069] In Figure 7, steps for forming a laminated z-filter media (or media pack) from strips of z-filter media are shown (schematically), with each strip being a fluted sheet secured to a liner sheet. Referring to Figure 6, a single facer strip 200 is shown added to a stack 201 of strips 202 similar to strip 200. Strip 200 can be cut from either strip 76, 77 of Figure 4. At 205 in Figure 6, the application of a lamination bead 206 is shown between each layer corresponding to strips 200, 202 at the opposite end from the single facer bead or seal. (Lamination can also be done by adding each layer underneath the stack rather than on top.)

[0070] 7, each strip 200, 202 has leading and trailing edges 207, 208 and opposing side edges 209a, 209b. The inlet and outlet flutes of the combined corrugated and liner sheets that comprise each strip 200, 202 generally extend between the leading and trailing edges 207, 208 and parallel to the side edges 209a, 209b.

[0071] 7, the formed filter media or media pack 201 has opposing inlet and outlet faces designated 210 and 211. It is possible to select which face 210, 211 serves as the inlet end and which face serves as the outlet end during filtration. In some instances, the stack bead 206 is positioned upstream, i.e., near the inlet face 211, and in other instances, the reverse is true. The inlet and outlet faces 210, 211 extend between opposing faces 220, 221.

[0072] The stacked filter media configuration or pack 201 shown as formed in Figure 7 is sometimes referred to as a "block-type" stacked filter media pack. The term "block-type" in this context indicates that the configuration is formed as a rectangular block with all faces at 90° with respect to all adjacent wall faces. For example, in some instances, the stack can be formed by slightly offsetting each strip 200 from alignment with adjacent strips to create a parallelogram or angled block shape with inlet and outlet faces parallel to one another but not perpendicular to the top and bottom faces.

[0073] In some instances, the filter media or media pack is described as having a parallelogram in any cross section, meaning that any two opposing faces extend generally parallel to one another.

[0074] It is noted that a block-type stack configuration corresponding to Figure 7 is described in the prior art U.S. Patent No. 5,820,646, which is incorporated herein by reference. It is also noted that stack configurations are described in U.S. Patent Nos. 5,772,883, 5,792,247, U.S. Provisional Patent Application No. 60 / 457,255, filed March 25, 2003, and U.S. Patent Application No. 10 / 731,564, filed December 8, 2003, and published as U.S. Patent Application Publication No. 2004 / 0187689. Each of these latter references is incorporated herein by reference. It is noted that the stack configuration described in U.S. Patent Application No. 10 / 731,504, published as U.S. Patent Application Publication No. 2005 / 0130508, is a tilted stack configuration.

[0075] It is also noted that in some instances, multiple laminates can be incorporated into a single filter media pack, and in some instances, the laminates can be produced with one or more intake and exhaust surfaces having recesses therein, as shown, for example, in U.S. Patent No. 7,625,419, which is incorporated herein by reference.

[0076] C. Selected filter media or media pack configurations including multiple spaced rolls of fluted filter media. Other types of filter media configurations or packs, including end-to-end extensions, can be used with selected principles according to the present disclosure. An example of such an alternative filter media configuration or pack is shown in Figures 8-8B. The media in Figures 8-8B is similar to that depicted and described in German Patent No. 20 2008 017 059 U1 and may be found in configurations available from Mann & Hummel under the trademark "IQORON."

[0077] Referring to FIG. 8, a filter media or media pack is generally designated 250. The filter media or media pack 250 includes a first outer pleated (ribbed) filter media loop 251 and a second inner pleated (ribbed) filter media loop 252, with each pleat tip (or rib) extending between opposing inlet and outlet ends. The view of FIG. 8 is toward the (inlet / outlet) end 255 of the filter media pack. End 255 of the view can be either the inlet (inlet) end or the outlet (outlet) end, depending on the selected flow direction. For many configurations using the characterized principles, the filter media pack 250 will be configured within a filter cartridge such that end 255 is the inlet / inlet end.

[0078] 8, the outer pleated (ribbed) filter media loop 251 is configured as an oval, although other options are possible. At 260, a pleat end closure means, e.g., molded-in-place, is shown closing the ends of the pleats or ribs 251 at the media pack end 255.

[0079] Pleats or ridges 252 (and associated pleat tips) are positioned so as to be surrounded by and spaced apart from loop 251, and thus pleated filter media loop 252 is also shown as generally oval. In this example, ends 252e of individual pleats or ridges 252p within loop 252 are sealed. Loop 252 also surrounds center 252c, which is closed by central strip 253 of material, typically molded in place.

[0080] During filtration, when end 255 is the inlet intake end, air enters gap 265 between the two filter media loops 251, 252. The air then flows through either loop 251 or loop 252 as it moves through media pack 250 and is filtered.

[0081] In the illustrated example, loop 251 is configured to angle inward toward loop 252 in the region away from end 255. Also shown is spacer 266 supporting centering ring 267 surrounding the end of loop 252 for structural integrity.

[0082] In Figure 8A, end 256 of cartridge 250, opposite end 255, is visible. Here, it can be seen that the interior of loop 252 surrounds open gas flow region 270. As air is directed through cartridge 250 toward end 256 in a general direction away from end 255, a portion of the air passing through loop 252 enters central region 270 and from there exits through end 256. Of course, during filtration, air entering loop 251 in Figure 8 will generally flow around (over) perimeter 256p of end 256.

[0083] 8B, a schematic cross-sectional view of cartridge 250 is provided. Selected features identified and described are designated with like reference numerals.

[0084] As can be seen from the above description of Figures 8-8B, the cartridge 250 described is generally a cartridge having a filter media tip extending longitudinally between opposite inlet and outlet ends 255, 256.

[0085] 8-8B, the filter media pack 250 is depicted as having an oval, specifically a track-shaped, perimeter. It is depicted in this manner because the air filter cartridges in many of the examples described below also have an oval or track-shaped configuration. However, this principle can be embodied with a variety of alternative perimeter shapes.

[0086] D. Other variations of filter media Figures 9-12 9-12, cross-sectional views of yet another alternative variation of filter media types usable in selected applications of the principles characterized herein are provided. Specific examples are described in U.S. Patent Application No. 62 / 077,749, filed November 10, 2014, and owned by Donaldson Company, Inc., the assignee of the present disclosure. Generally, each of the configurations in FIGS. 9-12 illustrates a type of filter media having opposing inlet and outlet intake and exhaust ends (or faces) and that can be stacked or rolled up into a straight-through flow configuration.

[0087] In Figure 9, an exemplary filter media configuration 301 from U.S. Patent Application No. 62 / 077,749 is shown in which an embossed sheet 302 is secured to a non-embossed sheet 303, which are then stacked or rolled up to form a filter media pack and sealed along opposite edges of the type already described with respect to Figure 1 of this application.

[0088] In FIG. 10, another exemplary filter media pack 310 from U.S. Patent Application No. 62 / 077,749 is shown in which a first embossed sheet 311 is secured to a second embossed sheet 312, which is then formed into a stacked or rolled filter media pack configuration and edge-sealed generally in accordance with FIG. 1 of the present application.

[0089] Edge sealing can be performed at either the upstream or downstream end, or in some instances both. It may be desirable to avoid typical adhesives or sealants, especially if the filter media is likely to encounter chemicals during filtering.

[0090] In Figure 11A, a cross section of a fluted sheet X is shown having various embossments thereon for mating with a liner sheet Y. Again, these can be separate or sections of the same filter media sheet.

[0091] In FIG. 11B, a schematic diagram of such an arrangement between fluted sheet X and liner sheet Y is also shown.

[0092] In Figure 11C, another variation of this principle is shown between fluted sheet X and liner sheet Y, to help understand how different approaches are possible.

[0093] In FIG. 12, yet another possible variation in fluted sheet X and liner sheet Y is shown.

[0094] It should be noted that there is no requirement that the same filter media be used for the fluted sheet sections and the liner sheet sections. Different filter media may be desired for each to achieve different effects. For example, one may be a cellulose filter media, while the other may be a filter media containing some type of fiber other than cellulose. These may have different porosities or structural characteristics to achieve the desired results.

[0095] 9-12 are intended to generally illustrate that a variety of alternative filter media packs may be used in accordance with the principles of the present application. Attention is also directed to U.S. Patent Application No. 62 / 077,749, which is incorporated herein by reference, for the general principles of construction and application of several alternative filter media types.

[0096] E. Another type of filter media Many of the techniques characterized herein preferably apply when the filter media oriented to filter between the opposing inlet and outlet ends of the cartridge have flutes or pleat tips extending in a direction between those ends. However, other options are possible. The techniques characterized herein for defining sealing configurations are also applicable to filter cartridges with opposing inlet and outlet ends, where the filter media is positioned to filter fluid flow between those ends, even when the filter media does not include flutes or pleat tips extending in a direction between those ends. The filter media can be, for example, a depth-type filter media, pleated in alternating directions, or non-pleated material.

[0097] In practice, however, the technology featured herein is particularly advantageous for use with cartridges that have a relatively deep end-to-end extension, usually at least 100 mm, typically at least 150 mm, often at least 200 mm, sometimes at least 250 mm, and in some instances 300 mm or more, and are configured to handle large load volumes during use. These types of systems typically have filter media configured with pleat tips or flutes that extend in a direction between opposing end portions.

[0098] II. Selected problems identified for various air cleaning devices A.General There is a wide variety of designs for air purification devices, particularly assemblies that utilize relatively deep filter media packs generally employing filter media according to one or more of Figures 6-12. With respect to examples of actual products available on the market, attention is drawn to air purification devices from Donaldson Company, Inc., the assignee of the present disclosure, sold under the trade name "Powercore," and products from Mann & Hummel, Inc., offered under the name "IQORON."

[0099] Additionally, air purification device assemblies using these filter media packs can be installed worldwide in a variety of original equipment (e.g., over-the-road trucks, buses, off-road construction equipment, agricultural and mining equipment, etc.) Repair parts and replacements are available from a variety of suppliers and service companies.

[0100] B. Identifying the appropriate filter cartridge It is very important that the filter cartridges selected for servicing are appropriate for the target air cleaning device. Air cleaning devices are a critical component of the overall equipment. If servicing needs to be performed more frequently than planned, this can increase expenses, downtime of the target equipment, and lost production. If servicing is not performed with the correct parts, there is a risk of equipment failure or other problems occurring.

[0101] The correct cartridge for a given air cleaning device and equipment is generally the result of product design / testing by the air cleaning device manufacturer and specifications / instructions / testing by the equipment manufacturer and / or engine manufacturer. In a field repair replacement, a technician may select a part that appears to be the same as the one previously installed, but is not the correct and strictly qualified component for the system involved.

[0102] It would be desirable to provide an air cleaning device assembly with features that help servicers easily determine whether the assembly is being serviced with the correct (or incorrect) filter cartridge, regardless of the type of filter media itself. To achieve this benefit, the optional features and techniques described herein can be provided as follows:

[0103] Additionally, assembly features and techniques are described that are advantageous with respect to manufacturing and / or filter component integrity, and may be realized with features and techniques of the type that help ensure the correct cartridge is installed in the assembly, or in alternative applications.

[0104] C. Intake air volume sensor problem In many systems, an intake air mass sensor is provided downstream of the filter cartridge and upstream of the engine to monitor airflow and contaminant characteristics. In some instances, small changes in the configuration and orientation of the filter media pack can cause variations in the operation of the intake air mass sensor. Therefore, it may be desirable to provide an air cleaning device assembly with filter cartridge and air cleaning device features that manage changes in airflow from the filter cartridge to a relatively minimum. This can facilitate use and operation of the intake air mass sensor. The features and techniques described herein can be provided to advantageously obtain this benefit.

[0105] D. Stable installation of filter cartridge In many instances, the equipment to which the air purification device is attached is subject to substantial vibration and shock during operation. The types of filter media packs described above with reference to Figures 6-12 are often constructed to be relatively deep, i.e., at least 50 mm deep in the direction of air flow, and often at least 80 mm deep or greater, and in many instances greater than 100 mm deep. Such deep filter cartridges can be loaded with substantial amounts of contaminants during use and can be substantially heavy. They can therefore be subject to large vibration moments during operation. It is desirable to provide filter cartridges with features that help ensure stable cartridge positioning, avoid damage to the filter media (or media pack) during movement, and avoid seal failure during such vibration and shock.

[0106] Similarly, devices may be exposed to wide temperature ranges during storage and use. These can cause materials to expand / contract relative to one another. It is desirable for filter cartridges and air cleaning devices to be constructed in a manner that ensures that seal integrity is not compromised under these conditions. The features and techniques described herein can be adapted to address these issues and are discussed below.

[0107] E. Preventing improper insertion Various configurations have been developed to address these types of problems, see, for example, International Publication Nos. WO 2006 / 076479, WO 2006 / 076456, WO 2007 / 133635, WO 2014 / 210541, and U.S. Patent Application No. 62 / 097,060, each of which is incorporated herein by reference. However, another problem that can sometimes arise with filter cartridge configurations is that cartridges that do not have reliable sealing features can still be installed, and in some cases, the housing can still be closed even if the installed cartridge is not the correct one for the housing and does not seal properly. It would be desirable to address these issues.

[0108] More generally, it would be desirable to provide a filter cartridge that solves the problems characterized above but is configured to prevent the housing of an air cleaning device from closing properly when such mis-installation occurs, for example, due to the use of a cartridge that appears to be suitable for the housing but does not have the proper sealing characteristics. The technology described herein addresses this problem. These can be used in conjunction with the features of the configurations characterized in WO 2006 / 076479, WO 2006 / 076456, WO 2007 / 133635, WO 2014 / 210541, and / or U.S. Patent Application No. 62 / 097,060, but they can also be used individually. This will be understood from the following description.

[0109] F. Overview The features characterized herein can be used to advantage to address one or more of the problems described above. There is no particular requirement that the features be implemented in a way that maximally addresses all problems. However, selected embodiments are described that address all of the above problems to a significant and desirable extent.

[0110] III. Exemplary Assemblies Figures 13-52 A. Characteristics of general air purifiers Figures 13-25 Reference numeral 500 in FIG. 13 generally designates an exemplary air purification device assembly according to the present disclosure. Air purification device assembly 500 generally includes a housing 501. Housing 501 includes a body 504 defining an internal cavity 505 (see FIGS. 19-20 ) over which a removable service / replacement or access cover 502 is provided, providing access to internally received components, such as a filter cartridge. Air purification device assembly 500 extends along a longitudinal axis X, around which internal components (e.g., filter cartridge) are also aligned. References to an axial direction are intended to refer to directions parallel to longitudinal axis X. References to a radial direction are intended to refer to directions extending perpendicular to longitudinal axis X.

[0111] 13-19, the air purification device 500 includes an outlet device 510 (positioned on the main body 402 in this example). The outlet device 510 is generally positioned so that filtered air is discharged from the air purification device assembly 500 through an outlet 510x. The outlet device or assembly 510 can be manufactured separately from and attached to the remainder of the main body 504, or can be integral with the remainder of the main body 504. In arrangements in which the outlet device 510 is manufactured separately, a modular assembly practice can be employed to provide alternative outlet devices for different systems used.

[0112] The housing 501 can be constructed from a variety of materials, provided that various principles according to the present disclosure are implemented. The features described are particularly well-suited for use in housings that are primarily molded plastic components, such as ABS plastic. The housing 501 of FIG. 13 generally represents such a component, with selected housing features, such as the body 504, including various structural ridges on its surface for strength and integrity, see ribs 508. The housing 501 can also be provided with ridges that help limit the passage of dust and contaminants into unsealed portions of the assembly 500. For example, ribs 508 (see FIGS. 21 and 22) can be provided to aid in visual alignment when attaching the cover 502 to the housing body 504 of the housing 501. The interior portion of the housing body 504 can also be provided with various features and indentations suitable for various purposes, such as material savings, shell strengthening, and / or ensuring a filter cartridge fits within the housing. For example, the housing body 504 may be provided with ribs 507 and recessed or grooved structures 541 (FIGS. 19-20, 22).

[0113] In general, the housing 501 can be characterized as including an air inlet 512 through which air to be filtered enters the assembly 500. The particular assembly 500 shown also includes a contaminant exhaust port or port device 514, as described below.

[0114] The particular illustrated air purification device assembly 500 is a two-stage air purification device assembly that includes a precleaner 516. The precleaner 516, in the illustrated example, includes a plurality of separator tube devices 518. The precleaner 516 can be used to preclean selected substances (contaminants) carried by the airflow into the air purification device assembly 500 before the air reaches the filter cartridges positioned therein. Such precleaning typically results in the substantial removal of liquid particulates, such as rainwater or splash water, and / or various (especially larger) coarse dust or other particles. Note that the particular illustrated exemplary precleaner 510 includes a portion of the access cover 502.

[0115] In the illustrated example, the precleaner 516 includes two shell or cover components secured together: an outer (inlet) cover portion 502 and an inner (exhaust) cover portion 506. The inner cover portion 506 is shown in FIG. 23. In some applications featured herein, the components 502, 506 are snap-fit ​​or otherwise secured together but are configured to be separable for ease of cleaning. However, in some applications of the technology featured herein, the two cover or shell components 502, 506 may be secured together during assembly and then inseparable.

[0116] As previously mentioned, the inlet cover 502 may include a plurality of separation tube devices 518. As best seen in FIGS. 16 and 17, each separation tube device 518 may include an inlet end 518a and an outlet end 518b. Near the inlet end 502, the separation tube device 518 includes a wing device 518c disposed within an inlet flow tube 518d extending in a direction toward the outlet end 518b. As shown, the wing device 518c and the inlet flow tube 518d are integrally formed within the outlet cover 502. However, these components may alternatively be provided separately and then attached to the outer cover 502, such as by a press fit. In the illustrated example, the inlet inner cover 506 includes a plurality of outlet flow tubes 518e projecting from a tubesheet 518f. Each of the outlet flow tubes 518e projects toward the inlet end 518a and partially receives an inlet flow tube 518d, with a ring or gap 518g between the inlet and outlet flow tubes 518d.

[0117] The general operation of the precleaner 516 is to separate material (contaminants) as it enters the air cleaning device, again to allow it to exit through the exhaust port in the housing body 502. This path is best seen in FIG. 16 . This prevents certain materials from reaching the filter cartridge components received inside. Generally, each tube 518 operates by centrifugal separation of contaminants introduced into it. To accomplish this, air entering the inlet end 518 a is generally directed in a cyclone-type pattern by the vanes of the vane device 518 c. This action forces contaminants into the inlet flow tube 518 d and ultimately out through the port 514. Because the inlet end of the outlet flow tube 518 e is inside the outlet end of the inlet flow tube 518 c, contaminants that can be separated and forced against the interior walls of the inlet flow tube 518 c cannot enter the outlet flow tube 518 e. Tube sheet 518f blocks airflow between inner cover 506 and the downstream portion of air cleaning device assembly 500, forcing all air separated by air separator 516 to be directed through outlet flow tube 518e. In the illustrated configuration, fourteen separator tube devices 518 are provided. However, more or fewer, the same or different separator tube devices 518 may be provided. One exemplary separator tube device that can be used in the systems disclosed herein is shown and described in U.S. Provisional Patent Application No. 62 / 097,060, filed December 27, 2014, which is incorporated herein by reference in its entirety. Alternative arrangements exist. For example, cover portion 502 can include two separate components, the first including inlet flow tube 518c and the second including integrally formed outlet flow tube 518e and tube sheet 518f. Such a design is essentially a combination of components 502 and 506 for the second component and the upper portion of 502 forming the first component.

[0118] 13, 15, and 19, a mounting pad arrangement is provided at 520 by which the air cleaning device assembly 500 can be secured to a fixture for use. The exemplary mounting pad arrangement 520 generally includes a plurality of feet or pads 520x, in the example molded integrally with the housing body 504, which in this example properly fits over a recessed metal connector or other type of connector arrangement.

[0119] 13-19, with further reference to FIGS. 20-22 and 24, the particular illustrated access cover 502 is secured in place by a connector arrangement 522, which in the illustrated example includes one or more lugs 524 on the cover 502 (see FIG. 24) that engage one or more lugs 526 (see FIGS. 20-22) located on the housing body 504. To secure the cover 502 to the housing body 504, the cover 502 is placed on the housing body 504 and turned until the lugs 524, 526 engage with one another in an overlapping arrangement, locking the cover 502 to the housing body 504. The connector arrangement 522 includes a handle 528 connected to a spring lock clip 530 that can be depressed to engage one of the housing lugs, thereby preventing the cover 502 from being rotated in the reverse direction to remove the lugs 524, 526. The cover 520 can be unlocked by pulling the handle 528 in an axial direction opposite the lugs 524, 526. In this example, three lugs 524 and three lugs 526 are shown. Of course, the number and location of the lugs 524, 526 can vary. This arrangement allows the cover 502 to be attached to the housing portion 504 in various orientations, thereby orienting the exhaust port 514 as desired. Additionally, the twist lock device can be configured to initially rotate the cover in either a clockwise or counterclockwise direction to secure the cover to the housing body. An exemplary twist lock device that can be used in the systems disclosed herein is shown and described in U.S. Provisional Patent Application No. 62 / 128,567, filed June 25, 2015, which is incorporated herein by reference in its entirety. Other locking devices, such as over-center latching devices, bolts, or other fasteners, can also be used.

[0120] 16-22, the housing body 504 is shown provided with a plurality of first members 542 of the protrusion receiver device 540. As can be seen in FIG. 18, the first members 542 are each configured to interact with a second member 608 of the protrusion receiver device 540. The second members 608 can be associated with the filter cartridge 600, both features of which are described in more detail below. In one embodiment, the first members 542 are positioned within the circumferential sidewall 504b of the housing body 504 near the open end 504a of the housing body 504 (see FIGS. 19-21). Features of the first members 542 of the protrusion receiver device are described in more detail below.

[0121] 13-19, the particular air cleaning device housing 501 shown generally has a cross-sectional shape with a major axis X (which lies in a plane perpendicular to the axis or general direction of airflow) and a minor axis perpendicular to the major axis X, and the air cleaning device assembly 500 is configured such that, during use, it can be mounted in virtually any orientation, for example with the cross-sectional major axis X generally vertical, horizontal, or at any angle therebetween. The principles described herein are applicable to alternative arrangements, as will become apparent from the following description.

[0122] In the illustrated example, the interior cavity 505 of the housing body 504 has a generally round cross-sectional shape. However, other shapes are possible. For example, rectangles, ovals, and other essentially geometric shapes with rounded or non-rounded corners may be utilized. Some examples of rectangles include ellipses, which have curved ends connected by opposing sides. In some elliptical shapes, both sides are also curved. In other elliptical shapes, sometimes referred to as racetrack shapes, both sides are generally straight.

[0123] C. Air filter cartridge 600 Figures 26-40 26-29, a filter cartridge is shown at 600. The filter cartridge 600 is generally a primary or primary filter cartridge that, in use, selectively separates particulates or contaminants not separated by the precleaner 516. The cartridge 600 is generally a serviceable part (or removable component), meaning that during the life of the air cleaning device 600, the filter cartridge 600 is periodically removed and refurbished or replaced. The filter cartridge 600 includes a filter or filter media 602, which may be of any of a variety of types, including circular and non-circular cross-sectional shapes, such as each of those previously characterized herein. Thus, the filter cartridge 600, including the filter media 602, as well as the peripheral shell 610 and sealing device 630 (described below), may be provided in many different shapes, such as circular, rectangular, oval, and other essentially geometric shapes with rounded or non-rounded corners to match a similarly shaped housing body 504. Some examples of oval shapes include an ellipse, with curved ends connected by opposing sides. In some elliptical shapes, both sides are also curved. In other elliptical shapes, sometimes called racetrack shapes, the opposing sides are generally straight.

[0124] A typical cartridge 600 used with principles according to the present disclosure is in a "straight-through flow" configuration, having a first (inlet) flow face or end 604 and an opposite outlet (flow) face or end 606, with air flow for filtration through the filter cartridge 600 generally from the inlet end 604 to the outlet end 606.

[0125] Still referring to FIGS. 26-29 , in the illustrated example, the cartridge 600 includes a shell 610 surrounding the filter media 602. The shell 610 protects the outer periphery of the filter media 602 from damage that might otherwise occur to the filter media 602 from the housing body 504 or during handling. Thus, the shell 610 may be referred to as a protective cover. The shell 610 can be formed from a number of impermeable and permeable materials, such as ABS plastic and paper-based materials. The shell can also be provided in a solid impermeable configuration, such as a solid ABS plastic wall, or a permeable configuration with holes in the sidewall. In the illustrated example, the shell 610 extends the entire length of the filter media 602. In other examples, the shell 610 can extend along only a portion of the length of the filter media.

[0126] 30-35, the shell 610 is shown separate from the remaining features of the filter cartridge 600. In one embodiment, the shell 610 includes a circumferential sidewall 612 that extends from a first end 614 to a second end 616 and defines an interior space 618. The sidewall 612 has an inner surface 612a that faces the interior space 618 and an opposing outer surface 612b. When the filter media 602 is installed within the interior space 618, the inner surface 612a abuts the outer periphery of the filter media 602.

[0127] 32, in the illustrated example, the shell 610 also includes a support structure 620 disposed near the second end 616. The support structure 620 is for securing the filter media 602 within the interior space 618 of the shell 610, so that the filter media 602 cannot protrude beyond the support structure 620 and exit the shell 610 through the second end 616. The filter media 602 may be further secured within the shell 610 by adhesive between the outer periphery and the inner surface 612a of the filter media 602 and / or between the first end 614 and the inner surface 612a of the filter media.

[0128] In the illustrated example, support structure 620 is provided as a grid extending across the open end of shell 610 near second end 616, and includes an inwardly extending flange portion 620a, an intermediate ring 620b, a central portion 620c supporting a central core of filter media 602, a plurality of radially extending ribs 620d surrounding intermediate ring 620b, and central portion 620c. Grid structure 620 defines a plurality of open sections 621 between features 620a-620d, thereby allowing filtered air to flow unrestricted through filter media 602. Other support structure configurations may be provided that support filter media 602 while allowing sufficient flow through the structure. For example, support structure 620 may be configured as an inwardly extending ledge or flange, e.g., with only portion 620a provided. In some examples, shell 610 may be provided without support structure 620.

[0129] 32-35, filter cartridge 600 is provided with a plurality of second members 608 of projection receiver arrangement 540. Features of second members 608 are described below. In the illustrated example, second members 608 are integrally formed with shell 610 and are closer to first end 614 than second end 616. Other arrangements are possible.

[0130] 30-35, the shell 610 is also shown to include an end portion 622 near the first end 614 of the shell 610. The end portion 622 extends beyond the end of the filter media 602 and transitions to a larger inner diameter at a transition structure 624 compared to the inner diameter defined by the filter media 602 where it is mounted within the interior space 618. In one example, as seen in FIGS. 16, 16A, and 16B, an adhesive 642 can be applied to or near the transition structure 624 to secure the filter media 602 within the shell 610. With reference to FIG. 16B, the filter cartridge 600 is shown optionally axially secured by contact between the end portion 622 and a circumferential rib 518h on the precleaner inner portion 506. With reference to FIGS. 16 and 16C, a member 643 is shown attached to either the housing body 504 or the shell 612 to help secure the filter cartridge 600 at the opposite end. Member 643 is preferably an elastomeric material that stabilizes cartridge 600 and prevents hard-to-hard contact between the interior of shell 610 and housing body 504 .

[0131] 30-35, shell 610 also includes a plurality of axially extending, circumferentially spaced ribs 626 that are disposed about end portion 622 and extend from circumferential rib 628. Ribs 626, 628 serve to reinforce shell 610, particularly shell first end 614 and end portion 622. Circumferential rib 628 also supports second member 608 of protrusion receiver device 540.

[0132] The filter cartridge 600 is also provided with a sealing device 630. The sealing device 630 is shown on the filter cartridge in FIGS. 26-29 and separated from the shell in FIGS. 36-40. The sealing device 630 forms a seal between the filter cartridge 600 and the interior of the second housing portion 504 to ensure that air flowing from the inlet 512 must pass through the filter cartridge 600 before reaching the outlet 510. The sealing device 630 therefore prevents air from the inlet 512 from bypassing the filter cartridge 600 and reaching the outlet 510. In the illustrated example, the sealing device 630 is formed as a continuous band around the outer surface 612b of the shell sidewall 612 and extends radially outward from the outer surface 612b. The sealing device 630 can be provided along the periphery of the filter media 602 where the shell 610 is not present. In some instances, the sealing device 630 can be a discontinuous band or have discontinuous portions, so long as effective sealing is provided. This can be achieved by providing multiple overlapping sealing portions or sealing portions with alternating gaps to form a labyrinth-type seal.

[0133] As best seen in Figures 36-40, in the illustrated example, the sealing device 630 is formed with a plurality of sealing lips 632 extending radially from a base portion 634. The base portion 634 is shown in Figures 26-29 as being bonded to the shell exterior surface. As shown, each sealing lip 632 is a flexible, long, radial extension that tapers slightly, or narrows, as it extends from the base portion 634 toward its free tip. The outer diameter defined by the sealing lip 632 is larger than the inner diameter defined by the sidewall 504b of the housing body 504. When the filter cartridge 600 is installed in the housing body 504, the sealing lip 632 flexes in a direction opposite to the insertion direction and opposite to the direction of airflow through the cartridge 600. The resilience of the sealing lip 632 causes the sealing lip 632 to rest against the inside of the housing body sidewall 504b, forming an outward radial seal. When the sealing lip 632 deflects in the direction opposite to that of the airflow, the airflow within the air cleaning device assembly 500 exerts a force on the sealing lip 632, thereby increasing the sealing effect that the sealing lip 632 exerts on the side wall 504b of the housing body.

[0134] Still referring to FIGS. 36-40 , three axially spaced seal lips 632 are provided, each extending continuously around the entire outer circumference of the shell 610. More or fewer seal lips 632 may be used, e.g., one, two, four, or five. An example of a single-lip seal embodiment is shown in FIG. 28 . Additionally, while the seal lips 632 are shown as evenly spaced, the seal device 630 may have variable spacing between the seal lips 632. In one method, the shell 610 can be formed by injection molding and then placed into a second mold in which the seal device 630 can be injection molded onto the shell 610. One class of materials suitable for injection molding the seal device 630 is thermoplastic elastomers (TPEs). TPE materials allow for injection molding of tightly profiled, highly flexible parts and are therefore advantageous for forming the seal lips 632. Other forming processes may also be used. For example, sealing device 630 can be formed independently from TPE or other material and then attached to shell 610 or filter media 602 with an adhesive and / or sealant, or secured mechanically or by friction without an adhesive. Because sealing device 630 is disposed around the periphery of shell 610, sealing device 630 naturally has the same peripheral shape as shell 610. Accordingly, sealing device can also be provided in numerous shapes, such as round or circular, rectangular, oval, elliptical, and other essentially geometric shapes with rounded or non-rounded corners.

[0135] Continuing with reference to FIGS. 36-40 , the seal device 630 can be formed of a plurality of alternating first and second adjacent segments 636, 638, including at least one first segment 636 and at least one second segment 638. The use of the term “segment” is intended simply to refer to a portion of the seal device and does not relate to the shape of the seal, and unless specifically stated otherwise, the portion need not be perfectly linear, flat, curved, or of any particular shape. In the illustrated example, three first segments 636 and three second segments 638 are provided, forming a continuous band around the shell 610. The first segments 636 are generally flat and are shown extending along the circumference of the shell 610, such that each portion of the first segment 636 is the same distance from the first and second ends 614, 616 as every other corresponding portion of the first segment 636 (i.e., the first segments 636 are oriented parallel to the inlet and outlet flow planes 604, 606). However, in other embodiments, the first segment 636 can be non-planar.

[0136] Each second segment 638 is shown as being offset from the interconnected first segment 636 toward the second end 616 of the shell. As such, the second segments 638 are closer to the second end 616 of the shell than the corresponding portion of the first segment 636. The resulting space 637 (see FIGS. 36-39 ) created by the second segments 638 can accommodate the second member 608 of the shell 610. While the illustrated example shows the second segments 638 as being evenly spaced, identically shaped, and offset the same distance away from the first segments 638 toward the second end 616, the second segments can be otherwise positioned. For example, the second segments 638 can be provided with different shapes from one another, or that extend different distances from the first segments 638 toward the second end 616, and / or have different radial spacings therebetween (i.e., at least two of the first members 636 have unequal lengths).

[0137] As shown in detail in FIGS. 37-39 , second segment 638 is formed from generally interconnected planar portions 638a, 638b, and 638c, with portion 638a generally parallel to inlet flow plane 604 and portions 638b and 638c extending obliquely from portion 638a toward first segment 636. In this manner, portions 638b and 638c serve as transition segments between portion 638c and first segment 636. As shown, portions 638a and 638b each extend at an approximately 45-degree angle from portion 638c, with portion 638c generally parallel to first segment 636 and the inlet flow plane of cartridge 600. Of course, other angles and variations are possible. Second segment 638 can be generally curved, for example, having a semicircular, semi-oval, or semi-elliptical shape. Second segment 638 can also be formed with a slot or notch shape (e.g., portions 638a, 638b are orthogonal to portion 638c), with the resulting open space being square or rectangular. By incorporating second segment 638 into sealing device 630 instead of simply having one flat circumferential segment 636, sealing device 630 can be configured without housing features (e.g., ribs 507 and grooves / recesses 541) that would otherwise prevent a seal from being formed between sealing device 630 and housing 504, as discussed above.

[0138] The number of second segments 638 is shown to be the same as the number of second members 608, provided three at a time. However, the number of second segments 638 may be greater than the number of second members 608, if desired. In the illustrated example, the second members 608 are spaced approximately 120 degrees apart from one another, with the arc angle being between approximately 30 degrees and approximately 45 degrees, closest to approximately 36 degrees. The arc angle is defined as the angle at which a line extends from one end of member 608a to the opposite end of member 608b. Thus, the shell surface between projections 608 is shown to be between approximately 75 degrees and approximately 90 degrees, closest to approximately 84 degrees. Segments 638 generally have the same arc angle as described above for members 608, while sealing device segments 636 may have the same approximate arc angle as described above for the spacing between members 608, although it should be understood that the angle may vary depending on the measurement point. The member 608 and the seal device 630 may be configured to have many other angles of arc, which may or may not be equal.

[0139] In the illustrated example, and as can be seen in Figures 26-29, the shape of the second segment 638 is generally complementary to the shape of the second member 608 of the protrusion receiver device 540, which extends from the shell 610. The use of the term "complementary" is intended to indicate that the two portions have the same shape or contour and run generally parallel to one another along their closest boundaries. By providing the second segment 638 to be biased toward the second end 616 of the shell or the outlet flow surface 606 of the filter, the first segment 636 can be axially positioned in the same plane around the shell 610 or filter media 602 and circumferentially aligned with the second member 608, meaning that at least a portion of the second member 608 and second segment extend along a common plane around the circumference of the filter media 602 / shell 610. In this case, the common plane is parallel to the inlet and outlet flow surfaces 604, 606 (i.e., perpendicular to axis X). This arrangement allows the second member 608 to be positioned between the sealing device 630 and the first end 614 of the shell, and also allows as much of the sealing device as possible to be positioned near the first end 614 of the shell. If ribs 507 or other similar features are provided on the housing, the biasing shape of the sealing device 630 causes the sealing device 630 to corrugate between the ribs 507 and the protrusions 608 on the housing body 504, thereby ensuring a proper seal between the sealing device 630 and the housing body 504.

[0140] Referring again to Figures 36-40, sealing device 630 is also shown as being rotationally symmetric, which allows the sealing device to be rotated and aligned about longitudinal axis X. In the illustrated example, sealing device 630 has third-order rotational symmetry, such that the sealing device appears the same every 120 degrees of rotation. The same is true for filter cartridge 600 as a whole. If additional second members 608 and second segments 638 are provided, the number of orders of rotational symmetry increases, as long as equal spacing is provided between second members 608 and 638. As previously mentioned, second members 608 and second segments 638 need not be equally radially spaced in all embodiments.

[0141] C. Protrusion Receptor Device 16-19, it can be seen that the housing body 504 receives the filter cartridge 600 within the cavity 505. The housing body 504 and the filter cartridge 600 together form the aforementioned protrusion receiver arrangement 540, with one or more first members 542 disposed on the housing body 504 interacting with one or more second members 608 disposed on the filter cartridge 600. In the illustrated example, the housing body 504 is provided with a plurality of first members 542 configured as receiving structures 542. The receiving structures 542 receive corresponding second members 608 configured as protrusions 608 on the filter cartridge 600. Although the receiving structures 542 are shown on the housing body 504 and the protrusions 608 are shown on the filter cartridge 600, these may be reversed, with the filter cartridge 600 provided with the receiving structures and the housing body 504 provided with the protrusions. The protrusion receiver device 540 operates to secure the filter cartridge 600 in a rotationally fixed position within the housing body 504, thereby constraining the filter cartridge 600 from rotation about the cross-sectional major axis of the housing body 504 and filter cartridge 600 (i.e., axis X). The protrusion receiver device 540 also operates to ensure the filter cartridge 600 is properly oriented before being fully inserted into the housing body 504. Another function of the biasing shape of the protrusion receiver device 540 and seal device 630 is to minimize contact between the housing body 504 and the seal when rotationally aligning the cartridge 600 during insertion. Otherwise, the contact line between the seal and the housing body 540 would be long, making it difficult to rotate the cartridge 600 to the correct rotational position before final axial engagement.

[0142] As best seen in Figures 19-22, in the illustrated example, the receiving structures 542 are positioned near the open end 504a of the housing body 504 and are radially spaced apart between the lugs 526. At this end, the housing body 504 has a circumferential sidewall 504b that extends to the open end 504a. Each of the receiving structures includes an end wall 544 that is radially spaced apart from the sidewall 504b. The end walls 544 can be formed with a curved or arcuate shape to match the curvature of the sidewall 504b, or can be formed as a flat, straight segment. As shown, the end walls 544 have a curved shape that follows an arc parallel to the arc defined by the sidewall 504b. The end walls 544 are also shown as being generally parallel to the sidewall 504a along the height of the end walls 544. However, the end wall 544 can be angled to provide a taper such that the end wall 544 is positioned at the open end 504a farther from the side wall 504b and further into the interior of the housing body 504 than the opposite end of the end wall 544.

[0143] A radially extending sidewall 546 connects sidewall 504b to end wall 544 at the bottom of end wall 544, and the top of receiving structure 542 also opens at open end 504a. Sidewall 546 includes a first portion 546a disposed generally parallel to open end 504a of the housing, and second and third portions 546b, 546c extending from the end of first portion 546a to open end 504a. In the illustrated example, second and third portions 546b, 546c extend at an inclined angle from first portion 545a to first portion 546a and open end 504a. In the illustrated example, the inclined angle is approximately 45 degrees. This configuration allows receiving structure 542 to initially have a wide open receiving area for receiving protrusion 608, eliminating the need for precise alignment of cartridge 600. As the projection 608 is received further into the receiving structure 542, the second and third portions 546b, 546c narrow, ultimately holding the projection 608 in a fixed position and constraining the cartridge from rotating relative to the housing body 504.

[0144] In other examples, the second and third portions 546b, 546c can also extend generally perpendicularly from the first portion 546a to the open end 504a. In other arrangements, the sidewall 546 is formed as a curved wall, e.g., semicircular, semi-oval, or semi-elliptical. While the sidewall 546 is shown as having a generally constant width in the radial direction, a variable width may also be provided. For example, the sidewall 546 may be wider at the housing open end 504a than the first portion 546a, such that the end wall 544 tapers inwardly relative to the housing sidewall 504b.

[0145] In some examples, end wall 544 need not be provided such that housing side wall 504b simply opens up where end wall 544 would otherwise be. In such a configuration, side wall 546 can still be provided to provide a flat surface upon which protrusion 608 can rest. Alternatively, receiving structure 542 can be formed without end wall 544 or side wall 546, with receiving structure 542 simply defined as a hole in housing side wall 504. In such a configuration, protrusion 608 simply rests on the resulting edge formed by the hole in side wall 504.

[0146] 18 and 31-34, protrusion 608 is complementary in shape to receiving structure 540 and includes a base portion 608a with portions 608b, 608c extending diagonally from base portion 608a toward shell first end 614 and into rib 628. Each of portions 608a, 608b, and 608c extends radially from shell outer surface 612b, creating a generally flat surface that projects perpendicularly when viewed from the axial end of shell 610. Base portion 608a is shown parallel to the inlet and outlet flow planes 604, 606 and to the holes defined in shell 610's first and second ends 614, 616. Thus configured, protrusion portions 608b, 608c are disposed at the same angle as receiving structure portions 546b, 546c, such that portion 608c is parallel to portion 546c and portion 608b is parallel to portion 546b. Thus, in the illustrated example, portions 608 a and 608 b each extend at an angle of approximately 45 degrees from portion 608 c , with each portion 608 c generally parallel to first segment 636 and the inlet flow plane of cartridge 600 .

[0147] As best seen in FIG. 18 , protrusion 608 is received by receiving structure 546. When fully received, the flat edges of portions 608b and 546b contact one another, as do the flat edges of portions 608c and 546c. This engagement constrains filter cartridge 600 from rotating relative to housing body 504. As can be seen in FIG. 18 , portions 608a and 546a are spaced apart and do not contact one another. This configuration ensures that potential contact between portions 608a and 546a is avoided, which would otherwise prevent portions 546b / 608b and 546c / 608c from contacting one another and providing a tighter fit between protrusion 608 and receiving structure 546. However, protrusion 608 and receiving structure 608 can be shaped such that all three portions contact one another.

[0148] As previously mentioned, many other complementary and non-complementary shapes are possible for first member / receiving structure 546 and second member / protrusion 608. Additionally, first member 546 and / or second member 608 may be provided with or coated with a soft material to prevent hard plastic-to-plastic contact between the members. For example, a TPE material can be overmolded onto portions 608b, 608c at the same time that sealing device 630 is overmolded onto shell 610.

[0149] 18 , it can be seen that each projection 608 is not fully received within the receiving structure 546. Rather, protruding portions 608b and 608c extend beyond the receiving structure 546. This configuration results in a portion of the filter cartridge 600 resting beyond the open end 504a of the housing body 504. As can be seen more clearly in FIG. 17 , the first end 614 of the shell 610 extends a height H1 above the open end 504a of the housing body 504. This height allows a user to easily grasp features at the first end 614 of the shell 610 (such as projections 608, end portions 622, ribs 628, and transition structures 624 of projections 608) when installing or removing the cartridge 600. To further assist in installing or removing the filter cartridge 600, an additional handle feature 640 may also be provided, as shown schematically in FIG. 26 .

[0150] In the illustrated example, three protrusion receiver devices 540 are shown, which include three receiving structures 542 and three corresponding protrusions 608. However, more or fewer receiving structures 540 may be provided without departing from the concept of the present application. The number of receiving structures 542 provided directly corresponds to the number of filter cartridge orientations that can be received by the housing body 504, as long as the receiving structures are rotationally symmetric (i.e., the receiving structures are evenly radially spaced, e.g., three receiving structures 540 spaced 120 degrees apart). This is true regardless of the number of protrusions 608, as long as the number of protrusions 608 does not exceed the number of receiving structures 540, resulting in an uninsertable filter cartridge. Thus, the filter cartridge 600 can be rotated to three different positions that can be received by the housing body 504 as shown. In other examples, if only one receiving structure 542 is provided, there is only one insertion orientation of the filter cartridge; if two receiving structures 542 are provided with second-order rotational symmetry, there are two insertion orientations of the filter cartridge; etc. If an oval or rate-track shaped filter cartridge and housing body is provided, providing one protrusion receiver device 540 will result in only one insertion direction of the filter cartridge into the housing body; providing two protrusion receiver devices can accommodate both of the unique rotational orientations of the filter cartridge, as long as the protrusion receiver devices are rotationally symmetric.

[0151] D. Filter Cartridge 600' Figures 58-64C 58-64C, an alternative filter cartridge 600' is presented. In this example, the filter media 602 and shell 610 (and the alternatives discussed above) are the same as in filter cartridge 600 and can be mounted within housing body 504 as shown in FIGS. 64-64C. Accordingly, the same reference numerals are used for these features and no further description is necessary here. It should be noted that filter cartridge 600 need not be provided with the same filter media and shell as shown for filter cartridge 600', as alternative arrangements exist.

[0152] In this example, filter cartridge 600' is provided with a sealing device 630' that is different from sealing device 630. However, sealing device 630' certainly shares many common features with sealing device 630. For example, sealing device 630' has alternative first and second adjacent segments 636', 638', with second segment 638' offset from first segment 636' and having interconnecting portions 638a', 638b', and 638c'. Accordingly, the discussion regarding the geometry of sealing device 630 and the alternative devices applies to sealing device 630', particularly with respect to the discussion regarding shell 610 and protrusion receiver device 540.

[0153] Sealing device 630' differs from sealing device 630 in that sealing device 630' has a relatively more integral profile and does not have a radially extending sealing lip. Sealing device 630' also includes a plurality of steps 632' that transition sealing device 630' from a first thickness t1 near cartridge inlet end 614 to a second thickness t2 near second end 616, where second thickness t2 is thinner than thickness t1. This configuration forms a pinch-type radial seal between sealing device 630' and housing body 504, as seen in FIGS. 64-64B. In the illustrated example, an outer portion of sealing device 630' forms a seal against the inside of housing body sidewall 504b. Sealing device 630' is also shown extending beyond sidewall 504b in this example. Other arrangements are possible. In alternative examples, the sealing device 630' can have a beveled or sloped surface that transitions between thicknesses t1 and t2, or can have a uniform thickness rather than a step 632'.

[0154] The relatively more integral contour of sealing device 630' likely dictates that it be formed from a polyurethane material. Other materials are possible. The material used for sealing device 630' can be molded onto shell 610 in a manner generally similar to that described for sealing device 630. Sealing device 630' can also be molded separately from polyurethane or other material and secured to shell 610 and / or filter media 602 with an adhesive and / or sealant. Because sealing device 630' is disposed around the periphery of shell 610, sealing device 630' naturally has the same peripheral shape as shell 610.

[0155] In FIG. 58, an embodiment is shown in which the shell 610 extends along the entire length of the media pack 602.

[0156] Alternatively, the shell, in this case rather a support structure 610', extends only over an end portion of the media pack 602, e.g., the end portion near the cartridge inlet end 614. It may, for example, include a ring or similar structure 6100' surrounding the end portion of the media pack 602 near the cartridge inlet 614. This is shown, for example, in FIG. 69(b), with a corresponding cross-sectional view along surface A shown in FIG. 69(a). In such a case, the sidewall of the filter cartridge is determined not only by the shell 610 (or support structure 610'), but also by the outer surface of the media pack 602. The shell or support structure may also be formed as and / or include features as disclosed for the embodiment described with respect to FIG. 58.

[0157] Figures 70-72 show one example of a possible manufacturing process for the sealing device 630' (e.g., gasket) described with respect to Figure 58 or Figure 69. The sealing device can be manufactured directly onto the shell 610, or onto the support structure 610' (the side portions surrounding its ring portion 6100') and / or the filter media 602, utilizing a physical process known as thixotropy.

[0158] Here, a thixotropic material (or other foam material) is applied to the area where the gasket is to be formed, thereby filling only a portion of the area or the entire area. Then, shortly after applying the thixotropic material TM, one or more molding structures (M1, M2), e.g., one, two, or more molds (M1, M2), are attached to the thixotropic material TM, thereby limiting the volume available for the foaming system. The thixotropic material then resides within the interior space defined by the upper portion of the filter cartridge sidewall and the molding structures. The thixotropic material then expands or foams, eventually filling the defined space or cavity. The space or cavity preferably defines the final shape of the gasket 630' to be manufactured. The cavity or space can be defined, for example, internally, at least in part, by a ring structure 6100' surrounding the support structure 610' / filter media pack 602 or shell structure 610. Preferably, the amount of thixotropic material is predetermined taking into account the predetermined volume, shape, and positioning of the gasket 630′ to be manufactured. Preferably, the sidewalls of the cavity thus defined do not completely surround the cavity, thereby allowing a small amount S of thixotropic material TM to escape the cavity at a predetermined location upon expansion. This may facilitate more complete filling of the defined cavity during the expansion process. This also allows for density control of the gasket 630′. One or more molds M1, M2 may include holes O to achieve this. Alternatively, or in combination, one or more holes or open ring-shaped spaces V may be provided between the mold M (M1, M2, ...) and the remainder of the filter cartridge.

[0159] The thixotropic material can be applied in one step or in multiple steps. For example, one relatively thick band of thixotropic material can be applied (see FIG. 71). Alternatively, two or more bands of thixotropic material (e.g., three in the embodiment shown with respect to FIG. 72) can be applied next to each other. The thixotropic material can be applied in the form of multiple beads of the same or different sizes and shapes. The thixotropic material can, for example, be provided in all of the required locations simultaneously.

[0160] During expansion, the multiple bands can bond or fuse together to define a uniform gasket structure 630'.

[0161] According to some embodiments, the materials of the shell 610 or support structure (610', 6100') and the sidewalls of the filter media pack 602, the foam or thixotropic material FM, and the one or more molds M, respectively, can be predetermined so that the foam or thixotropic material adheres well to the shell or support structure and the sidewalls of the filter media pack, while adhering poorly or not at all to the one or more molds.

[0162] According to some embodiments, the portion of the sidewall of the (in-process, intermediate) filter cartridge where the thixotropic material is to be applied, such as the sidewall of the shell 610 or the support structure 610-6100' / filter media pack 602, is pre-treated with an adhesion promoter for the thixotropic material. According to some embodiments, the inner sidewall of one or more shaping means / molds M is provided with an adhesion inhibitor (e.g., mold release agent) for the thixotropic material.

[0163] After expansion and a predetermined curing time, the mold(s) M are removed to achieve the final filter cartridge.

[0164] According to some embodiments, when an embodiment according to FIG. 58 is envisaged, the thixotropic material is applied along each portion of the shell 610.

[0165] According to some embodiments, when an embodiment according to FIG. 69 is envisioned, the thixotropic material is applied along the support structure 610 ′ (its outer portion, eg, ring-shaped portion 6100 ′) and adjacent portions of the filter media pack 602 .

[0166] Preferably, a two-component polyurethane system can be used to produce a flexible foam seal (gasket). Alternatively, a three-component or four-component or higher polyurethane system can be used. As previously mentioned, alternatively, other foam materials may also be used.

[0167] Two-component systems, for example, consist of a resin and a hardener, which are mixed in a predetermined ratio to produce a flexible sealing foam within minutes.

[0168] It will be appreciated that the proposed method can be used to fabricate any 3D gasket structure by applying a thixotropic material onto a predetermined 3D surface and using a 3D formed or molded structure.

[0169] Accordingly, the sealing device 630' can also be provided in many shapes, such as round or circular, rectangular, oval, elliptical, and other basically geometric shapes with rounded or non-rounded corners.

[0170] E. Air filter cartridge 700 Figures 41-52 16, 17, 19, and 41-52, the particular illustrated air cleaning device assembly 500 includes an optional secondary or safety filter 700. The (optional) safety or secondary filter 700 is generally positioned between the primary filter cartridge 600 and the outlet 510x. In a typical arrangement, the (optional) secondary filter cartridge 700 is removably positioned within the air cleaning device assembly 500 and can be a serviceable component. However, it is typically not exposed to significant dust loads during use and may be replaced rarely, if ever. Having the cartridge 700 structurally separate from the primary cartridge 600 is an advantageous feature because it remains in place, protecting the internal components from dust even when the primary filter cartridge 600 is removed. In the illustrated example, the filter cartridge 700 includes a pleated filter media 702, although other types of filter media may also be included.

[0171] The filter cartridge 700 includes a shell 710 and a sealing device 730, which share features with the shell 610 and sealing device 630 described above. For example, the shell 710 can be molded from a relatively rigid plastic, such as ABS plastic, and the sealing device 730 can be overmolded onto the shell 710 via injection molding of a TPE material to form a radially extending lip seal 732 extending from a base portion 734. In some examples, the sealing device 730 can be separately molded from TPE or other materials and secured to the shell 710 and / or filter media 702 with or without adhesives and / or sealants. The shell 710 is shown in isolation in FIGS. 45-48, and the sealing device 730 is shown in isolation in FIGS. 49-52. The shell is shown having a sidewall 712 extending between first and second ends 714, 716 and defining an interior 718 into which the filter media 702 is inserted. The filter media 702 can be secured to the shell 710 via an adhesive.

[0172] Shell 710 differs from shell 610 in that, in one embodiment, shell 710 is provided with circumferentially extending rib structures 710a, 710b. Sealing device 730 is molded to abut rib structure 710a and over rib structure 710b. Rib structures 710a, 710b help lock / retain sealing device 730 to shell 710. In addition, sealing device 730 is molded with flange structure 733, which extends radially further than lip seal 732 and functions as the upstream-most primary seal. As can be seen in FIG. 16C , lip seal 732 and flange seal 733 each form a radial seal against the interior of housing body 504. When filter cartridge 700 is installed, shell second end 716 rests against interior wall / rib 505 of housing body 504, supporting filter cartridge 700 and preventing further insertion into housing body 504.

[0173] Similar to filter cartridge 600, filter cartridge 700, including filter media 702, surrounding shell 710, and sealing device 730, may be provided in a variety of shapes, such as circles, rectangles, ovals, and other essentially geometric shapes with rounded or non-rounded corners. Some examples of ovals include ellipses, in which curved ends are connected by a pair of opposing sides. In some ellipses, the opposing sides are also curved. In other ellipses, sometimes called racetrack shapes, the opposing sides are generally straight.

[0174] F. Air Filter Cartridge 700' Figures 65-68 65-68, an alternative arrangement for optional second, or safety, filter 700' is presented. In this example, the filter media and shell (and the alternatives discussed above) are similar to filter cartridge 700 and can be inserted into housing body 504 as shown in FIGS. 64 and 64C. Accordingly, the same reference numerals are used for these features, which need not be further described here. Note that filter cartridge 700' need not be provided with the same filter media and shell as shown for filter cartridge 700, and alternative arrangements are possible.

[0175] In this example, filter cartridge 700' is provided with sealing device 730' that is different from sealing device 730, but shares many common features with sealing device 730. For example, sealing device 730' abuts and is retained on shell 710 via engagement with circumferentially extending rib structures 710a, 710b of shell 710.

[0176] Seal device 730' differs from seal device 730 in that seal device 730' has a relatively more integral profile, is of generally uniform thickness, and does not have a radially extending sealing lip. In the illustrated example, an outer portion of seal device 730' forms a seal against the inside of housing body sidewall 504b, allowing air to flow through filter media 702 and not around cartridge 700'. To aid in installation, seal device 730' can be provided with a beveled or angled portion 732'. In an alternative example, seal device 730' can also be provided with a stepped arrangement similar to that shown for seal device 630'.

[0177] The relatively simpler contours of sealing device 730' likely lead to it being formed from a polyurethane material. Other materials are possible. The material used for sealing device 730' can be molded onto shell 710 in generally the same manner as described for sealing devices 630 and 730.

[0178] Similar to filter cartridges 600, 600', and 700, filter cartridge 700', including filter media 702, surrounding shell 710, and sealing device 730', may be provided in a variety of shapes, such as circular, rectangular, oval, and other essentially geometric shapes with rounded or non-rounded corners. Some examples of ovals include ellipses, in which curved ends are connected by a pair of opposing sides. In some elliptical shapes, the opposing sides are also curved. In other elliptical shapes, sometimes called racetrack shapes, the opposing faces are generally straight.

[0179] G. Air filter cartridge 800 Figures 53-57 53-57, an alternative filter cartridge 800 is presented. In this example, filter media 802 has an inlet flow surface 804 and an outlet flow surface 806, similar to filter media 602. As such, filter media 802 will not be further described here. Unlike cartridges 600 and 700, filter cartridge 800 includes a sealing device 830 that, like sealing device 630', can be formed from a polyurethane material instead of TPE. Additionally, rather than being provided with a separate shell extending the entire length of the filter media, filter cartridge 800 is provided with a shell 810 that extends only partially along filter media 802. A partially extending shell can also be provided in cartridges 600, 600', 700, and 700', if desired.

[0180] As shown, the shell 810 defines a sidewall 812 that surrounds the filter media 802. An inner portion of the sidewall 812 is provided with a plurality of circumferentially spaced tabs 809 that provide stops against the filter media inlet face 804. Thus, the shell 810 can be inserted over the inlet face 804 of the filter media 802 until the tabs 809 engage the inlet face 804. The shell further includes a protrusion 808 that functions as the first member 808 of the protrusion receiver device 540. Thus, the protrusion 808 is received within the receiving structure 542 of the housing body 504. The protrusion 808 includes an end wall 844 shaped similarly to the protrusion 608, but instead is supported by a radially extending sidewall 846 and extends across the top surface of the shell 810. As a result of this configuration, peripheral edges 844a, 844b, and 844c of the end wall 844 are features that directly engage the receiving structure 542. Note that end wall and side wall structures 844, 846 can be used with cartridge 600, while structures 644, 646 can be used with cartridge 800.

[0181] Unlike cartridge 600, sealing device 830 is shown molded directly onto a portion of filter media 802 and a portion of shell 810. Thus, cartridge 800 is formed by placing both shell 810 and filter media 802 into a mold and then injecting polyurethane into the mold. This process acts to bond shell 810 to filter media 802 in addition to forming a seal. In one example, shell 810 can be provided with openings to allow polyurethane to flow between shell 810 and filter media 802, further facilitating securing and sealing filter media 802 to shell 810. Shells 600 and 700 can also be provided with openings to allow seal structure material to bond the filter media to the shell. In the example shown, sealing device 830 can be provided with a step 832 to allow a pinch-type radial seal to be formed between sealing device 830 and housing body 504, similar to the arrangement shown for sealing device 630'. Similar to filter cartridges 630 and 630', sealing device 830 can be formed to have alternating first and second segments 836, 838 in the same relationship to projection 808. As such, the discussion regarding the sealing geometry of sealing device 630 applies to sealing device 830 and no further discussion is necessary here.

[0182] Similar to filter cartridges 600, 600', 700, and 700', filter cartridge 800', including filter media 802, surrounding shell 810, and sealing device 830, may be provided in a variety of shapes, such as circular, rectangular, oval, and other essentially geometric shapes with rounded or non-rounded corners. Some examples of ovals include ellipses, in which curved ends are connected by a pair of opposing sides. In some ellipses, the opposing sides are also curved. In other ellipses, sometimes referred to as racetrack shapes, the opposing faces are generally straight.

[0183] H. Air Filter Cartridge 900, Air Filter Cartridge 700', and Housing 500' Figures 73-77 73-77, an alternative filter cartridge 900 and modified housing 500' are presented. The illustrated air cleaning device assembly also includes a modified safety filter cartridge 700'. In this example, the filter media 902 and shell 910 (and the alternatives discussed above) share many overlapping or similar features with the filter cartridge 600 and housing 500. Accordingly, like reference numerals are used for like features (e.g., 902 instead of 602), and the overlapping features need not be further described here.

[0184] Referring to FIG. 73 , filter cartridge 900 includes an additional sealing device 950 that extends axially from first end 914 of shell 912 opposite second end 916. Sealing device 950 forms an axial seal against tube sheet 518f′ of inner cover portion 506′ associated with the precleaner. Therefore, sealing device 950 ensures that air exiting the precleaner is introduced into filter cartridge 900 while preventing air from bypassing the precleaner and entering filter cartridge 900. In one example, sealing device 950 is an injection-molded seal (e.g., TPE) formed directly on shell 912. In another example, sealing device 950 is formed separately and later attached to shell 912 with or without adhesive. First sealing device 930 also has modifications compared to sealing device 630, as will be described in more detail below with respect to FIG. 76a. Another difference from the filter cartridge 900 is that the shell 910 is provided with a handle portion 948, which is formed by the circumferential sidewall 928 and extends over the second member 908 of the prong receiver arrangement. FIG. 73 also shows a safety filter 700' with a modified configuration, in which the sealing arrangement 730' includes two relatively thick sealing lips 732' rather than three. The safety filter 700' is also shown with a handle portion 701' that is received in a central cavity area 903 formed by the filter media pack 902. The handle portion 701', which is integrally molded into the shell 710', allows service personnel to easily install and remove the safety filter cartridge 700' from the housing 500'.

[0185] Referring to FIG. 74, the differences between housing 500' and housing 500 are shown. The primary difference is that first member 542' of protrusion receiver device 540' does not extend all the way to open end 504a, but instead follows the generally trapezoidal shape of sidewall 546 to form a lip. This modified shape creates an open area that allows an operator's fingers to reach inside and grasp filter cartridge handle portion 948 without member 542' getting in the way, even when filter cartridge 900 is fully inserted into housing 900. As previously mentioned, housing first member 542, filter cartridge second member 908, and associated handle portion 948 can be provided in numbers other than three as shown. For example, an arrangement with two anteroposteriorly positioned members and handles can be provided, as can an arrangement with four evenly spaced members and handles. In embodiments where an even number of oppositely positioned handle members are provided, the first cartridge 900 can be removed by a pulling motion parallel to the longitudinal axis of the filter cartridge 900. In the illustrated example with three handle members, grasping and pulling any two of the handle members generates an eccentric force. The housing 500' also includes a slightly different rib structure 507'.

[0186] 75-77, filter cartridge 900 is shown in further detail. As best seen in the enlarged view shown in FIG. 76a, sealing device 950 can be seen partially disposed within passageway 958 formed in shell 910 at leg portion 950a, and sealing device 950 tapers from a base portion 950b near shell open end 914 to a tip portion 950c. Sealing device 950 is also shown to flare radially outward while extending axially, and sealing device 950 can be described as conical or frustoconical. Sealing device 950 is also shown to extend across shell open end 914, such that a radially inner surface 950d of sealing device 950 is flush with a radially inner surface 914a of shell open end 914, ensuring a smooth path for airflow.

[0187] 76a, the differences between sealing device 930 and sealing device 630 can be seen in more detail. Instead of having three radially extending sealing lips 632, sealing device 930 includes two sealing lips 932, 933 that extend from a base portion 934 at an oblique angle relative to the longitudinal axis of the filter cartridge, with the sealing lips extending radially outward and axially toward open end 914a. Sealing device 930 also includes a bumper projection 935 that extends from base portion 935 at a location between sealing lips 932, 933. Bumper projection 935 is a thickened area of ​​material that extends radially outward and acts to help retain filter cartridge 900 in a generally centered position within housing 500′ and limit radial movement of filter cartridge 900 within housing 500′. Thus, the bumper protrusion 933 ensures that the sealing lips 932, 933 are not compressed too much on one side and not compressed enough on the other side to seal tightly against the housing 500'. The bumper protrusion 935 can also be placed in other locations.

[0188] As shown, sealing lip 932 tapers from a wider base portion 932a to a narrower tip portion 933a, and sealing lip 933 tapers from a wider base portion 933a to a narrower tip portion 933b. The tapered configuration is advantageous because it allows the sealing lip to be easily demolded and allows for easier flow of plastic during injection into the mold.

[0189] It should also be noted that the sealing lip 933 is generally narrower than the lip seal 932, with the sealing lip 933 acting as a secondary type of seal to prevent dust ingress, while the sealing lip 932 acts as a primary type of seal to completely seal the filter cartridge 900, forcing all air passing through the housing 500' to pass through the filter cartridge media 902.

[0190] Similar to sealing device 950, sealing device 930 can be injection molded onto shell 910 from a thermoplastic material such as TPE. The shell surface can be provided with surface features 952 to facilitate bonding to shell 910. As seen in FIG. 77 , the surface features include spaced depressions into which the injection molding material can flow and bond. Shell 910 can be provided with stops or ridges 954 and 956 to ensure controlled flow of the injection material. The stops or ridges 954, 956 can also function as mechanical locks to further secure sealing device 930 in place on shell 910. Due to manufacturing limitations, injection molded sealing device 930 will have a mold-line seam along some portion of sealing device 930. In one advantageous configuration, the mold is configured such that seam line 932c across sealing lip 932 is circumferentially disposed around tip 932b. In such a configuration, the seam line does not interfere with the sealing performance of the sealing device 930. Because the sealing lip 933 is a secondary type of seal, any seam line remaining in the mold extends transverse to the circumferential surface of the sealing lip (i.e., parallel to the longitudinal axis of the filter cartridge 900) and does not significantly impair the function of the sealing lip 933.

[0191] In an alternative arrangement, seal devices 930 and / or 950 can be formed separately and later bonded to shell 910, for example with an adhesive, or without an adhesive by friction or mechanical fastening means. In such a case, ridges 954, 956 can be provided with a larger cross-section to more securely retain the bonded seal members 930.

[0192] I. Air Purifier Assembly 1000 Figures 78-80 78-80, an air purification device assembly 1000 is shown that is similar to the previously described arrangement in that it includes a housing 1100 within which a filter cartridge 1200 is provided, the filter cartridge 1200 having a filter media pack 1202, a sealing device 1230 surrounding the outer periphery 1204 of the filter media pack, the sealing device 1230 including a first seal segment 1232 and at least one adjacent biasing seal segment 1234 extending from the first seal segment in a direction toward one of the inlet and outlet flow ends 1206, 1208 of the filter media pack 1202. As can be seen in FIGS. 78 and 79, the housing 1100 includes a first portion 1102 and a mating second portion 1104 defining an interior space within which the filter cartridge 1200 is positioned. The first portion 1102 includes an air inlet 1108, and the second portion includes an air outlet 1110. During operation, air enters the air inlet 1108, passes through the filter cartridge 1200, and then exits through the air outlet 1110. The air is prevented from bypassing the filter cartridge by the operation of the sealing device 1230. As with the other filter media packs described and illustrated herein, the filter media pack 1202 can have a fluted or pleated type of filter media, or other types of filter media.

[0193] As best seen in FIG. 78, the first housing portion 1102 and the second housing portion 1104 have adjacent, complementary shaped, axially biasing ends 1112, 1114. The seal arrangement 1230 also follows the path defined by the ends 1112, 1114, such that the seal also biases axially at height 1230h in a manner similar to the previous example. A latch 1116 can be provided to secure the housing halves 1102, 1104 together.

[0194] Referring to FIG. 80 , the seal device 1230 can be seen in more detail. As shown, the seal device 1230 includes a circumferential support member 1232, which is either coupled to the filter media pack 1202 or is part of a shell surrounding the filter media pack of the type previously described. The circumferential support member 1232 includes an axially extending portion 1234 and an adjacent, radially extending portion 1236. From portion 1236, an axially extending seal support portion 1238 extends in a direction essentially parallel to the mounting pad 1234. The seal device 1230 can further include a sealing member 1240, which includes a plurality of seal lips 1242 and a bumper portion 1244. In the illustrated example, the seal support portion 1238 is provided as a relatively hard plastic, while the seal lip 1242 and bumper portion 1244 are injection molded onto the seal support portion 1238 from a relatively soft material (e.g., TPE). The housing portion 1104 can be formed with a passageway 1120 of width 1120w defined by an inner wall 1122 and an outer wall 1124. A sealing lip 1242 seals against the inner and outer walls 1122, 1124. A bumper portion 1244 prevents hard-to-hard contact between the housing portions 1102, 1104 and the seal support 1232 and also provides an axial compression surface between the two latched housing portions 1102, 1104.

[0195] It should be understood that width 1120w corresponds to only a small portion of the diameter of filter media pack 1102. For larger filter media packs, a sealing member 1240 small enough to insert and seal against small passages may be advantageous over an arrangement in which the sealing member surrounds the filter media pack. The illustrated arrangement may therefore have advantages such as lower cost, a more attractive product appearance, and improved performance (less masking of the inlet and outlet faces of the filter media pack). The design of sealing member 240 is also largely immune to dimensional issues associated with mating / interlocking components (present with large injection-molded seals surrounding the filter media pack) and is limited to features in the injection-molded housing with short characteristic lengths that can be controlled to within a few thousandths of an inch. With proper design, the illustrated arrangement has several redundant sealing surfaces with very small contact areas, but relatively high local contact pressures, which maintain seal integrity while minimizing installation and removal forces. The design shown in Figure 80 is largely insensitive to insertion depth, which means that it is possible to eliminate the need for over-center / music wire latches and the construction of spring-loaded snap means molded into the service cover. Additionally, the insensitivity to insertion depth allows for any number of irregularities to be created for the interface between the housing and service cover without compromising the seal integrity, such as the axially biased pattern shown in Figure 78.

[0196] J. Air Purifier Assembly 2000 Figures 81-85 81-85, an air purification device assembly 2000 is shown that is similar to the arrangements described above in that the air purification device assembly 2000 includes a housing 2100 within which a filter cartridge 2200 is provided, having a filter media pack 2202, a sealing device 2230 surrounding the periphery 2204 of the filter media pack, the sealing device 2230 including a first seal segment 2232 and at least one adjacent biasing seal segment 2234 extending from the first seal segment in a direction toward one of the inlet and outlet flow ends 2206, 2208 of the filter media pack 2202. As can be seen in FIGS. 81 and 82, the housing 2100 includes a first portion 2102 and a second portion 2104 defining an interior space within which the filter cartridge 2200 is positioned. As shown, the second section 2104 is rotatable relative to the first section 2102 and is held in a closed position by a rotatable handle 2106 or other feature to lock the cartridge within the first section 2102 of the housing. The first section 2102 includes an air inlet 2108, and the second section 2104 has an air outlet 2110. During operation, air enters the air inlet 2108, passes through the filter cartridge 2200, and then exits through the air outlet 2110. Air is prevented from bypassing the filter cartridge by operation of a sealing device 2230 that forms a radially outward seal against the inner sidewall surface 2102a of the first housing section 2102. As with the other filter media packs described and illustrated herein, the filter media pack 2202 can have a fluted or pleated type of filter media, or other types of filter media.

[0197] In one embodiment, the first housing portion 2102 includes an opening or slot 2112 in one of its side walls. The slot 2112 is for receiving the extension 2240 of the filter media pack 2202. The extension and slot arrangement improves the maintainability of the panel-type filter element, for example, when the air purification device 2000 is used as a cabin air filter on the roof of a tractor. Before fully installing the filter cartridge 2200 into the first housing portion 2102, the extension 2240 of the element is first fitted into the slot 2112 of the housing 2102. The panel 2200 is then advantageously held in place and restrained to one side of the housing 2102. This position can be seen in FIG. 84. The next step, shown in FIG. 85, is to utilize the hinge formed by the extension and slot to further push the cartridge 2200 into its final position.

[0198] Another objective of this concept is to limit the mounting features and interface surfaces that require tight manufacturing tolerances between different parts, such as the opening / closing handle-filter element-housing. The position of the element relative to the housing on the hinge side is controlled by the position of the slot and extension. On the other side, less strict precision is required only for the radial portion of the seal. The position of the removable element can be controlled by the second housing part 2104 (if provided) and the handle 2106 on the same side or other features that lock the position of the panel filter.

[0199] A rotation point aligned with the sealing device 2230 is preferred so that compression of the sealing device 2230 is controlled. The hinge formed by the extension 2240 of the element and the slot 2112 in the housing 2102 therefore lies in an imaginary plane defined by the primary contact area between the housing and the radial seal. Because this rotation point is aligned with the sealing device 2230, radial sealing around the entire circumference of the element is not possible due to the presence of the slot 2112 and extension 2240. Essentially, the extension 2240 encroaches on the gasket area, which causes leakage along the gasket. This is solved by having an axially biasing sealing device 2240 such that the first portion 2232 of the sealing device 2230 is aligned with the extension 2240 and the second portion 2242 is biased axially around the extension 2240 toward the inlet end 2108. Alternatively, the second portion 2242 could be biased toward the outlet end 2110 instead. In some examples, the sealing device 2230 and the first portion 2102 of the housing can be configured such that a radial seal is formed between the inner wall surface 2102a and the sealing device 2230 and / or such that an axial seal is formed between the housing portion 1102 and the sealing device 2230.

[0200] VII. Final Observations and Considerations The following sections provide text in claim form. The claims include features that represent various options, features, and combinations of features that can be used in accordance with the teachings of this disclosure. Features may be alternatives to those explicitly stated that are not inconsistent with the description herein above.

Claims

1. In the air filter cartridge, (a) a media pack having a media pack periphery and including a filter media having opposite inlet and outlet flow ends; (b) a sealing device surrounding the outer periphery of the filter media pack, the sealing device including a radially directed first seal segment and at least one adjacent radially directed biasing seal segment extending from the first seal segment toward one of the inlet and outlet flow ends; Including air filter cartridge.

2. the radial seal defines a plurality of alternating radially oriented first seal segments and bias seal segments; 10. The air filter cartridge of claim 1.

3. 3. The air filter cartridge of claim 1 or 2, wherein the biasing seal segment includes a transition segment disposed at an oblique angle relative to the radially directed first seal segment.

4. 4. An air filter cartridge according to any one of claims 1 to 3, wherein the sealing device is an outward sealing device.

5. An air filter cartridge according to any one of claims 1 to 4, wherein the sealing device is formed from a polyurethane material.

6. 6. An air filter cartridge according to any preceding claim, wherein the sealing device is formed from a thermoplastic elastomer material.

7. 7. The air filter cartridge of claim 1, wherein the sealing device is injection molded onto the filter media pack.

8. 8. The air filter cartridge of claim 1, wherein the sealing device is formed from a thermoplastic elastomer.

9. An air filter cartridge according to any preceding claim, wherein the sealing arrangement comprises at least one lip seal.

10. An air filter cartridge according to any preceding claim, wherein the sealing arrangement comprises three lip seals arranged in spaced apart, parallel relationship.

11. 11. The air filter cartridge of claim 9 or 10, wherein each lip seal is disposed at an oblique angle relative to the outer periphery of the filter media pack.

12. 12. The air filter cartridge of claim 1, wherein the sealing arrangement includes three radially directed first seal segments separated by three biasing seal segments, the sealing arrangement having third order rotational symmetry.

13. 13. The air filter cartridge of claim 1, wherein the filter media includes a plurality of flutes extending between the inlet flow surface and the outlet flow surface, the filter media being closed to the passage of unfiltered air therethrough between the inlet face and the outlet face.

14. 14. The air filter cartridge of any one of claims 1 to 13, wherein the sealing device and filter media pack each have a round cross-sectional shape.

15. In the air filter cartridge, (a) a filter media pack including a filter media having an outer periphery and having opposed first and second ends; (a) a sealing device disposed around the outer periphery of the filter media pack; (b) a first member of a projection receiver device extending from the outer periphery of the filter media pack, the first member being circumferentially aligned with at least a portion of the sealing device; Including air filter cartridge.

16. 16. The air filter cartridge of claim 15, wherein the first member of the protrusion receiver device is disposed between the sealing device and a first end of the filter media pack.

17. 17. The air filter cartridge of claim 15 or 16, wherein the first member of the projection receiver arrangement is a projection extending radially from the outer periphery of the filter media pack.

18. An air filter cartridge according to any one of claims 15 to 17, wherein the first member of the projection receiver arrangement comprises a plurality of first members.

19. 20. The air filter cartridge of claim 18, wherein each of the plurality of first members is a projection extending radially from the outer periphery of the filter media pack.

20. An air filter cartridge according to any one of claims 15 to 19, wherein the air filter cartridge is rotationally symmetric to at least two orders of magnitude.

21. 21. The air filter cartridge of claim 20, wherein the plurality of first members includes three radially spaced projections, and the air filter cartridge has third order rotational symmetry.

22. 22. The air filter cartridge of claim 15, wherein each projection has a first section and an adjacent second section, the second section extending at an oblique angle to the first section in a direction from the first member toward the first end of the filter media pack.

23. 21. The air filter cartridge of claim 20, wherein each projection has a third section adjacent to the first section, the third section extending at an oblique angle relative to the first section in a direction toward the first end of the filter media pack.

24. (a) a protective cover surrounding the outer periphery of the filter media pack; 24. The air filter cartridge of any one of claims 15 to 23, further comprising:

25. An air filter cartridge according to any one of claims 15 to 24, wherein the first member of the projection receiver arrangement comprises a plurality of first members.

26. 26. The air filter cartridge of claim 15, wherein each of the plurality of first members is a projection extending radially from the filter media pack.

27. 27. The air filter cartridge of claim 26, wherein each projection has a first section and an adjacent second section, the second section extending from the first section in a direction toward the first end of the filter media pack at an oblique angle to the first section.

28. 28. The air filter cartridge of claim 27, wherein each projection has a third section adjacent to the first section, the third section extending at an oblique angle relative to the first section in a direction toward the first end of the filter media pack.

29. 29. The air filter cartridge of claim 15, wherein the filter media includes a plurality of flutes extending between an inlet flow surface at the first end and an outlet flow surface at the second end, the filter media being closed to the passage of unfiltered air therethrough between the inlet and outlet surfaces.

30. 30. The air filter cartridge of any one of claims 15 to 29, wherein the sealing device and filter media pack each have a round cross-sectional shape.

31. In the air filter cartridge, (a) a filter media pack, comprising: i. a filter media pack having a periphery and including a filter media having opposite inlet and outlet flow ends; ii. A protective cover surrounding the outer periphery of the filter media pack A filter pack and (b) a sealing arrangement forming a band around the protective cover, the sealing arrangement including alternating radially oriented first and second seal segments, the first segments having a first arc length and the second segments having a second arc length, each first segment having a first shape along its first arc length that is different from a second shape of each second seal segment along its second arc length; Including air filter cartridge.

32. 32. The air filter cartridge of claim 31, wherein the radial seal defines a plurality of alternating radially oriented first and second seal segments.

33. 33. The air filter cartridge of claim 31 or 32, wherein the second seal segment includes a transition segment disposed at an oblique angle relative to the radially directed first seal segment.

34. An air filter cartridge according to any one of claims 31 to 33, wherein the sealing device is an outward sealing device.

35. An air filter cartridge according to any one of claims 31 to 34, wherein the sealing device is formed from a polyurethane material.

36. 36. An air filter cartridge according to any one of claims 31 to 35, wherein the sealing device is formed from a thermoplastic elastomer material.

37. 37. The air filter cartridge of any one of claims 31 to 36, wherein the sealing device is injection molded onto the filter media pack.

38. 38. The air filter cartridge of any one of claims 31 to 37, wherein the sealing device is formed from a thermoplastic elastomer.

39. An air filter cartridge according to any one of claims 31 to 38, wherein the sealing arrangement includes at least one lip seal.

40. An air filter cartridge according to any one of claims 31 to 39, wherein the sealing arrangement comprises three lip seals arranged in spaced apart parallel relationship.

41. 41. The air filter cartridge of claim 39 or 40, wherein each lip seal is disposed at an oblique angle relative to the outer periphery of the protective cover.

42. 42. The air filter cartridge of claim 31, wherein the sealing arrangement includes three radially oriented first seal segments separated by three second seal segments, the sealing arrangement having third-order rotational symmetry.

43. 43. The air filter cartridge of claim 31, wherein the filter media includes a plurality of flutes extending between the inlet flow surface and the outlet flow surface, the filter media being closed to the passage of unfiltered air therethrough between the inlet face and the outlet face.

44. 44. The air filter cartridge of any one of claims 31 to 43, wherein the sealing device and filter media pack each have a round cross-sectional shape.

45. In the air filter cartridge, (a) a filter media pack, comprising: i. a filter media pack having a perimeter and including a filter media having opposed first and second ends; ii. A protective cover extending around the filter media; iii. A first member of a projection receiving device is integrally formed with the protective cover. A filter pack and (b) a sealing device forming a band around the protective cover, a sealing device having a radial sealing surface, the first member being positioned between the sealing device and a first end of the filter media pack; Including air filter cartridge.

46. 46. ​​The air filter cartridge of claim 45, wherein the first member of the protrusion receiver device is disposed between the sealing device and a first end of the filter media pack.

47. 47. The air filter cartridge of claim 45 or 46, wherein the first member of the projection receiver arrangement is a projection extending radially from the outer periphery of the filter media pack.

48. An air filter cartridge according to any one of claims 45 to 47, wherein the first member of the projection receiver arrangement comprises a plurality of first members.

49. 49. The air filter cartridge of claim 48, wherein each of the plurality of first members is a projection extending radially from the outer periphery of the filter media pack.

50. 50. An air filter cartridge according to any one of claims 45 to 49, wherein the air filter cartridge is rotationally symmetric to at least two orders of magnitude.

51. 51. The air filter cartridge of any one of claims 45 to 50, wherein the plurality of first members includes three radially spaced projections, and the air filter cartridge has third order rotational symmetry.

52. 50. The air filter cartridge of claim 49, wherein each projection has a first section and an adjacent second section, the second section extending from the first section in a direction toward the first end of the filter media pack at an oblique angle to the first section.

53. 53. The air filter cartridge of claim 52, wherein each projection has a third section adjacent to the first section, the third section extending at an oblique angle relative to the first section in a direction toward the first end of the filter media pack.

54. 54. The air filter cartridge of claim 45, wherein the filter media includes a plurality of flutes extending between an inlet flow surface at the first end and an outlet flow surface at the second end, the filter media being closed to the passage of unfiltered air therethrough between the inlet and outlet surfaces.

55. 55. The air filter cartridge of any one of claims 45 to 54, wherein the sealing device and filter media pack each have a round cross-sectional shape.

56. In an air cleaning device assembly, (a) an openable cleaning device housing defining an interior with a radial cavity and having a first member of a projection receiving device; (b) an air filter cartridge removably mounted within the housing interior cavity, i. a filter media pack including a filter media having a perimeter and having opposed first and second ends; i. a sealing device disposed around the periphery of the filter media pack; ii. a first member of a projection receiver device extending from the outer periphery of the filter media pack and circumferentially aligned with at least a portion of the sealing device; an air filter cartridge including:

1. An air cleaning device assembly comprising:

57. 57. The air cleaning device assembly of claim 56, wherein the first member includes an end wall radially spaced from a main portion of the housing and a radially projecting side wall extending between the end wall and the main portion.

58. 58. An air cleaning device assembly according to claim 56 or 57, wherein the end wall includes at least one sloped portion disposed at an oblique angle relative to a plane defined by the first end of the filter media pack.

59. 59. The air purification device assembly of any one of claims 56 to 58, wherein the first member is a cavity, and the second member is a protrusion extending from a protective cover that surrounds the filter medium.

60. 59. An air cleaning device assembly according to any one of claims 56 to 58, wherein the first member includes a plurality of radially spaced cavities, and the second member includes a plurality of protrusions in the same number as the cavities.

61. 61. The air purification device assembly of any one of claims 56 to 60, wherein the filter media pack can be aligned for insertion into the housing interior cavity in a number of orientations equal to the number of protrusions on the filter media pack.

62. 62. An air cleaning device assembly according to any one of claims 56 to 61, wherein the first member includes three cavities and the second member includes three protrusions received within the cavities.

63. 63. The air cleaning device assembly of any one of claims 56 to 62, wherein the second member of the projection receiver device is disposed between the radial sealing surface and a first end of the filter media pack.

64. 60. The air purification device assembly of claim 59, wherein each projection has a first section and an adjacent second section, the second section extending from the first section toward the first end of the filter media pack at an oblique angle relative to the first section.

65. 65. The air purification device assembly of claim 64, wherein each projection has a third section adjacent to the first section, the third section extending toward the first end of the filter media pack at an oblique angle relative to the first section.

66. 66. An air cleaning device assembly according to any one of claims 56 to 65, wherein the first member has a shape complementary to the second member.

67. 67. An air cleaning device assembly according to any one of claims 56 to 66, wherein each of the first and second members includes a first section and a second adjacent section, the second section extending from the first section at an oblique angle relative to the first section.

68. 68. An air purification device assembly according to any one of claims 56 to 67, wherein each of the first and second members includes a third section adjacent to the first section, the third section extending at an oblique angle to the first section.

69. 68. The air cleaning device assembly of any one of claims 56 to 67, wherein the housing, sealing device, and filter media pack each have a round cross-sectional shape.

70. In the air filter cartridge, (a) a filter media pack having an outer periphery and including a filter media having opposite inlet and outlet flow ends; (b) a sealing device forming a continuous band around the periphery of the filter media pack, the sealing device having a radial sealing surface including at least one flat section joined by at least one deflected section that is not coplanar with the at least one flat section; Including air filter cartridge.

71. In the air filter cartridge, (a) a filter media pack having an outer periphery and including a filter media having opposite inlet and outlet flow ends; (b) a sealing device forming a continuous band around the periphery of the filter media pack, the sealing device having a radial sealing surface including at least one flat section and at least one deflecting section extending from the flat section toward the outlet flow end, the radial sealing surface having at least two orders of rotational symmetry; Including air filter cartridge.

72. 1. An air filter cartridge comprising: (a) a filter media pack having an outer periphery and including a filter media having opposite inlet and outlet flow ends; (b) a sealing device forming a continuous band around the outer periphery of the filter media pack, the sealing device having a radial sealing surface having a first portion extending partially along the first sealing surface and at least one deflected portion extending at least partially outside the first sealing surface; Including air filter cartridge.

73. In the air filter cartridge, (a) a filter media pack having an outer periphery and extending axially between opposing first and second filter media pack ends; (b) a sealing device forming a continuous band around the periphery of the filter media pack, the radial seal defining a first segment and a second segment circumferentially spaced from the first segment; Including, i. the first segment is parallel to a first plane defined by an edge of the first protective cover and is disposed a first axial distance from the edge of the first protective cover; ii. the second segment is parallel to the first plane and disposed a second axial distance from the first protective cover edge; iii. The first distance is shorter than the second distance. Air filter cartridge.

74. In an air cleaning device assembly, (a) an openable cleaning device housing defining an interior having a radial cavity; (b) an air filter cartridge removably positioned within the housing interior cavity, i. a filter media pack having a filter media pack periphery and including a filter media having opposite inlet and outlet flow ends; ii. a sealing device surrounding the outer periphery of the filter media pack, the sealing device including a radially directed first seal segment and at least one adjacent radially directed biasing seal segment extending from the first seal segment in a direction toward one of the inlet and outlet flow ends; an air filter cartridge including:

1. An air cleaning device assembly comprising:

75. In an air cleaning device assembly, (a) an openable cleaning device housing defining an interior having a radial cavity; (b) an air filter cartridge removably positioned within the housing interior cavity, i. A filter media pack comprising:

1. A filter media pack having a periphery and including a filter media having opposite inlet and outlet flow ends; 2. A protective cover is provided around the outer periphery of the filter media pack. A filter pack and ii. a sealing device forming a band around the protective cover, the sealing device including alternating radially oriented first and second seal segments, the first segments having a first arcuate length and the second segments having a second arcuate length, the first segments having a first shape along the first arcuate length that is different from a second shape of each second seal segment along the second arcuate length; an air filter cartridge including:

1. An air cleaning device assembly comprising:

76. In an air cleaning device assembly, (a) an openable cleaning device housing defining an interior having a radial cavity; (b) an air filter cartridge removably positioned within the housing interior cavity, i. A filter media pack comprising:

1. A filter media pack having a periphery and including a filter media having opposite inlet and outlet flow ends; 2. A protective cover extends around the filter medium; 3. A first member of the projection receiving device is integrally formed with the protective cover. A filter pack and ii. a sealing device forming a band around the protective cover, the sealing device having a radial sealing surface, the first member being positioned between the sealing device and a first end of the filter media pack; an air filter cartridge including:

1. An air cleaning device assembly comprising:

77. In the air filter cartridge, (a) a filter media pack, comprising: i. a filter media pack having a perimeter and including a filter media having opposed first and second ends; ii. A protective cover extending around the filter media; iii. A first member of a projection receiving device is integrally formed with the protective cover. A filter pack and (b) a first sealing device forming a band around the protective cover, the first sealing device having a radial sealing surface, the first member being positioned between the sealing device and a first end of the filter media pack; (c) a second sealing device extending axially from the first end of the protective cover opposite the second end of the filter media pack, the second sealing device having an axial sealing surface; Including air filter cartridge.

78. 78. The air filter cartridge of claim 77, wherein the first and second sealing devices are injection molded onto the protective cover.

79. 78. The air filter cartridge of claim 77, wherein the first sealing arrangement includes a first tapered sealing lip and a second tapered sealing lip.

80. 80. The air filter cartridge of claim 79, wherein a base thickness of the first tapered sealing lip is greater than a base thickness of the second tapered sealing lip.

81. 80. The air filter cartridge of claim 79, wherein the first sealing device includes a radial projection extending from the base portion and positioned between the first and second sealing lips.

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