FILTER CARTRIDGES, AIR CLEANER ASSEMBLY, HOUSING, FEATURES, COMPONENTS, AND METHODS

Abstract

The air cleaner assembly includes a housing defining an interior volume, a first filter cartridge disposed within the interior volume of the housing, and a second filter cartridge disposed within the interior volume of the housing at a location downstream of the first filter cartridge, the second filter cartridge including a seal member having a first radially oriented seal arrangement that forms a seal between the second filter cartridge and the housing, and a second radially oriented seal arrangement that forms a seal between the second filter cartridge and the first filter cartridge.

Description

[Technical field]

[0001] The present disclosure relates to a filter arrangement typically used to filter air, such as the intake air of an internal combustion engine. In certain selected examples, the present disclosure relates specifically to a filter arrangement using a serviceable cartridge having mutually opposed flow ends, although other applications are further described. Air cleaner configurations, features, and methods of assembly and use are further described. Some embodiments herein are directed to a filter cartridge seal component for an air cleaner assembly, and more particularly to a seal component secured to or supported by a shell. Some embodiments are also directed to a catch arrangement for facilitating insertion of a filter cartridge into a housing of an air cleaner assembly.

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 300,505, filed January 18, 2022, which is incorporated by reference herein in its entirety. [Background technology]

[0003] Air flows may carry contaminants such as dust and liquid particulates. In many cases, it is desirable to filter some or all of the contaminants from the air flow. For example, air flows (e.g., combustion air flows) to engines for automobiles or power plants, gas flows to gas turbine systems, and air flows to various combustion furnaces carry particulate contaminants thereto that are to be filtered. In such systems, it is preferable to remove selected contaminants from the air (or reduce the level of contaminants in the air). Various air filters have been developed for the removal of contaminants. Thus, improvements are needed. Summary of the Invention

[0004] Filter assemblies (such as air cleaner assemblies and ventilation filter assemblies for crankcases), their components, and features are described, as well as methods of assembly and use. The filter assemblies generally include a housing assembly having a primary filter cartridge and a secondary filter cartridge removably disposed therein.

[0005] In one embodiment, the air cleaner includes a primary filter cartridge and a secondary filter cartridge. The secondary filter cartridge supports a first seal arrangement for sealing the secondary filter cartridge to the outlet of the air cleaner. The secondary filter cartridge further supports second and third seal arrangements that act to seal radially between a surface at the primary filter cartridge and a surface at the air cleaner housing upstream of the secondary filter cartridge seal. In the illustrated example, these seal arrangements are in series so that failure of the primary filter cartridge seal or the secondary filter cartridge seal does not result in a leaking flow path to the engine inlet. In some examples, the primary seal surface does not substantially engage the air cleaner housing until the primary filter cartridge is in place, which prevents the primary seal from affecting the service force of the secondary filter cartridge. In some examples, the primary filter cartridge can further act to hold the secondary filter cartridge in place without requiring plastic-to-plastic interaction between the frames of the primary filter cartridge and the secondary filter cartridge.

[0006] In one embodiment, the primary seal cooperates with an upstream seal on the dirty side of the filter cartridge to maintain a clean air cleaner interior in a side-service air cleaner. In embodiments in which the primary filter cartridge is side-mounted, the primary filter cartridge has one or more locating features that engage with the air cleaner housing. This feature helps guide the installation of the primary filter cartridge and ensures that the primary filter cartridge will only engage with a properly installed secondary filter cartridge.

[0007] Attaching the primary filter cartridge seal to the secondary filter cartridge keeps the primary filter cartridge seal in one piece and increases the utility of the secondary seal. Attaching the primary seal to the secondary seal eliminates the need for a seal on the primary filter and allows the primary seal to be reused for multiple changes of the primary filter cartridge, reducing overall costs and the cost of the primary filter. Separate locating features on the primary ensure that the primary is inserted in the correct position during service. The primary-secondary interaction ensures that the secondary filter cartridge is in the proper position in the housing during service and holds the secondary filter cartridge in place even under vibration.

[0008] In one example, an air cleaner assembly includes: (a) a housing defining an interior volume; (b) a first filter cartridge disposed within the interior volume of the housing; and (c) a second filter cartridge disposed within the interior volume of the housing at a location downstream of the first filter cartridge; the second filter cartridge including a seal member including: (i) a first radially oriented seal arrangement forming a seal between the second filter cartridge and the housing; and (ii) a second radially oriented seal arrangement forming a seal between the second filter cartridge and the first filter cartridge; the first seal arrangement being axially located between the second seal arrangement and an outlet flow end of the media pack.

[0009] A filter cartridge for an air cleaner housing may include (a) a media pack defining an outer periphery extending between an inlet flow end and an outlet flow end; (b) a shell circumferentially disposed around at least a portion of the outer periphery of the media pack; and (c) a seal member circumferentially disposed around the shell; the seal member including (i) a first radially oriented seal arrangement forming a seal between the filter cartridge and the air cleaner housing; and (ii) a second radially oriented seal arrangement, separate from the first radially oriented seal arrangement, forming a seal between the filter cartridge and the other filter cartridge; the first seal arrangement is axially located between the second seal arrangement and the outlet flow end of the media pack.

[0010] In an example, the seal member further includes a third seal arrangement, the third seal arrangement including a lip seal directed radially outward, the lip seal directed radially outward forming a seal between the filter cartridge and the other filter cartridge.

[0011] In an example, the first seal arrangement is located closer to the outlet flow end relative to the second seal arrangement.

[0012] In an example, at least a portion of the second seal arrangement is located axially beyond the inlet flow end of the media pack in a direction extending from the outlet flow end towards the inlet flow end of the media pack.

[0013] In an example, one or both of the first seal arrangement and the second seal arrangement include a plurality of lip seals.

[0014] In an example, the lip seals of the first and second sealing arrangements extend at an oblique angle relative to a longitudinal axis of the filter cartridge.

[0015] In an example, the media pack includes fluted media.

[0016] In an example, the media pack includes pleated media.

[0017] A filter cartridge for an air cleaner housing having a longitudinal axis may comprise: (a) a media pack extending along the longitudinal axis between an inlet flow end and an outlet flow end; (b) a shell circumferentially disposed around at least a portion of the media pack; and (c) a first portion of a catch arrangement disposed on the shell proximate the outlet flow end of the media pack, the first portion of the catch arrangement configured to pivotally engage a second portion of the catch arrangement provided on the air cleaner housing, allowing the filter cartridge to pivot about the second portion between an inclined position and an installed position; the longitudinal axis of the filter cartridge is oriented at a first angle when in the installed position, and is oriented at a second angle that is oblique to the first angle when in the inclined position.

[0018] The air cleaner assembly may comprise: (a) a filter cartridge including: (i) a media pack extending along a longitudinal axis between an inlet flow end and an outlet flow end; (ii) a shell circumferentially disposed about at least a portion of the media pack; and (iii) a first portion of a catch arrangement disposed on the shell proximate the outlet flow end of the media pack; (b) a housing extending along a longitudinal axis between the inlet end and the outlet end, the housing defining an access opening for receiving the filter cartridge into an interior volume of the housing and including the second portion of the catch arrangement; and (c) the first portion of the catch arrangement configured to pivotally engage the second portion of the catch arrangement such that the filter cartridge is pivotable about the second portion between an inclined position in which the longitudinal axis of the media pack is at an oblique angle to the longitudinal axis of the air cleaner and an installed position in the housing in which the longitudinal axis of the media pack is parallel to the longitudinal axis of the air cleaner.

[0019] In an example, the first portion is integrally formed with the shell.

[0020] The example further includes (a) a handle disposed on the shell and positioned adjacent the inlet flow end of the media pack such that the center of gravity of the filter cartridge is axially located between the handle and the first portion of the catch arrangement.

[0021] In an example, the handle is integrally formed with the shell.

[0022] The example further includes (a) a seal arrangement circumferentially disposed about the shell.

[0023] In an example, the seal arrangement is located proximate the inlet flow end of the media pack.

[0024] In the example, the seal arrangement is an outwardly facing radial seal member.

[0025] In the example, in the tilted position, the filter cartridge is unsealed relative to the air cleaner housing, and in the installed position, the filter cartridge is fully sealed relative to the air cleaner housing.

[0026] In an example, the first portion is axially located at least partially beyond the outlet flow end of the media pack.

[0027] In an example, the first portion is axially disposed completely beyond the outlet flow end of the media pack.

[0028] In an example, the filter cartridge has an oblong cross-sectional shape.

[0029] In an example, the media pack is formed from fluted media.

[0030] In an example, the first portion of the catch arrangement includes a concave surface that engages with the second portion of the catch arrangement.

[0031] In an example, the first portion of the catch arrangement includes a convex surface that engages with the second portion of the catch arrangement.

[0032] An air cleaner assembly may include (a) a housing defining an interior volume; (b) a first filter cartridge disposed within the interior volume of the housing; and (c) a second filter cartridge disposed within the interior volume of the housing at a location downstream of the first filter cartridge; the second filter cartridge including a seal member having an outwardly radially oriented seal surface that forms a seal with a first interior surface of the housing and an inwardly radially oriented seal surface that forms a seal with a second interior surface of the housing.

[0033] In an example, the seal member further includes a second sealing surface that forms a seal between the filter cartridge and the other filter cartridge and is oriented radially outward.

[0034] In an example, the outwardly radially directed sealing surface is located axially between the inlet flow end of the media pack and the outlet flow end of the media pack.

[0035] In an example, at least a portion of the sealing surface that is radially directed inwardly in a direction extending from the outlet flow end toward the inlet flow end of the media pack is located axially beyond the inlet flow end of the media pack.

[0036] In an example, one or all of the inwardly radially directed sealing surface, the outwardly directed sealing surface, and the outwardly directed second sealing surface include one or more lip seals.

[0037] It is not specifically required that an air cleaner assembly, components therefor, or features thereof include all of the details characterized in the description to obtain any benefit from the present disclosure. [Brief description of the drawings]

[0038] [Figure 1] 1 is a schematic perspective view of an air cleaner assembly having features according to the present disclosure; FIG. [Diagram 2] FIG. 2 is a schematic perspective view of the air cleaner assembly shown in FIG. 1 with the cover removed. [Diagram 3] FIG. 2 is a schematic longitudinal sectional side view of the air cleaner assembly shown in FIG. 1. [Figure 4] FIG. 2 is a schematic exploded perspective view of the air cleaner assembly shown in FIG. 1, showing the first filter cartridge and the second filter cartridge removed from the housing. [Diagram 5] FIG. 5 is a schematic first perspective view of a first filter cartridge of the air purifier assembly shown in FIG. 4; [Figure 6] FIG. 6 is a schematic side view of the first filter cartridge shown in FIG. 5. [Figure 7] FIG. 6 is a schematic first side view of the first filter cartridge shown in FIG. 5. [Figure 8]FIG. 5 is a schematic first perspective view of a second filter cartridge of the air purifier assembly shown in FIG. 4. [Figure 9] FIG. 9 is a second schematic perspective view of the second filter cartridge shown in FIG. 8. [Figure 10] FIG. 9 is a schematic first side view of the second filter cartridge shown in FIG. 8. [Figure 11] FIG. 7 is a schematic second side view of the second filter cartridge shown in FIG. 6. [Figure 12] FIG. 9 is a schematic first side view of the second filter cartridge shown in FIG. 8. [Figure 13] FIG. 9 is a schematic second side view of the second filter cartridge shown in FIG. 8. [Figure 14] FIG. 9 is a schematic third side view of the second filter cartridge shown in FIG. 8. [Figure 15] FIG. 9 is a schematic fourth side view of the second filter cartridge shown in FIG. 8. [Figure 16] FIG. 9 is a schematic exploded perspective view of the second filter cartridge shown in FIG. 8. [Figure 17] 9 is a partial cross-sectional side view of a sealing member of the second filter cartridge shown in FIG. 8. [Figure 18] FIG. 2 is a schematic partial cross-sectional view of the air cleaner assembly shown in FIG. 1 with the first filter cartridge removed. [Figure 19] FIG. 2 is a schematic partial cross-sectional view of the air cleaner assembly shown in FIG. 1 with a first filter cartridge mounted and sealed against a second filter cartridge. [Figure 20] FIG. 2 is a schematic partial cross-sectional view of the air cleaner assembly shown in FIG. 1, illustrating positioning features of the first filter cartridge engaged with receiving features of the housing. [Figure 21] 2 is another schematic partial cross-sectional view of the air cleaner assembly shown in FIG. 1, illustrating the positioning features of the first filter cartridge engaged with the receiving features of the housing. [Figure 22]FIG. 2 is a schematic top partial cross-sectional view of the air cleaner assembly shown in FIG. 1, illustrating the sealing arrangement of the second filter cartridge. [Figure 23] FIG. 2 is a schematic side partial cross-sectional view of the air cleaner assembly shown in FIG. 1, illustrating the sealing arrangement of the second filter cartridge. [Figure 24] FIG. 2 is a schematic perspective view of a second example of an air cleaner assembly having features according to the present disclosure. [Diagram 25] FIG. 21 is a schematic perspective view of the air cleaner assembly shown in FIG. 20 with the cover removed. [Figure 26] FIG. 25 is a schematic exploded perspective view of the air cleaner assembly shown in FIG. 24. [Figure 27] FIG. 25 is a schematic top view of the air cleaner assembly shown in FIG. 24 with the cover removed and the first filter cartridge in an initial tilted position within the main housing. [Figure 28] FIG. 25 is a schematic perspective view of the air cleaner assembly shown in FIG. 24 with the cover removed and the first filter cartridge in an initial tilted position within the main housing. [Figure 29] FIG. 25 is a schematic cross-sectional side view of the air cleaner assembly shown in FIG. 24. [Diagram 30] FIG. 25 is a schematic cross-sectional side view of the air cleaner assembly shown in FIG. 24 with the first filter cartridge in an initial tilted position within the main housing. [Diagram 31] FIG. 25 is a schematic partial cross-sectional top view of the air cleaner assembly shown in FIG. 24 with the first filter cartridge removed. [Diagram 32] FIG. 25 is a schematic partial cross-sectional top view of the air cleaner assembly shown in FIG. 24 with the first filter cartridge installed. [Diagram 33] 32. FIG. 32 is a schematic partial cross-sectional top view of the air cleaner assembly shown in FIG. 24, showing an enlarged portion of the view shown in FIG. [Diagram 34] FIG. 25 is a schematic partial perspective view of the air cleaner assembly shown in FIG. 24. [Diagram 35]FIG. 34(24) is a schematic partial cross-sectional side view of the air cleaner assembly shown in FIG. 34(24) with the first filter cartridge disposed in an initial tilted position. [Diagram 36] FIG. 25 is a schematic partial cross-sectional side view of the air cleaner assembly shown in FIG. 24 with the first filter cartridge in an installed position. [Figure 37] 25 is a partial cross-sectional side view of a sealing member of the second filter cartridge of the air cleaner assembly shown in FIG. 24. [Figure 38] FIG. 25 is a schematic first perspective view of a first filter cartridge of the air cleaner assembly shown in FIG. 24. [Figure 39] FIG. 39 is a schematic side view of the first filter cartridge shown in FIG. 38. [Diagram 40] FIG. 39 is a schematic side view of the first filter cartridge shown in FIG. 38, the cartridge shown in an initial tilted position. [Diagram 41] FIG. 39 is a schematic top view of the first filter cartridge shown in FIG. 38. [Diagram 42] FIG. 39 is a schematic bottom view of the first filter cartridge shown in FIG. 38. [Diagram 43] FIG. 39 is a schematic inlet or first end view of the first filter cartridge shown in FIG. 38. [Diagram 44] FIG. 39 is a schematic outlet or second end view of the first filter cartridge shown in FIG. 38. [Diagram 45] FIG. 25 is a schematic first perspective view of the second filter cartridge of the air purifier assembly shown in FIG. 24. [Figure 46] FIG. 45 is a second schematic perspective view of the second filter cartridge shown in FIG. 44. [Figure 47] FIG. 45 is a schematic first side view of the second filter cartridge shown in FIG. 44. [Figure 48] FIG. 45 is a schematic second side view of the second filter cartridge shown in FIG. 44. [Figure 49] FIG. 45 is a schematic first side view of the second filter cartridge shown in FIG. 44. [Figure 50]FIG. 45 is a schematic second side view of the second filter cartridge shown in FIG. 44. [Figure 51] FIG. 45 is a schematic third side view of the second filter cartridge shown in FIG. 44. [Figure 52] FIG. 45 is a schematic fourth side view of the second filter cartridge shown in FIG. 44. [Figure 53] FIG. 46 is a schematic exploded perspective view of the second filter cartridge shown in FIG. 45. [Figure 54] FIG. 46 is a schematic exploded perspective view of the second filter cartridge shown in FIG. 45. [Figure 55] FIG. 55 is a schematic partial perspective view of an alternative air cleaner and catch arrangement having features usable with the air cleaner housing and filter cartridge of FIGS. 1-23 and 24-54. [Figure 56] FIG. 56 is a schematic partial perspective view of a second portion of the catch arrangement associated with the housing shown in FIG. 55; [Figure 57] FIG. 56 is a schematic partial cross-sectional side view of the air cleaner catch arrangement shown in FIG. 55 with the filter cartridge in an inclined position. [Figure 58] FIG. 56 is a schematic partial cross-sectional side view of the air cleaner catch arrangement shown in FIG. 55 with the filter cartridge in the installed position. [Figure 59] FIG. 56 is a schematic perspective view of a first filter cartridge of the air purifier shown in FIG. 55. [Figure 60] FIG. 60 is a schematic side view of the filter cartridge shown in FIG. 59. [Figure 61] FIG. 60 is a schematic cross-sectional side view of the filter cartridge shown in FIG. 59. [Figure 62] FIG. 60 is a schematic partial top rear perspective view of the filter cartridge shown in FIG. 59. [Figure 63] FIG. 60 is a schematic partial top front perspective view of the filter cartridge shown in FIG. 59. [Figure 64] FIG. 60 is a schematic partial top view of the filter cartridge shown in FIG. 59. [Figure 65]FIG. 1 is a fragmentary, schematic, perspective view of a first example of a media type usable in configurations according to the present disclosure. [Figure 66] FIG. 66 is an enlarged schematic cross-sectional view of a portion of the media type depicted in FIG. [Figure 67] 65 and 66 include schematic diagrams of examples of various fluted media definitions for the types of media. [Figure 68] FIG. 68 is a schematic diagram of an exemplary process for manufacturing media of the type of FIGS. 65 to 67. [Figure 69] FIG. 70 is a schematic cross-sectional view of an optional end dart for a media flute of the type of FIGS. 65 to 68. [Figure 70] FIG. 66 is a schematic perspective view of a coiled filter configuration usable in a filter cartridge having features according to the present disclosure, for example, a coiled filter configuration made from a strip of media according to FIG. [Figure 71] FIG. 66 is a schematic perspective view of a laminated media pack configuration usable in a filter configuration having selected features according to the present disclosure, for example made from strips of media according to FIG. 65. [Figure 72] FIG. 66 is a schematic flow end view of a filter media pack that uses an alternative media to that of FIG. 65 and that may alternatively be used in selected filter cartridges in accordance with the present disclosure. [Figure 73] FIG. 73 is a schematic counter-flow end view to the view of FIG. 72. [Figure 74] FIG. 74 is a schematic cross-sectional view of the media pack of FIGS. 72 and 73. [Figure 75] 11A-11C are schematic fragmentary cross-sectional views of additional alternative media types usable in media packs of filter cartridges having features in accordance with the present disclosure. [Figure 76] FIG. 76 is a schematic fragmentary cross-sectional view of an example of a first variation of the media type of FIG. [Figure 77] FIG. 13 is a schematic fragmentary view of another usable fluted sheet / facing sheet combination according to the present disclosure. [Figure 78]FIG. 78 is a fragmentary second schematic diagram of media of the type of FIG. 77 shown in a media pack. [Figure 79] 13A-13C are schematic fragmentary plan views of examples of yet other media transformations usable in configurations according to the present disclosure. [Figure 80] 1 is a schematic diagram showing another example of a change in usable media according to the present disclosure. [Figure 81] FIG. 13 is a schematic diagram of another usable fluted sheet / facing sheet combination according to the present disclosure. [Figure 82] FIG. 82 is a perspective view of a portion of a usable fluted sheet / facing sheet combination depicted in FIG. 81. [Figure 83] 13A-13C are perspective views of examples of alternative media variations that may be used in configurations according to the present disclosure. [Figure 84] FIG. 84 is a schematic perspective view of a portion of the support section of the filter media of FIG. 83, shown in a folded configuration but expanded or separated for illustrative purposes. [Figure 85] FIG. 84 is a schematic cross-sectional view of a portion of the support section of the filter media of FIG. 83, shown in a folded configuration, but expanded or separated for illustrative purposes. [Figure 86] 13A-13C are perspective views of examples of alternative media variations that may be used in configurations according to the present disclosure. [Figure 87] FIG. 1 is a schematic diagram of an equipment assembly including an air cleaner according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] An exemplary filter assembly, its features, and components are described and illustrated herein. Various specific features and components are characterized in detail. Many may be applied to provide advantages. There is no specific requirement that various individual features and components be applied to an overall assembly having all of the described features and characteristics in order to provide some advantage according to the present disclosure.

[0040] I. General Issues in Air Purifier Design and Service [A. Equipment systems using air cleaner assemblies, generally, FIG. 87] FIG. 87 shows a schematic diagram of an engine equipment configuration 1360. The equipment system 1360 includes, in an example, a vehicle or other equipment 1361 having an internal combustion engine configuration 1362 with a combustion air intake 1363. The equipment configuration 1360 includes an air cleaner system 1365 having a filter arrangement 1366 therein, typically including a serviceable (i.e., removable and replaceable) filter cartridge. The air cleaner system 1365 and filter arrangement 1366 may include any of the air cleaners and filter cartridges described below, as well as combinations thereof. Intake air to the system is shown at 1367 and directed to the air cleaner assembly 1365 before filtering unfiltered air through the media of the filter cartridge arrangement 1366. At 1368, filtered air is shown directed to the equipment air intake 1363. At 1370, optional equipment such as a turbo system is shown.

[0041] Of course, alternative equipment systems may be presented in a configuration similar to Fig. 87. The equipment systems may be, for example, industrial air filters, air cleaner configurations, etc., used in conjunction with turbines, etc. While use in conjunction with internal combustion engines is typical, it is not specifically required for many of the principles characterized herein.

[0042] [B. Verify that the cartridges available for use with the air purifier are appropriate for the air purifier of interest] Generally, air cleaners, such as those used to filter the intake air of an appliance, include a housing having at least a primary filter cartridge and, in some cases, a secondary filter cartridge disposed therein. The primary filter cartridge is generally configured to capture particulate contaminants entering the intake air stream of the appliance, thereby protecting the appliance from damage. Such filter cartridges are generally configured to be removable and replaceable, i.e., are serviceable parts. The cartridges are removed from the air cleaner and refurbished or replaced at various prescribed service intervals and / or when increasing limitations (due to dust load) become an issue.

[0043] In many cases, cartridges are specifically designed to the operational requirements of the equipment manufacturer, and it is important to ensure that cartridges replaced in the field are suitable for the associated equipment, i.e., properly fitted and sealed.

[0044] Generally, the primary interface between the filter cartridge and the air cleaner is along the housing seal. In some cases, this interface is used to ensure that a matching cartridge is also suitable for the target system. An example is given from the description in U.S. Pat. No. 8,864,866, the disclosure of which is incorporated herein by reference. In this particular document, the modification of the sealing surface by projections and / or recesses is described in general terms. These general principles apply herein with modifications and variations for specific applications.

[0045] [C. Observations regarding cartridge installation challenges in systems where the subject housing radial seal is deeply recessed into the housing and / or where side loading is involved] In many cases, the sealing surface engaged by the seal in the cartridge is deeply recessed into the housing and out of the view of the service provider. In addition, the size of the housing and the shielding effect of the cartridge may make it difficult, if not impossible, to manually reach the sealing surface during installation of the cartridge. The problem with using cartridges with seals that are not simply simple uniform geometric shapes, such as round or elliptical, is that, depending on the design, it may be difficult to properly orient the cartridge so that the seal will properly occur during installation. As will be appreciated from the more detailed description above, some of the techniques characterized herein are useful in facilitating this in applications.

[0046] This problem may be exacerbated when the cartridge is configured for side loading. By side loading, it is intended to refer to the portion of the housing into which the cartridge is attached during use. In particular, in some instances, a straight flow cartridge is loaded from the side of the housing and pushed sideways into a sealing position. It is difficult to properly manipulate and leverage the cartridge to obtain a good seal. Examples of advantageous side loading configurations with useful features that facilitate loading are described, for example, in U.S. Pat. Nos. 7,396,375, 7,655,074, 7,905,936, 7,713,321, and 7,972,404, which are incorporated herein by reference.

[0047] The literature arrangements identified in the previous paragraph generally use elliptical seals, typically racetrack ellipses (shapes with straight lines bounded by semicircularly curved ends in the seal face). Depending on how it is implemented, if it is desired to have a variation in the seal face, it can sometimes be difficult to obtain good and convenient mounting in side-loading applications. Some of the principles described herein are particularly useful in such situations and feature ease of loading.

[0048] [II. Examples of air purifiers and filter cartridges] [A. Air Purifier 100] 1-4, an air cleaner assembly 100 is shown. In one embodiment, the air cleaner assembly 100 includes a housing assembly 102, a first filter cartridge 200, and a second filter cartridge 300, and extends along a longitudinal axis X. The first filter cartridge 200 may be referred to by a variety of commonly interchangeable terms, such as a primary filter cartridge or a main filter cartridge. The second filter cartridge 300 may be referred to by a variety of commonly interchangeable terms, such as a secondary filter cartridge or a safety filter cartridge. As used herein, the terms "axial" and "axially" generally refer to a direction parallel to the longitudinal axis X, and the term "radial" generally refers to a direction perpendicular to the longitudinal axis X. Also, as used herein, the term "radially inward" generally refers to a direction toward the longitudinal axis X, and the term "radially outward" generally refers to a direction away from the longitudinal axis X. As used herein, the term "radially located" generally refers to a component or feature being radially farther or closer to the longitudinal axis X than another component or feature, and does not necessarily refer to the component or feature being on a common radial line with the other component or feature. As used herein, the term "axially located" generally refers to a component or feature being located in a given axial direction relative to another component or feature, and does not necessarily refer to the component or feature being on a common axis with the other component or feature. Similarly, the term "axially located between" generally refers to a component or feature being axially located between two other components, and does not necessarily refer to the component or feature being on a common line or axis between the two other components.

[0049] As shown, the housing assembly 102 may be configured with a main housing 104 and a cover 105. The cover 105 allows access to the interior volume 104a of the main housing 104 through an opening 104b. The cover may be of any known type and may be secured to the main housing 104 using any number of methods or approaches known in the art, such as, for example, over-center latches, interacting lugs, etc. In the illustrated example, the cover 105 is pivotally attached to the main housing 104. In one embodiment, a seal member 107 may be provided surrounding the opening 104b to form a seal between the main housing 104 and the cover 105. In one embodiment, the main housing 104 and the interior volume 104a extend between an inlet end 104c and an outlet end 104d. As will be described in more detail below, the housing further defines a pair of receiving features 104e for engaging corresponding features on the filter cartridge 200. Additionally, the main housing 104 is shown as having an axially extending sidewall 104f that is located within the interior volume 104a and defines an outwardly radially oriented sealing surface 104g. As will be described below, a sealing arrangement on the filter cartridge 300 seals against the sealing surface 104g. The axially extending sidewall 104f further defines an inwardly radially oriented sealing surface 104h against which a sealing arrangement on another location on the filter cartridge 300 seals. Although the sealing surfaces 104g, 104h are formed on opposite sides of the common sidewall 104f, alternatively, the main housing 104 may be arranged such that the sealing surfaces are formed on different sidewalls of the housing.

[0050] In one embodiment, the air cleaner assembly 100 includes a precleaner assembly 106 attached to the main housing 104 at the inlet end 104c. In the illustrated example, the precleaner assembly 106 is presented as a two-stage air cleaner assembly and includes a plurality of separator tube configurations 106a. The precleaner assembly 106 can be used to preclean selected materials (contaminants) carried by the airflow to the air cleaner assembly 100 before the air reaches a first filter cartridge 200 disposed therein. Such precleaning generally results in substantial removal of liquid particulates, such as rainwater or splash water, and / or various (particularly large) dust or other particles. In the illustrated example, the contaminants removed by the precleaner assembly 106 may be exhausted via an exhaust port 106b.

[0051] [B. Filter Cartridge 200] 5-7, an exemplary embodiment of a first filter cartridge 200 of the air cleaner assembly 100 is illustrated. The filter cartridge 200 extends between a first end 202 and a second end 204. In one aspect, the first end 202 may be characterized as the upstream end of the filter cartridge 200, while the second end 204 may be characterized as the downstream end of the filter cartridge 200. The filter cartridge 200 may be considered a main or primary filter cartridge (or element) and is used to selectively separate a desired amount of particulate matter or contaminants.

[0052] The filter cartridge 200 is generally a serviceable part, or removable component, such that it can be periodically removed and replaced as desired or necessary during the life of the air cleaner assembly 100. In particular, if the filter cartridge 200 becomes clogged or otherwise needs to be replaced, the filter cartridge 200 can be removed from the housing 104, for example, by means of a handle 228, after removing or shifting a cover. After such removal, another filter cartridge 200 may be placed into the housing 104 by inserting the filter cartridge 200 into the interior volume 104a via the opening 104b.

[0053] The filter cartridge 200 generally comprises a media pack 210. In the illustrated example, the media pack 210 has an inlet flow end 212 that receives unfiltered air or pre-cleaned air from a precleaner (if provided) and an outlet flow end 214 that supplies filtered air. In the illustrated example, the media pack 210 has an obround cross-sectional shape. However, other shapes are possible, such as circular, oval, rectangular cross-sectional shapes. In one aspect, the media pack 210 defines a periphery that extends between the inlet and outlet flow ends 212, 214. In the illustrated example, the media pack 210 is formed from a coiled media structure, such as a media structure having a fluted (typically corrugated) media sheet and a facing media sheet. The media sheets together define parallel flutes to form a fluted or z-filter media structure. Media structures suitable for the media pack 210 are described in more detail in the "Media Types and Configurations" section.

[0054] In one embodiment, a shell 220 is provided that surrounds the outer periphery of the media pack 210. In one embodiment, the shell 220 may be characterized as being circumferentially disposed around the outer periphery of the media pack 210. In one embodiment, the shell 220 may be characterized as providing radial circumferential support for at least a portion of the media pack 210. In some examples, an adhesive is used to secure the media pack 210 within the shell 220. In some examples, the media pack 210 has an interference fit with the shell 220. In the illustrated example, the shell 220 has a unitary structure. However, the shell 220 may be provided in multiple pieces, such as, for example, two mating shell halves. In the illustrated example, the shell 220 includes a support structure 222 located on a downstream surface of the media pack 210. The support structure 222 may include a number of ribs or bridge segments that support an end surface of the media pack 210. With such structure, the shell 220 may be further characterized as providing axial support for the media pack 210. The shell 220 is further shown as defining an axial flange 224 at the second end 204 that extends beyond the support structure 222 and the media pack 210. The axial flange 224 defines an inwardly radially directed seal surface 224a. As will be described below, a seal associated with the filter cartridge 300 will seal against the seal surface 224a when both filter cartridges 200, 300 are fully installed within the housing. As can be seen most easily in FIGS. 5 and 6, the shell 220 also has a radially extending flange 230 proximate the inlet flow end 212 that presents an axial surface 230a that supports a seal arrangement 232. For clarity, the seal arrangement 232 is not shown in FIGS. 5 and 6, but is shown in FIGS. 1-4. In some instances, the seal arrangement 232 is overmolded (formed by two-shot molding) onto the flange 230. In other instances, the seal arrangement 232 is formed separately and later secured to the surface 230a by adhesive or other means. In one aspect, the seal arrangement 232 defines a radial seal surface 232 a about the outer periphery of the seal arrangement 232 .The radial seal surface 232a serves to form a seal against the main housing 104 and cover 105 and positively direct the treated air from the precleaner assembly 106 to the inlet flow end 212 of the media pack 210. In that the interaction between the main housing 104 and the seal arrangement 232 acts to fix the lateral and axial rotational positions of the cartridge 200, this arrangement also helps guide the filter cartridge 200 from an initial tilted position to a fully installed installed position during the installation process. Referring to FIG. 40, the filter cartridge 200' is shown in a tilted position, with the longitudinal axis of the filter cartridge 200' in the tilted position designated as X-TILT and the longitudinal axis of the filter cartridge 200' in the installed position designated as X-INSTALL. These directions and the following description are applicable to both filter cartridges 200 and 200'. In the tilted position, the longitudinal axis of the filter cartridge, X-TILT, is at an oblique angle compared to the longitudinal axis of the filter cartridge, X-INSTALL, when in the installed position. In the installed position, the longitudinal axis of the filter cartridge is parallel to the air purifier longitudinal axis, X. In the tilted position, the longitudinal axis of the filter cartridge is at an oblique angle relative to the air purifier longitudinal axis, X.

[0055] The shell 220 is also shown as defining a pair of positioning features 226 that engage with corresponding receiving features 104e on the housing 104. Although two positioning features 226 are shown, more or fewer appropriately located positioning features may be utilized. In one characterization, the positioning features 226 and the receiving features 104e may be referred to as a catch feature, in which the positioning feature(s) 226 form a first portion of the catch feature and the receiving feature(s) 104e form a second portion of the catch feature. In one embodiment, the first portion of the catch feature extends beyond the outlet flow end of the media pack 220 and also extends radially beyond the outer periphery of the media pack 220. As most easily seen in FIGS. 20 and 21, the positioning features 226 and the receiving features 104e are provided as complementary detent-type hook-like members 226a, 104i, so as to readily engage with one another. In one embodiment, the hook-like member 226a presents a convex curved surface (protruding surface) that engages the receiving feature 104e. In some examples, the receiving feature 104e may include a correspondingly shaped concave surface. In one embodiment, the receiving feature 104e further includes a sloped or inclined surface 104j, 104k that guides the positioning feature 226 in an installation manner, thereby guiding the filter cartridge 200 laterally into a centered position relative to the filter cartridge 300 and the housing assembly 102. The housing surfaces 104i, 104j, 104k and the sidewall surface 104p together define a trough area 104m in which each positioning feature 226 is received and retained. Together, these features help guide the installation of the filter cartridge 200 and ensure that the filter cartridge only sealingly engages with a properly installed filter cartridge 300. The interaction between positioning feature 226 and receiving feature 104e, once engaged, fixes the axial position of filter cartridge 200, thereby providing resistance to relative movement between filter cartridges 200, 300, thereby ensuring that the seal formed therebetween is maintained.

[0056] 3, it can be seen that an axial region or gap 50 with an axial dimension 50a exists between the end of the filter cartridge 200 and the precleaner 106. This gap 50 provides clearance for the filter cartridge 200 to be inserted into the interior volume 104a of the housing at a first angle where the second end 204 hangs lower than the first end 202. In one example, the first angle is about 3 degrees relative to a plane perpendicular to the longitudinal axis X. In some examples, the first angle is between 2 and 10 degrees. In particular, the handle 228 is axially disposed between the ends 202, 204 such that the cartridge naturally hangs at the first angle. Thus, when the operator lowers the filter cartridge 200 into the interior volume 104a, the positioning feature 226 contacts the receiving feature 104e and the filter cartridge 200 is laterally aligned with respect to the housing 104 and the filter cartridge 300. As the operator continues to lower filter cartridge 200, it will rotate about the contact point between locating feature 206 and receiving feature 104e such that the longitudinal axis of filter cartridge 200 is aligned with the longitudinal axis of the housing until filter cartridge 200 is fully installed, causing flange 224 to enter sealing engagement with filter cartridge 300, as described in further detail below. Removal of filter cartridge 200 from housing 104 is a reverse operation in which the operator pulls on handle 228, naturally rotating the filter cartridge back to the first angle and out of engagement with filter cartridge 300.

[0057] The shell 220 may be secured to the media pack 210 by an adhesive. The shell 220 is also shown as integrally forming the handle 228 described above. In one embodiment, the shell 220 of the filter cartridge 200 is formed from a polymeric material such as nylon, polypropylene, ABS plastic, or the like.

[0058] [C. Filter Cartridge 300] 8-17, an exemplary embodiment of a second filter cartridge 300 of the air cleaner assembly 100 is illustrated. The filter cartridge 300 extends between a first end 302 and a second end 304. In one aspect, the first end 302 may be characterized as the upstream end of the filter cartridge 300, while the second end 304 may be characterized as the downstream end of the filter cartridge 300. The filter cartridge 300 may be considered a secondary or safety filter cartridge (or element) and is used to selectively separate a desired amount of particulate matter or contaminants.

[0059] The filter cartridge 300 is generally a serviceable part or removable component such that it can be periodically removed and replaced as desired or necessary during the life of the air cleaner assembly 100. In particular, when the cartridge 300 is closed or otherwise needs to be replaced, after removing the filter cartridge 200 by removing or shifting the cover, the cartridge 300 can be removed from the housing 104, for example, by the handle portion 306. After such removal, another filter cartridge 300 may be placed in the housing 104 by inserting the filter cartridge 300 into the interior volume 104a via the opening 104b.

[0060] The filter cartridge 300 generally includes a media pack 310. In the illustrated example, the media pack 310 has an inlet flow end 312 that receives filtered air from the filter cartridge 200 and an outlet flow end 314 that supplies filtered air. In the illustrated example, the media pack 310 has an oblong cross-sectional shape. However, other shapes are possible, such as circular, elliptical, and polygonal (e.g., rectangular) cross-sectional shapes. In one aspect, the media pack 310 defines a perimeter that extends between the inlet and outlet flow ends 312, 314. In the illustrated example, the media pack 310 is formed from a pleated media structure. Suitable media structures for the media pack 310 are described in more detail in the "Media Types and Configurations" section.

[0061] In one embodiment, a shell 320 is provided that surrounds the outer periphery of the media pack 310. In one embodiment, the shell 320 may be characterized as being circumferentially disposed around the outer periphery of the media pack 310. In one embodiment, the shell 320 may be characterized as providing radial circumferential support for at least a portion of the media pack 310. In some examples, an adhesive is used to secure the media pack 310 within the shell 320. In some examples, the media pack 310 has an interference fit with the shell 320. In the illustrated example, the shell 320 is a one-piece structure. However, the shell 320 may be provided in multiple pieces, such as, for example, two mating shell halves. In the illustrated example, the shell 320 includes a support structure 322. The support structure 322 may include a number of ribs or bridge segments that support the media pack 310. With such structure, the shell 320 may further be characterized as providing axial support for the media pack 310.

[0062] In one aspect, the filter cartridge 300 includes a seal member 330 that is circumferentially disposed about and surrounds the media pack 310 and the shell 320. Here, the principles described are specifically embodied in a configuration in which the housing seal disposed in the filter cartridge is a "radial" seal, or a "radially directed" seal. By this, it is intended to refer to a seal that is used to apply a compressive sealing force, typically toward a peripheral portion of the housing, or alternatively toward a portion of the housing surrounded by the seal, for sealing in use. In the filter cartridges of the type characterized herein, a radial seal is generally a seal that surrounds a flow passage, and the primary compressive direction (when installed) is toward or away from that flow passage. An outwardly directed seal, or an outwardly radially directed seal, is one in which the (cartridge) seal arrangement has a sealing surface that sealingly engages the surrounding structure in use. An inwardly radially directed seal is a seal arrangement in which the sealing surface of the cartridge surrounds the structure to be sealed during use.

[0063] As most easily seen in the cross-sectional views of seal member 330 provided in FIGS. 17, 22, and 23, seal member 330 may include a base member 332 including a plurality of segments or portions, such as segments or portions 332a-332g. In the particular example shown, segments 332a, 332e, and 332g extend axially, while segment 332c extends radially, with segment 332b providing a transition between segments 332a and 332c. Segment 332d provides a transition between segments 332c and 332e. Segment 332f provides a transition between segments 332e and 332g. In the illustrated configuration, segments 332g and 332a are generally parallel to one another and form a trough region 332i that extends to section 332f, within which seal arrangement 336 is located. In one embodiment, the seal member 330 is secured to the shell 320 at the inwardly radially directed side 332h of the segment 332a. It is noted that segments 332b-332g are provided only at the end of the filter cartridge 300 that includes the handle portion 306, allowing the seal member configurations 336 and 338 to surround or follow the outer circumference of the handle portion 306. A view of this portion of the seal member 330 is provided in FIG. 23. The remaining sections of the seal member 330 are similar to the configuration shown at the bottom of FIG. 17, where section 332a extends to section 332f. Additionally, a top cross-sectional view of this portion of the seal member 330 is shown in FIG. 22. It is noted that the seal configuration is shown in the drawings, e.g., FIGS. 22 and 23, in an undeflected state while installed in the housing such that there is an overlap between the seal member and the housing. However, one skilled in the art will readily and easily appreciate that the seal member of the sealing arrangement will be biased by the surfaces of the housing once installed therein. In the illustrated example, the seal member 330 extends and completely covers the shell 320 between the inlet flow end 312 and the outlet flow end 314 of the cartridge 300. However, other configurations are possible in which the seal member 330 only partially covers the shell 320, such as in the case of filter cartridge 300' described below.

[0064] In one embodiment, the seal member 330 includes a plurality of seal arrangements 334, 336, 338 extending from a base member 332. The seal arrangements 334, 336, 338 ensure that a proper seal is formed between the filter cartridges 200, 300 and the housing assembly 102. This necessitates that air delivered from the outlet end 104d passes through both filter cartridges first. In one embodiment, and as most easily seen in FIG. 17, the base or proximal section 332a of the seal arrangement 334 is located radially closer to the longitudinal axis of the filter cartridge 300 and the outer periphery of the media pack 320 than the base or proximal section 332g of the seal arrangement 336. In one embodiment, the base or proximal section 332g of the seal arrangement 338 is located farther from the longitudinal axis of the filter cartridge 300 and the outer periphery of the media pack 320 than the bases of both the seal arrangements 334, 336. Thus, in general terms, seal arrangement 332 may be characterized as being radially closest to the longitudinal axis and the media pack periphery. Seal arrangement 338 may be characterized as being radially furthest from the longitudinal axis and the media pack periphery. Seal arrangement 336 may be characterized as being located at a midpoint radial distance between seal arrangements 334, 338.

[0065] As shown, the seal arrangement 334 includes a pair of seal members 334a, 334b ​​extending from the segment 332a. Although two seal members 334a are shown, more or fewer seal members 334a may be provided, such as one or three seal members 334a. In some examples, the seal members are lip seals. In some examples, the lip seal is a tapered lip seal. The lip seals 334a, 334b ​​may have the same length, but the lip seal 334b ​​is longer than the lip seal 334a in the example presented, which can provide improved sealing and easier installation. In one aspect, the lip seals 334a, 334b ​​extend radially outward from the segment 332a at an oblique angle toward the first end 302 of the filter cartridge 300. Thus, the seal arrangement 334 may be characterized as an outward radially oriented seal arrangement. The beveled angle provides ease of installation since the seal features 334, 338 are angled in the same direction as the insertion direction of the filter cartridge 300. Additionally, since the seal features 334, 336 are angled toward the high pressure side of the air cleaner (i.e., angled toward the upstream flow direction), the seals are angled to provide additional sealing against the housing due to internal air pressure. When the filter cartridge 300 is installed in the housing 104, the seal feature 334 forms a seal against the housing with the inwardly radially directed seal surface 104h, as most easily seen in Figures 18 and 19. In alternative examples, the lip seals 334a, 334b ​​extend in opposite diagonal directions or orthogonally from the segment 332a.

[0066] In the illustrated example, the seal arrangement 334 is axially offset such that a portion of the seal arrangement 334 is closer to the inlet or outlet flow ends 312, 314 compared to another portion of the seal arrangement 334, while the seal arrangements 336, 338 are disposed along a plane parallel to the inlet and outlet flow ends 312, 314. Thus, the axial distance between the seal arrangement 334 and the seal arrangements 336, 338 is variable, with the axial gap 50 being smallest at a location proximate the handle portion 306 and the axial gap being largest at the opposite end of the cartridge 300. Other configurations also exist. For example, the seal arrangements 336, 338 may also be structured to be axially offset. For example, the seal arrangement 334 may be structured to be disposed along a plane parallel to the inlet and outlet flow ends 312, 314. In some examples, all of the seal arrangements 334, 336, 338 are axially offset. In some examples, none of the seal arrangements 334, 336, 338 are axially offset.

[0067] As shown, the seal arrangement 336 includes a pair of seal members 336a, 336b extending from the segment 332g. In some examples, the seal members are lip seals. In some examples, the lip seal is a tapered lip seal. The lip seals 336a, 336b may have the same length, but the lip seal 336b is longer than the lip seal 336a in the example presented, which may provide improved sealing and easier installation. In one embodiment, the lip seals 336a, 336b extend radially inward from the segment 332g at an oblique angle toward the first end 302 of the filter cartridge 300. Thus, the seal arrangement 336 may be characterized as an inward radially oriented seal arrangement. The oblique angle provides ease of installation since the seal is angled in the same direction as the insertion direction of the filter cartridge 300. In another configuration, the seal is angled toward the high pressure side of the air cleaner (i.e., angled toward the upstream flow direction) so that the internal air pressure provides an additional seal against the housing. When the filter cartridge 300 is installed in the housing 104, the seal arrangement 336 forms a seal against the housing with the seal surface 104g directed radially outward, as most easily seen in Figures 18 and 19. In an alternative example, the lip seals 336a, 336b extend in opposite diagonal directions or orthogonally from the segment 332g.

[0068] In one aspect, the sealing arrangement 336 provides a reaction or backup force that helps ensure that the sealing arrangement 338 is held in a sufficient radial position to form a seal with the housing as it abuts against the housing after installation of the filter cartridge 300. In some examples, the sealing arrangement 336 may be formed for this purpose only, contacting the housing to provide a beneficial reaction force, but not necessarily forming a seal with the housing. In such a case, the sealing arrangement 336 may be referred to as a positioning arrangement 336. When so configured, the positioning arrangement 336 does not need to continuously contact the periphery of the housing surface, since it is not necessary to maintain a seal. Thus, the positioning arrangement 336 may include spaced apart members circumferentially oriented with respect to the housing periphery. It is noted that when the arrangement 336 is provided such that a continuous seal is not formed with the housing body 104, there is no longer a pair of seals in series. Thus, if a leak occurs in the sealing arrangement 334 in such a configuration, there will be a leak around the filter cartridge 300. It should also be noted that in such a configuration, sections 332b through 332g and the portion of section 332a between section 332b and sealing arrangement 334 should be continuous so that air does not bypass around filter cartridge 200 before entering filter cartridge 300.

[0069] As shown, the seal arrangement 338 includes a pair of seal members 338a, 338b extending from the segment 332g. In some examples, the seal members are lip seals. In some examples, the lip seals are tapered lip seals. Although the lip seals 338a, 338b may have the same length, the lip seal 338b is longer than the lip seal 338a in the example presented, which may provide improved sealing and easier installation. As can be seen most easily in FIG. 21, the flange wall 224 has a flared opening to facilitate installation, such that the contact point for the lip seal 338b is further from the longitudinal axis compared to the contact point for the lip seal 338a. In one embodiment, the lip seals 338a, 338b extend at an oblique angle in a radially outward direction from the segment 332g toward the second end 304 of the filter cartridge 300. Thus, the seal arrangement 338 may be characterized as an outward radially oriented seal arrangement. The bevel provides ease of installation since the seal is angled in the same direction as the insertion direction of the filter cartridge 300. Additionally, since the seal is angled toward the high pressure side of the air cleaner (i.e., angled toward the upstream flow direction), the seal is angled to provide additional sealing against the housing due to internal air pressure. When the filter cartridges 200 and 300 are installed in the housing 104, as most easily seen in FIG. 19, the seal arrangement 338 forms a seal against the flange 224 of the filter cartridge 200 with the inwardly radially directed seal surface 224a. In alternative examples, the lip seals 338a, 338b extend in opposite diagonal directions or orthogonally from the segment 332g.

[0070] 19, it can be seen that the sealing arrangements 336, 338 extending from the segment 332g are compressed within the clearance area defined between the flange 224 of the filter cartridge 200 and the sidewall 104f of the housing 104. This configuration ensures that the sealing arrangements 336, 338 form a proper seal against the respective sealing surfaces 104g, 224a, and further ensures that the filter cartridge 300 is properly retained within the housing 104. In such a configuration, the sealing arrangements 336, 338 may be collectively referred to as a primary seal that ensures a seal between the filter cartridge 300 and the housing 104. The sealing arrangement 334 may be correspondingly referred to as a secondary sealing arrangement. In some characterizations, the sealing arrangement 334 may be referred to as a first sealing arrangement, and the sealing arrangements 336, 338 may be collectively referred to as a second sealing arrangement. One advantage of the disclosed configuration is that the filter cartridge 300 can be easily removed from the housing 104 when the filter cartridge 200 is removed, since the filter cartridge 200 no longer exerts a compressive force on the second seal arrangement 336, 338. This advantage may be characterized as providing the filter cartridge 300 with a low service force. Another advantage of the disclosed configuration is that the seal arrangement 336, 338 is in-line with the seal arrangement 334. Such a configuration prevents failure of the first seal arrangement 334 or the second seal arrangement 336, 338 from creating a leak path around the filter cartridge 200, 300. In one aspect, and as can be seen in FIG. 22, the seal arrangement 336, 338 is located axially beyond the inlet flow end 312 of the media pack 310 in a direction extending from the media pack outlet flow end 314 toward the inlet flow end 312, and is also located radially beyond the periphery of the media pack 310.

[0071] In one approach to forming the shell 320 and the seal member 330, the shell 320 can be first formed by injection molding and then placed into a second mold where the seal member 330 can be injection molded into the shell 320. One class of materials suitable for injection molding the seal member 330 are thermoplastic elastomers (TPEs). TPE materials allow for injection molding of highly flexible parts with detailed profiles and are therefore advantageous for forming the sealing lip of the seal member 330. Other forming processes may also be used. For example, the seal member 330 may be molded separately from TPE or other materials and later attached to the shell 320 or media pack 310 with adhesives and / or sealants, or may be mechanically or frictionally fixed in place without the use of adhesives. Because the seal member 330 is disposed around the shell 320, the inner surface of the seal member 330 may have the same peripheral shape as the outer surface of the shell 320. In some examples, the seal member 330 may have a different peripheral shape than the shell 320. In some instances, such as when no shell is provided, the inner surface of the seal member 330 may have the same peripheral shape as the outer periphery of the media pack 310. Additionally, while the seal member 330 is disclosed as being a single component, the seal member 330 may be formed as multiple components, such as a first component including the seal arrangement 334 and a second component including the seal arrangements 336 and 338. Additionally, it is noted that since the seal is formed between the housing at the seal arrangements 334 and 336, the sections 332a, 332b, 332c, 332d, and 332f do not need to be continuous to ensure the integrity of the seal. As such, these sections may have interruptions or openings without compromising the seal performance. As discussed above, when the seal arrangement 336 does not form a continuous seal with the housing body 104 but is instead configured as the positioning arrangement 336, the sections 332a through 332g shall be continuous to ensure that air does not bypass the filter cartridge 200.

[0072] In some examples, the seal member 330 may be initially formed as a flat structure with segments 332a, 332f, and 332g aligned along a single plane. Once so formed, segment 332g may then be folded outwardly about section 332f into the shape shown in the drawings. In view of the above, a method of forming a filter cartridge may comprise providing a media pack and then affixing or forming a seal member either directly to the media pack or to a shell into which the media pack is disposed. If the seal member is initially formed as a flat structure, the method may include folding the seal member into the shape shown in the drawings either before or after the seal is affixed to the media pack or shell.

[0073] Although the seal arrangements 334, 336, 338 are shown as being integrally formed with the same base member 332, other configurations are possible. For example, the filter cartridge 300 may have separate seal arrangements 334, 336, 338 that are independently formed or molded into the shell 320. Additionally, although the seal arrangements 334, 336, 338 are each shown as including a pair of lip seals, the seal arrangements may include more or less lip seals or other types of seal members.

[0074] [D. Air Purifier 100', Filter Cartridge 200', Filter Cartridge 300'] 24 to 54, a second example of an air cleaner 100' is shown. The air cleaner 100' has many features in common with the air cleaner 100 and has the same general configuration, including a housing assembly 102', a first filter cartridge 200', and a second filter cartridge 300'. Where commonalities exist, the above descriptions of the air cleaner 100, the filter cartridge 200, and the filter cartridge 300 provided herein are fully applicable to the air cleaner 100', the filter cartridge 200', and the filter cartridge 300' and need not be repeated in this section. In that case, the same reference numbers are used for the air cleaner 100', but with the addition of an apostrophe. This section instead focuses on the relevant differences of the air cleaner 100' with respect to the air cleaner 100.

[0075] In one embodiment, the seal member 330' associated with the filter cartridge 300' has an altered configuration. For example, the overall length of the seal member 330' has a section 332e' disposed at a slight oblique angle relative to the longitudinal axis X. Additionally, the sections 332e', 332g' have greater lengths compared to the sections 332e, 332g. As noted above, the seal member 330' is also configured such that the seal member 330' does not completely cover the shell 320'. Rather, the seal member 330' is configured such that the segment 332a' follows the axially offset portion of the seal arrangement 334' and extends slightly beyond it.

[0076] The seal configuration of filter cartridge 300' further includes differences from the seal configuration of filter cartridge 300. For example, seal configuration 334' includes seal members, which may be characterized as lip seals 334a', 334b', which have a greater length and are spaced apart to accommodate bumper member 334c', as compared to seal members 334a, 334b. To ensure that seal members 334a', 334b' maintain contact with the housing sealing surface about the entire circumference of seal member 330', bumper member 334c' provides a radial limit to displacement of filter cartridge 300' within main housing 104'. With lip seals of the type shown in Figures 17 and 37, there is a concern that radial compression of one side of the filter cartridge, e.g., due to gravity, may result in the cartridge being radially offset to such an extent that a portion of the seal member on the opposite side of the cartridge is out of sealing contact with the housing, thereby creating a leakage flow path. The bumper member 334c' acts as a stopper for the housing to prevent such a condition. Additionally, the bumper member 334c' may be provided on the seal member 330. In some examples, multiple bumper members 334c' may be provided. In the illustrated example, the bumper member 334c' is disposed between the seal members 334a', 334b', but may be provided in other locations proximate the seal members 334a', 334b'.

[0077] The seal arrangement 338' further differs from the seal arrangement 338 in that the seal members 338a', 338b' have a shorter length compared to the seal members 338a, 338b and are not disposed at an oblique angle relative to the longitudinal axis X. The seal members 338a', 338b' may be characterized as lip seals. The features of the seal arrangement 336' are generally the same as the seal arrangement 336, including the seal members or lip seals 336a', 336b'. In particular, the seal arrangement 334' is offset in an opposite axial direction to that of the seal arrangement 334, such that the axial gap between the seal arrangement 334' and the seal arrangements 336' / 338' is largest at the end proximate to the handle 306' and smallest around the remaining circumference of the filter cartridge 300'. The above-mentioned features of the seal member 330' may be incorporated into the seal member 330 without departing from the concepts presented herein.

[0078] As most easily seen in FIG. 45, filter cartridge 300' includes an additional handle 307' extending from inlet flow end 312' of media pack 310'. In some instances, filter cartridge 300' may be provided without handle 306', such that handle 307' is the only handle provided on filter cartridge 300'. In such cases, seal member 330' need not include portions 332b'-332e' provided to accommodate handle portion 306', and may have a uniform cross-sectional shape at seal features 336', 338'. Such an arrangement is possible for filter cartridge 300 without departing from the concepts presented herein.

[0079] In one aspect, the main housing 104' and the filter cartridge 200' are provided with a catch feature configuration having different interacting positioning and receiving features compared to those described above for the air cleaner 100. As can be seen most easily in Figs. 34-36, the main housing 104' includes a vertical wall section 104q'. The vertical wall section 104q' defines an open notch or recess 104r' configured to receive a single, centrally located positioning feature 226' on the filter cartridge 200'. In one aspect, the positioning feature 226' and the wall section 104q' may be referred to as a catch feature. In one aspect, in which the positioning feature 226' is a first portion of the catch feature and the wall section 104q' is a second portion of the catch feature, the vertical wall section 104q' runs perpendicular to the longitudinal axis X and parallel to the outlet flow end 214' of the filter cartridge 200'. In one aspect, the positioning feature 226' presents a concave inner surface 226c' (convex outer surface 226c'). Additionally, the main housing 104' is shown as including a pair of longitudinally extending walls 104s' that extend perpendicularly and in a direction from the wall section 104q' toward the outlet end 104d'. The positioning feature 226' is shown as having a pair of notches 226b' configured to receive the walls 104s', thereby allowing the positioning feature 226' to be fully received in the recess 104r'. The interaction between the walls 104s' and the notches 226b' ensures that the cartridge 200' is properly aligned along the axis X of the air cleaner assembly 100' before the cartridge 200' is further inserted into the main housing 104'. Additionally, the walls 104s' and notches 226b' can function as features to ensure that the proper filter cartridge 200' is installed within the main housing 104', in that a filter cartridge 200' without a properly sized and positioned notch 226b' cannot be completely received within the main housing. The positioning feature 226' is further shown to include a pair of detent or hooking members 226a' extending laterally from the body of the positioning feature 226' a width greater than the width of the recess 104r'.In the illustrated example, the detent or hooking member 226a' is cylindrical with a convex outer surface 226c'. The convex outer surface 226c' rests on and pivots relative to the end surface 104t' of the wall section 104q'. As illustrated, the end surface 104t' has a rounded convex surface. Thus, as shown in FIG. 35 with the cartridge 200' in the initial tilted position, when the positioning feature 226' is hooked across the wall section 104q' into the recess 104r', the detent member 226a' engages against the downstream side of the wall section 104q' and prevents the filter cartridge 200' from backing up the upstream direction out of the wall section 104q'. This feature helps hold the top of the filter cartridge 200' in place while providing a pivot location for the filter cartridge 200' to rotate from the initial tilted position toward the installed position. 27, 28, 30, 35 and 40 show the initial tilted position of filter cartridge 200'. FIGS. 24, 25, 29, 32, 33 and 36 show the fully installed installed position of filter cartridge 200' with cover 105' attached to main housing 104'. As described for filter cartridge 200, filter cartridge 200' has a handle 228' that can be used to manipulate cartridge 200' to the initial tilted position, as shown in isolation in FIG. 40. However, handle 228' is formed on flange 230' and is therefore closer to inlet flow end 212' than handle 228. The center of gravity of filter cartridge 200' is axially located between handle 228' and positioning feature 226', as shown in FIG. 40. This is also the case for filter cartridge 200. Stated another way, a first radial plane perpendicular to longitudinal axis X extending through the center of gravity of filter cartridge 200' is located between a second radial plane perpendicular to longitudinal axis X extending through handle 228' and a third radial plane perpendicular to longitudinal axis X extending through positioning feature 226'.Such an arrangement allows the filter cartridge 200' to naturally hang at at least an initial tilt angle, or at least at an angle at which the positioning feature 226' hangs vertically below the handle 228', facilitating easy initial engagement between the positioning feature 226' and the wall section 104q'. Such a configuration allows the positioning feature 226' to hinge about the wall section 104q' without initial interference between the seal member 330' and the filter cartridge 200'. In the illustrated example, the difference between the initial tilt angle of the filter cartridge and the fully installed installed position is at least 5 degrees and is about 8 degrees. The initial tilt position is limited by the axial dimension 50a' of the gap 50', which allows the initial tilt position (angle) to be increased as the axial dimension 50a' of the gap 50' increases.

[0080] Additionally, filter cartridge 200' differs from filter cartridge 200 in that media pack inlet flow end 212' extends beyond seal arrangement 232'. In such an arrangement, axial dimension 50a' of gap 50' is defined by inlet flow end 212', not by seal arrangement 232'. Also, in the illustrated example, seal arrangement 232' is overmolded onto flange 230' of shell 220'. Seal arrangement 232', like seal arrangement 232, may be formed separately and later bonded to flange 230' in a separate arrangement. In some examples, seal arrangement 232' may be provided at or around shell 220' proximate outlet flow end 214'.

[0081] [E. Air Purifier 100”, Filter Cartridge 200”, Filter Cartridge 300”] Referring to Figures 55-64, features of a third example of an air cleaner 100" that can be used with air cleaner 100, 100' are shown. Air cleaner 100" has many features in common with air cleaner 100, 100' and has the same general configuration including a housing assembly 102", a first filter cartridge 200", and a second filter cartridge 300". Where commonalities exist, the descriptions provided herein above regarding air cleaner 100, 100', filter cartridge 200, 200', and filter cartridge 300, 300' are fully applicable to air cleaner 100", filter cartridge 200", and filter cartridge 300" and need not be repeated in this section. In that case, the same reference numbers are used for air cleaner 100", but with two additional apostrophes. This section will instead focus on the relevant differences of air cleaner 100" relative to air cleaner 100, 100'.

[0082] The air cleaner 100" differs from the previously disclosed embodiment mainly in that a third example of the catch arrangement is disclosed in which the first portion 226" of the catch arrangement is provided as a horizontal pin 226" and the second portion 104e" of the catch arrangement is provided as a receiving structure 104e" having a pair of open channel structures 104u" with a cylindrical support surface. As shown, the open channel structures 104u" are supported by an extension member 104v" extending horizontally from a vertical wall 104w" of the housing 104". Figures 55 and 58 show the first portion 226" received in the second portion 104e" with the cartridge 200" in the installed position. Figure 56 shows the air cleaner housing 104" without the filter cartridge 200" and the filter cartridge 300" shown so that the second portion 104e" can be more easily seen. Figure 57 shows the air filter cartridge 200" in a tilted position during installation or removal. Here, the longitudinal axis of filter cartridge 200'' is at an oblique angle relative to the longitudinal axis of air cleaner housing 104'', and is at an oblique angle relative to the longitudinal axis of filter cartridge 200'' when in the installed position.

[0083] 57 and also 58-61, filter cartridge 200" has a seal member 331" proximate the outlet end of filter cartridge 200" that has a pair of seal members 331a" configured as a lip seal, and a bumper member 331b". Although two seal members 331a" are illustrated, more or fewer seal members 331a" may be provided, such as one or three seal members 331a". In the illustrated example, housing 104" has a sealing surface 104x" against which seal member 330" can form a seal. Notably, seal member 331" is axially offset similarly to seal members 330, 330', but in the opposite direction, such that seal member 331" is further away from media pack outlet flow end 214" proximate catch arrangement first portion 226" as compared to the opposite end. This configuration therefore accommodates axial positioning of first portion 226" axially beyond outlet flow end 214" in a direction extending from inlet flow end 212" toward outlet flow end 214", while delaying the rotational angle of filter cartridge 200" at which the bottom of seal member 331" contacts housing seal surface 104x" as cartridge 200" is rotated from an inclined position to an installed position. Because filter cartridge 200" has seal member 331", seal member 330" of filter cartridge 300" may have seal arrangement 334 as already shown and described, but not seal arrangements 336, 338.

[0084] 62-64, the first portion 226" of the catch arrangement is shown in further detail. As shown, the first portion 226" includes a base structure 226d" extending from the shell 220". In the illustrated example, the base structure 226d" has a generally triangular shape, although other shapes are possible. The base structure 226d" supports a pair of horizontally extending pin members 226e" spaced apart to form a gap or open space 226f". In some examples, the housing 104" may have a correspondingly shaped protrusion at the location of the gap 226f" so that only a filter cartridge 200" having a correctly shaped gap or open space 226f" can be installed in the housing 104". In some examples, the pin member 226e" may be formed as a single pin member 226e" without a gap or open space 226f". As previously mentioned, the pin member 226e" has a generally cylindrical shape, but may have other shapes. As can be most easily seen in FIG. 61, the first portion 226" is seen to be located radially beyond the outer periphery of the media pack 210" and axially beyond the outlet flow end 214" of the media pack 210", in a direction extending from the inlet flow end 212" towards the outlet flow end 214". The first portion 226" is also located radially beyond the seal member 331" while being axially located between the seal member 331" and the outlet flow end 214" of the media pack 210".

[0085] III. General, Exemplary Media Configurations As will be further described in connection with FIGS. 65-86 , any type of filter media may be used as the media pack in the disclosed filter cartridges (e.g., 200, 200', 200", 300, 300"). Additionally, the media type in filter cartridges 200, 200', 200" may be the same type as the media in filter cartridge 300, 300", or may be a different type. For example, filter cartridges 200, 200', 200" may have a fluted-type media, while filter cartridge 300, 300' may have a pleated-type media.

[0086] The media may be of various types and configurations and may be made using a variety of materials, for example, a pleated media configuration may be used in a cartridge according to the principles of the present disclosure, as described below.

[0087] This principle is particularly well suited for use in situations where the media extends significantly between the inlet and outlet ends of the cartridge, although other principles are possible. Also, this principle is often used with cartridges having relatively large cross-sectional dimensions. In such configurations, an alternative media type to pleated media is often desired.

[0088] This section provides examples of some media configurations that may be used with the technology described herein. However, it is understood that a variety of alternative media types may be used. The selection of a media type is generally one of preference for availability, functionality in a given application, ease of manufacture, etc. The selection is not necessarily specifically related to the overall functionality of the selected one of the various filter cartridge / air cleaner interaction features characterized herein.

[0089] A. Media Pack Configurations Using Filter Media with Media Ridges (Flutes) Fixed to a Facing Media Fluted filter media (media having media ridges) may be used to provide fluid filter structures in a variety of ways. One well-known way is characterized herein as a z-filter structure. That is, one type of filter structure is one in which individual ones of the corrugated, folded, or otherwise formed filter flutes are used (typically in combination with a facing media) to define a set of longitudinal, typically parallel, inlet and outlet filter flutes for fluid flow through the media. As used herein, the term "z-filter structure" is meant to include (but is not limited to) this type of filter structure. Some examples of z-filter media are shown in the following: U.S. Patents: 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469; 6,190,432; 6,350,291; 6,179,890; 6,235,195; Des. 399,944; Des. 428,128; Des. 396,098; Des. 398,046; and Des. 437,401; each of these references is incorporated herein by reference.

[0090] One type of z-filter media utilizes two specific media components combined to form a media structure: (1) a fluted media sheet (usually a corrugated media sheet) or sheet section, and (2) a facing media sheet or sheet section. The facing media sheet is typically non-corrugated, but may be corrugated, for example, corrugated perpendicular to the flute direction, as described in U.S. Provisional Application No. 60 / 543,804, filed February 11, 2004, and published August 25, 2005 as PCT WO 05 / 077487.

[0091] The fluted media sections and the facing media sections may comprise separate materials from one another, but they may also be sections of a single sheet of media that are folded to properly juxtapose the facing media material with the fluted media portion of the media. For example, a single continuous sheet of media with alternating fluted and flat sections along the length of the media may be zig-zag folded back on itself to form the fluted media configuration.

[0092] Fluted (typically corrugated) media sheets and facing media sheets or sheet sections are used together to define a media having typically parallel flutes. In some instances, the fluted and facing sheets are separate and then secured together and then coiled as a media strip to form a z-filter media structure. Such configurations are described, for example, in U.S. Pat. Nos. 6,235,195 and 6,179,890, which are incorporated herein by reference. In certain other configurations, several non-coiled sections or strips of fluted (typically corrugated) media secured to a facing media are stacked on top of each other to create a filter structure. An example of this is disclosed in FIG. 11 of U.S. Pat. No. 5,820,646, which is incorporated herein by reference.

[0093] Here, strips of material including fluted sheets (sheets of media having ridges) secured to corrugated sheets, then assembled into a stack to form a media pack, are sometimes referred to as "single facer strips," "single faced strips," or "single facer" or "single faced" media. These terms and variations thereof mean that in each strip, one or a single side of the fluted (typically corrugated) sheet is faced (faced) by a facing sheet.

[0094] Coiling a strip of fluted sheet / facing sheet (i.e., single facer) combination around itself to create a coiled media pack is typically done with the facing sheet facing outward. Several techniques for coil winding are described in U.S. Provisional Application No. 60 / 467,521, filed May 2, 2003, and PCT Application No. US04 / 007927, filed March 17, 2004 (now published as WO04 / 082795), each of which is incorporated herein by reference. The resulting coiled arrangement generally has a portion of the facing sheet as the outer surface of the media pack.

[0095] The term "corrugated" as used herein to refer to structures in a media is often used to refer to a flute structure resulting from passing the media between two corrugating rollers, i.e., through a nip or bite between two rollers, each roller having surface features suitable for producing corrugations in the resulting media. However, the term "corrugating" is not meant to be limited to flutes present by techniques that include passing the media through a bite between corrugating rollers, unless described as resulting from such flutes. The term "corrugated" is meant to apply even if the media is further changed or transformed after corrugation, for example, by folding techniques described in PCT Publication WO 04 / 007054, published Jan. 22, 2004, which is incorporated herein by reference.

[0096] Corrugated media is a specific form of fluted media, which is media having individual flutes or ridges (formed, for example, by a corrugating or folding process) extending across it.

[0097] A serviceable filter element or cartridge configuration utilizing a z-filter media is sometimes referred to as a "straight-flow configuration" or variations thereof. In general, what is meant in this context is that a serviceable filter element or cartridge generally has an inlet flow end (or face) and an opposite outlet flow end (or face), with the flow entering and leaving the filter cartridge generally in the same straight-flow direction. The term "serviceable" in this context is meant to refer to a media-containing filter cartridge that is periodically removed and replaced from a corresponding fluid (e.g., air) purifier. In some instances, each of the inlet flow end (or face) and the outlet flow end (or face) are generally flat or planar, and the two are parallel to each other. However, variations to this, such as non-planar faces, are also possible.

[0098] The straight-through configuration (especially in the case of coiled or stacked media packs) is in contrast to serviceable filter cartridges, such as cylindrical pleated filter cartridges of the type shown in U.S. Pat. No. 6,039,778, which is incorporated herein by reference. In this patent, the flow generally makes a significant turn to enter and exit the media. That is, in the filter of U.S. Pat. No. 6,039,778, the flow enters the cylindrical filter cartridge from the side of the cylinder, then turns around and turns back to exit the open end of the media (a forward flow system). In a typical reverse flow system, the flow enters the serviceable cylindrical cartridge through the open end of the media, then turns back to exit 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.

[0099] As used herein, the term "z-filter media construction" and variations thereof are meant to include, but are not necessarily limited to, any or all of the following, if not otherwise specified: A web of corrugated or other fluted media (media with media ridges) fixed adjacent to the (facing) media, with suitable seals (closures) allowing the definition of inlet and outlet flutes, whether the sheets are separate or part of a single web; and / or a media pack constructed or formed from such media into a three-dimensional network of inlet and outlet flutes; and / or A filter cartridge or structure containing such a media pack.

[0100] Figure 65 shows an example of media 1001 that can be used in a z-filter media construction. Media 1001 is formed from a fluted, in this example corrugated, sheet 1003 and a facing sheet 1004. Structures such as media 1001 are referred to herein as single facers or single facer strips.

[0101] In some cases, the corrugated fluted or ridged sheet 1003 of FIG. 65 is of a type generally characterized herein as having a regular, curvilinear wave pattern of flutes, ridges, or corrugations 1007. The term "wave pattern" in this context means a flute, ridge, or corrugation pattern of alternating troughs 1007b and ridges 1007a. The term "regular" in this context means that pairs of troughs and ridges (1007b, 1007a) generally alternate with the same repeating corrugation (flute or ridge) shape and size. (And typically, in a regular configuration, each trough 1007b is substantially an inverse ridge to each ridge 1007a.) Thus, the term "regular" is meant to indicate that the corrugation (or flute) pattern includes a trough (inverse ridge) and ridge in each repeating pair (including adjacent troughs and ridges) without substantially changing the size and shape of the corrugations along at least 70% of the length of the flutes. The term "substantial" in this context refers to variations resulting from variations in the process or form used to create the corrugated or fluted sheet, as opposed to minor variations from the fact that the media sheet 1003 is flexible. With respect to characterizing repeating patterns, it is not meant to imply that there are necessarily the same number of ridges and troughs in any given filter structure. The media 1001 may, for example, be partially terminated between or along pairs of ridges and troughs. (For example, in FIG. 65, the media 1001 depicted in fragmentary form has eight complete ridges 1007a and seven complete troughs 1007b.) Also, opposing flute ends (trough and ridge ends) may differ from one another. Such variations in ends are ignored in these definitions unless otherwise noted. That is, variations in flute ends are intended to be covered by the above definitions.

[0102] In the context of characterizing the "curved wave" pattern of corrugations, in certain instances, the corrugation pattern is not the result of a folded or creased shape imparted to the media, but rather, the peak 1007a of each ridge and the bottom 1007b (7b) of each trough are formed along a radial curve. A typical radius for such z-filter media is at least 0.25 mm, and typically no more than 3 mm.

[0103] An additional feature of the particular regular curved wave pattern depicted in FIG. 65 for the corrugated sheet 1003 is that along most of the length of the flutes 1007, at approximately the midpoint 1030 between each trough and each adjacent ridge, there is a transition region where the curvature reverses. For example, looking toward the back side or rear surface 1003a of FIG. 65, the troughs 1007b are concave shaped regions and the ridges 1007a are convex shaped regions. Of course, looking toward the front side or front surface 1003b, the troughs 1007b on the back side 1003a form ridges and the ridges 1007a on the back surface 1003a form troughs. (In some instances, the regions 1030 may be straight line segments instead of points, and the curvature reverses at the ends of the segments 1030.)

[0104] A feature of the particular regular wave pattern fluted (in this example corrugated) sheet 1003 shown in FIG. 65 is that the individual corrugations, ridges or flutes are generally straight, although they can be otherwise. "Straight" in this context means that the ridges 1007a and troughs (or inverted ridges) 1007b do not vary substantially in cross section through at least 70% of their length, typically at least 80%. The term "straight" with respect to the corrugation pattern shown in FIG. 65 distinguishes, in part, from the tapered flutes of the corrugated media disclosed in FIG. 1 of WO 97 / 040918 and PCT publication WO 03 / 047722 published June 12, 2003, both of which are incorporated herein by reference. For example, the tapered flutes of FIG. 1 of WO 97 / 040918 are a curved wave pattern, but are not a "regular" pattern or a pattern of straight flutes as that term is used herein.

[0105] 65, and as mentioned above, media 1001 has first and second opposite edges 1008 and 1009. When media 1001 is formed into a media pack, edge 1009 typically forms an inlet end or face and edge 1008 forms an outlet end or face of the media pack, although the opposite orientation is also possible.

[0106] In the depicted example, the various flutes 1007 extend completely between the opposing edges 1008, 1009, but this is not limiting. For example, they may extend to a position adjacent or proximate to an edge, but not completely through the edge. They may also stop and start midway through the medium, such as in the medium of U.S. Publication No. 2014 / 0208705 A1, which is incorporated herein by reference.

[0107] When the media is as depicted in FIG. 65, the adjacent edge 1008 may provide a sealant bead 1010 to seal the corrugated sheet 1003 and the facing sheet 1004 together. In some cases, the bead 1010 is referred to as a "single facer" or "single sided" bead or variation, since it is a bead between the corrugated sheet 1003 and the facing sheet 1004 that form the single facer media strip 1001. The sealant bead 1010 seals the closed individual flutes 1011 adjacent the edge 1008 against the passage of air therethrough (or in reverse flow thereto).

[0108] In the media depicted in FIG. 65, the adjacent edge 1009 has a sealing bead 1014. The sealing bead 1014 generally abuts the edge 1009 to close the flutes 1015 against the passage of unfiltered fluid therefrom (or reverse flow therethrough). The bead 1014 is typically applied when the media 1001 is configured into a media pack. When the media pack is made from a stack of strips 1001, the bead 1014 forms a seal between the underside 1017 of the facing sheet 1004 and the side 1018 of the next adjacent corrugated sheet 1003. When the media 1001 is not coiled but cut into strips and stacked, the bead 1014 is referred to as a "stack bead." (When the bead 1014 is used in a coiled configuration formed from a long strip of media 1001, it may be referred to as a "wound bead.")

[0109] For other types of through-flow media, the sealant may be placed in a different location and additional sealants or adhesives may be avoided. For example, in some instances, the media may be folded to form an end or edge seam. Or, the media may be closed and sealed by alternative techniques such as ultrasonic irradiation. Additionally, even when a sealant material is used, it is not necessary for the ends to be adjacent to each other on opposite sides.

[0110] Referring to FIG. 65, when filter media 1001 is incorporated into a media pack, for example by stacking or wrapping, it can be operated as follows: First, air in the direction of arrow 1012 enters open flutes 1011 adjacent edge 1009 (end 1009). Closure of edge 1008 by bead 1010 causes air to pass through filter media 1001, for example as shown by arrow 1013. Air can then exit the media or media pack by passing through open ends 1015a of flutes 1015 adjacent edge 1008 of the media pack. Of course, operation with air flow in the reverse direction is also possible.

[0111] In the particular configuration shown herein in FIG. 65 (1001), the parallel corrugations 1007a, 1007b are generally perfectly straight across the medium from edge 1008 to edge 1009. The straight flutes, ridges or corrugations may be deformed or folded at selected locations, particularly at the ends. In the above definitions of "regular", "curved" and "wave pattern", instances of variation at the flute ends due to closure are generally ignored.

[0112] Z-filter constructions are known that do not utilize a straight, regular, curved wave pattern of corrugations. For example, U.S. Patent No. 5,562,825 to Yamada et al. discloses a corrugation pattern that utilizes somewhat semicircular (cross-section) inlet flutes adjacent to narrow V-shaped (curved sides) outlet flutes (see Figs. 1 and 3 of the patent). U.S. Patent No. 5,049,326 to Matsumoto et al. discloses circular (cross-section) or tubular flutes that are attached to a sheet with half tubes by another sheet with half tubes, resulting in flat areas between the parallel straight flutes (see Fig. 2 of the patent). U.S. Patent No. 4,925,561 to Ishii et al. (Fig. 1) discloses flutes that are folded to have a rectangular cross-section, with the flutes tapering along their length. WO 97 / 040918 (Figure 1) discloses flutes or parallel corrugations that have a curved wave pattern (from adjacent curved convex and concave troughs) and are tapered (and therefore not straight) along their length. WO 97 / 040918 also discloses flutes that have a curved wave pattern and have ridges and troughs of different sizes. Flutes that have been modified to include various ridges are also known.

[0113] Generally, filter media are relatively flexible materials, typically nonwoven fibrous materials (of cellulose fibers, synthetic fibers, or both), often containing resins therein, and sometimes treated with additional materials. As such, they may be conformed to or configured into a variety of corrugated patterns without unacceptable media damage. They may also be easily coiled or otherwise configured for use without unacceptable media damage. Of course, their properties must be such that they can maintain the required corrugated shape during use.

[0114] Typically, the corrugating process creates an inelastic deformation in the media, which prevents the media from returning to its original shape. However, once the tension is released, the flutes or corrugations tend to spring back, recovering only a portion of the stretch or bending that occurred. To prevent this springback, the facing media sheet is sometimes tacked to the fluted media sheet. Such tacks are shown at 1020.

[0115] Typically, the media also includes a resin, and in the corrugation process, the media may be heated above the glass transition temperature of the resin, which then helps maintain the flute shape when the resin cools.

[0116] The corrugated (fluted) sheet 1003, the facing sheet 1004, or both media may have fine fiber material on one or both sides thereof, for example, according to U.S. Patent No. 6,673,136, which is incorporated herein by reference. In some instances, when such fine fiber material is used, it may be desirable to provide fine fibers on the upstream side of the material and on the inside of the flutes. In such cases, air flow during filtering is typically toward the edge containing the stacking bead.

[0117] A problem with z-filter constructions relates to the closure of the individual flute ends. Although alternatives are possible, typically a sealant or adhesive is provided to achieve closure. As is evident from the above discussion, typical z-filter media, especially those that use straight flutes as opposed to tapered flutes and a sealant for flute sealing, 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 media construction. Problems arise in this regard when the sealant volume and area are large.

[0118] Attention is now directed to FIG. 66, which shows a schematic depiction of a z-filter media structure 1040 utilizing a regular, curved, wave-pattern corrugated sheet 1043 and a non-corrugated flat sheet 1044, i.e., a single facer strip. A distance D1 between points 1050 and 1051 defines the extension of the flat media 1044 in the area 1052 under a given corrugated flute 1053. The length D2 of the arcuate media for the corrugated flute 1053 over this distance D1 is of course greater than D1 due to the shape of the corrugated flute 1053. For a typical regular shaped media used in fluted filter applications, the linear length D2 of the media 1053 between points 1050 and 1051 will often be at least 1.2 times D1. Typically, D2 is in the range of 1.2 to 2.0 times D1 inclusive. One particularly advantageous configuration for air filters has D2 equal to about 1.25 to 1.35 times D1. Such media is used commercially, for example, in Donaldson PowerCore® z filter configurations. Another useful size is one in which D2 is equal to about 1.4 to 1.6 times D1, where the ratio D2 / D1 is sometimes characterized as the flute / flat ratio or media draw of the corrugated media.

[0119] In the corrugated box industry, various standard flutes have been defined, such as Standard E Flute, Standard X Flute, Standard B Flute, Standard C Flute, Standard A Flute, etc. The attached Figure 67 in conjunction with Table A below gives the definitions of these flutes.

[0120] Donaldson Corporation (DCI), the assignee of the present disclosure, has used examples of variations of standard A and standard B flutes in various z-filter configurations. These flutes are further defined in Table A and FIG. [Table A] (Flute definition in Figure 67) DCI A flute: flute / flat = 1.52:1, radius (R) as shown below. R1000=0.0675 inches (1.715 mm); R1001=0.0581 inches (1.476 mm); R1002=0.0575 inches (1.461 mm); R1003=0.0681 inches (1.730 mm). DCI B flute: flute / flat = 1.32:1, radius (R) as shown below. R1004=0.0600 inches (1.524 mm); R1005=0.0520 inches (1.321 mm); R1006=0.0500 inch (1.270 mm); R1007=0.0620 inch (1.575 mm). Standard E-flute: Flute / flat = 1.24:1, radius (R) as shown below. R1008=0.0200 inches (0.508 mm); R1009=0.0300 inches (0.762 mm); R1010=0.0100 inch (0.254 mm); R1011=0.0400 inch (1.016 mm). Standard X-Flute: Flute / Flat = 1.29:1, Radius (R) as shown below. R1012=0.0250 inch (0.635 mm); R1013=0.0150 inch (0.381 mm). Standard B flute: Flute / flat = 1.29:1, radius (R) as shown below. R1014=0.0410 inch (1.041 mm); R1015=0.0310 inch (0.7874 mm); R1016=0.0310 inch (0.7874 mm). Standard C flute: Flute / flat = 1.46:1, radius (R) as shown below. R1017=0.0720 inches (1.829 mm); R1018=0.0620 inches (1.575 mm). Standard A flute: Flute / flat = 1.53:1, radius (R) as shown below. R1019=0.0720 inch (1.829 mm); R1020=0.0620 inch (1.575 mm). Of course, other standard flute definitions are known in the corrugated box industry.

[0121] Generally, the corrugated box industry standard flute configurations may be used to define the corrugation shape, or approximate corrugation shape, of a corrugated medium. The above comparison of DCI A flutes with DCI B flutes and corrugated box industry standard A flutes with standard B flutes points out some useful examples of variations.

[0122] It is noted that alternative flute definitions as characterized in U.S. Patent Application No. 12 / 215,718, filed June 26, 2008 and published as U.S. Publication No. 2009 / 0127211, and / or U.S. Patent Application No. 12 / 012,785, filed February 4, 2008 and published as U.S. Publication No. 2008 / 0282890, and / or U.S. Patent Application No. 12 / 537,069, published as U.S. Publication No. 2010 / 0032365, may be used with the air cleaner features as characterized herein below. The entire disclosures of U.S. Publication No. 2009 / 0127211, U.S. Publication No. 2008 / 0282890, and U.S. Publication No. 2010 / 0032365 are incorporated herein by reference.

[0123] An example of another media variation consisting of a fluted media having a facing media secured thereto, either in a stacked or coiled configuration, may be used in the configurations according to the present disclosure, as described in U.S. Publication No. 2014 / 0208705 A1, owned by Baldwin Filters, Inc., published July 31, 2014, and incorporated herein by reference.

[0124] [B. Manufacturing of a media pack configuration containing the media of Figures 65-67, see Figures 68-71] FIG. 68 shows an example of a manufacturing process for producing a media strip (single facer) corresponding to strip 1001 of FIG. 65. Generally, a facing sheet 1064 and a fluted (corrugated) sheet 1066 having flutes 1068 are brought together to form a media web 1069 with an adhesive bead, shown as 1070, disposed therebetween. The adhesive bead 1070 forms the single facer bead 1010 of FIG. 65. An optional darting process occurs at station 1071 to form a central dart section 1072 located midway through the web. The z-filter media, or Z-media strip 1074, can be cut or slit at 1075 along the bead 1070 to create two pieces or strips 1076, 1077 of z-filter media 1074, each having an edge with a strip of sealant (single facer bead) extending between the corrugated sheet and the facing sheet. Of course, if the optional darting process is used, the edge that has the strip of sealant (single facer bead) will also have a set of flutes darted at this location.

[0125] Techniques for carrying out the process characterized with respect to FIG. 68 are described in PCT Publication WO04 / 007054, published Jan. 22, 2004, which is incorporated herein by reference.

[0126] Still referring to FIG. 68, before the z-filter media 1074 is passed through a darting station 1071 and ultimately slit at 1075 it needs to be formed. In the schematic shown in FIG. 68 (1004), this is done by passing a sheet of filter media 1092 through a pair of corrugating rollers 1094, 1095. In the schematic shown in FIG. 68, the sheet of filter media 1092 is unwound from a roll 1096, wrapped around a tension roller 1098 and then passed through a nip or bite 1102 between the corrugating rollers 1094, 1095. After the flat sheet 1092 passes through the nip 1102, the corrugating rollers 1094, 1095 have teeth 1104 which give the general desired shape of the corrugations. After passing through the nip 1102, the sheet 1092 becomes corrugated across the machine direction and is shown at 1066 as a corrugated sheet. The corrugated sheet 1066 is then secured to the facing sheet 1064 (the corrugating process may include a heating medium in some instances).

[0127] 68, the process further shows the facing sheet 1064 being fed to a darting process station 1071. The facing sheet 1064 is depicted as being stored on a roll 1106 and then directed against the corrugated sheet 1066 to form the Z-media 1074. The corrugated sheet 1066 and the facing sheet 1064 are typically secured together by adhesive or other means (e.g., sonic welding).

[0128] 68, the adhesive line 1070 used to secure the corrugated sheet 1066 and the facing sheet 1064 together is shown as a sealant bead. Alternatively, a sealant bead forming a facing bead may be applied as shown as 1070a. When sealant is applied at 1070a, it may be desirable to form a gap in the corrugated roller 1095, and possibly both corrugated rollers 1094, 1095, to accommodate the bead 1070a.

[0129] Of course, the device of FIG. 68 may be modified to provide the tack bead 1020 of FIG. 65, if desired.

[0130] The type of corrugation provided to the corrugated media is a matter of choice and is determined by the corrugations or corrugation teeth of the corrugating rollers 1094, 1095. One useful corrugation pattern is a regular wave pattern corrugation of straight flutes or ridges as defined above. A typical regular wave pattern used is one in which the distance D2, as defined above, in the corrugation pattern is at least 1.2 times the distance D1, as defined above. In applications, typically D2=1.25 to 1.35×D1, although others are possible. In some instances, the technique may be applied with wave patterns that are not “regular”, including, for example, those that do not use straight flutes. Variations from the illustrated wave patterns are also possible.

[0131] As described above, the process shown in Figure 68 can be used to form the central dart section 1072. Figure 69 shows one of the flutes 1068 in cross section after darting and slitting.

[0132] The pleat arrangement 1118 may be viewed as forming a darted flute 1120 having four folds 1121a, 1121b, 1121c, 1121d. The pleat arrangement 1118 includes a flat first layer or portion 1122 secured to the facing sheet 1064. A second layer or portion 1124 is shown pressed against the first layer or portion 1122. The second layer or portion 1124 is preferably formed by folding (i.e., darting) opposing outer ends 1126, 1127 of the first layer or portion 1122.

[0133] Still referring to Figure 69, two of the pleats or folds 1121a, 1121b are generally referred to herein as "upper, inwardly directed" pleats or folds. The term "upper" in this context is meant to indicate that there is a fold at the top of the entire pleat 1120 when the pleat 1120 is viewed in the orientation of Figure 69. The term "inwardly directed" refers to the fold or pleat lines of each of the folds 1121a, 1121b being directed toward one another.

[0134] In Figure 69, folds 1121c, 1121d are generally referred to herein as "lower, outwardly directed" folds. The term "lower" in this context means that folds 1121c, 1121d are not located on the upper side like folds 1121a, 1121b in the orientation of Figure 69. The term "outwardly directed" is meant to indicate that the fold lines of folds 1121c, 1121d are directed away from one another.

[0135] The terms "upper" and "lower" as used in this context are meant to refer specifically to the pleats 1120 as viewed from the orientation of Figure 69, i.e., they are not intended to otherwise indicate the direction of the pleats 1120 when oriented for use in an actual product.

[0136] Based on these characterizations, and a review of Figure 69, it can be seen that the regular pleat configuration 1118 according to Figure 5 of the present disclosure includes at least two "upper, inwardly directed folds." These inwardly directed folds are unique and help provide an overall configuration in which the folds do not cause significant intrusion into adjacent flutes.

[0137] The third layer or portion 1128 is further seen to be pressed against the second layer or portion 1124. The third layer or portion 1128 is formed by folding from opposed inner ends 1130, 1131 (1130e, 1131e) of the third layer 1128.

[0138] Another way to view the pleat configuration 1118 is to refer to the alternating ridge and trough geometry of the corrugated sheet 1066. A first layer or portion 1122 is formed from an inverted ridge. A second layer or portion 1124 corresponds to a double peak (after inverting the ridge) that folds toward and, in a preferred configuration, against the inverted ridge.

[0139] In a preferred manner, techniques for providing the optional darts described in connection with Figure 69 are described in PCT Publication WO04 / 007054, which is incorporated herein by reference. Techniques for applying a winding bead to wind the media are described in PCT Application US04 / 007927, filed March 17, 2004, published as WO04 / 082795, which is incorporated herein by reference.

[0140] Alternative approaches to darting the flute ends to a closed state are possible, including, for example, darting off the center of each flute, or rolling, pressing, or folding across the various flutes. In general, darting involves folding or otherwise manipulating the media adjacent the flute ends to achieve a compressed closed state.

[0141] The techniques described herein are particularly well suited for use with media packs resulting from rolling a single sheet or "single facer" strip that includes a corrugated sheet / facing sheet combination, however, the media packs may also be in a stacked configuration.

[0142] The configuration of the coiled media or media pack may have various perimeter definitions. In this context, the term "perimeter, perimeter definition" and variations thereof are intended to refer to the perimeter shape of the perimeter defined looking at either the inlet or outlet end of the media or media pack. A typical shape is a circle as described in PCT Publication WO04 / 007054. Another shape that may be used is an obround, with some examples of obround being oval shapes. An oval shape generally has opposing curved ends attached by a pair of opposing sides. Some ovals also have curved opposing sides. In other ovals, sometimes referred to as racetrack shapes, the opposing sides are generally straight. Racetrack shapes are described, for example, in PCT Publication WO04 / 007054 and PCT Application US04 / 007927, published as WO04 / 082795, each of which is incorporated herein by reference.

[0143] Another way to describe the perimeter or peripheral shape is to define the perimeter that results from taking a cross section through the media pack in a direction perpendicular to the coil winding access.

[0144] The opposing flow ends or faces of the media or media pack may have a variety of different definitions. In many configurations, the ends or faces are generally flat (planar) and perpendicular to one another. In other configurations, one or both of the end faces include a tapered, e.g., stepped, portion that can be defined as projecting axially outward from the axial end of the media pack sidewall, or that can be defined as projecting axially inward from the end of the media pack sidewall.

[0145] The flute seals (e.g., from a single facer bead, a wound bead, or a laminated bead) may be formed from a variety of materials. Various of the cited and incorporated documents state that hot melt or polyurethane seals can be used for a variety of applications.

[0146] FIG. 70 generally illustrates a coiled media pack (or coiled media) 1130 constructed by coiling a single strip of single facing media. The particular coiled media pack depicted is an oval media pack 1130a, specifically a racetrack shaped media pack 1131. The rear end of the media on the outside of the media pack 1130 is indicated at 1131x. For convenience and sealing, it will be typical to terminate that rear end along a straight section of the media pack 1130. Typically, a hot melt seal bead or seal bead is placed along that rear end to ensure a seal. Opposing flow (end) faces of the media pack 1130 are indicated at 1132, 1133. One is the inlet flow end or face and the other is the outlet flow end or face.

[0147] FIG. 71 shows (schematically) the steps of forming a laminated z-filter media (or media pack) from strips of z-filter media. Each strip is a fluted sheet secured to a facing sheet. Referring to FIG. 71, a single facer strip 1200 is shown being added to a stack 1201 of strips 1202 similar to strip 1200. Strip 1200 may be cut from either of strips 1076, 1077 of FIG. 68. At 1205 in FIG. 71, the application of a laminate bead 1206 is shown between each layer corresponding to strips 1200, 1202, on the edge opposite the single facer bead or seal. (Stacking may also be done by adding each layer to the bottom as opposed to the top of the stack.)

[0148] 71, each strip 1200, 1202 has front and rear edges 1207, 1208 and opposed side edges 1209a, 1209b. The inlet and outlet flutes of the corrugated sheet / facing sheet combination that comprises each strip 1200, 1202 generally extend between the front and rear edges 1207, 1208 and parallel to the side edges 1209a, 1209b.

[0149] 71, in the formed media or media pack 1201, opposing flow faces are shown at 1210, 1211. During filtering, the selection of which of the faces 1210, 1211 is the inlet end face and which is the outlet end face is simply a matter of choice. In some instances, the stack bead 1206 is disposed adjacent the upstream or inlet face 1211, and vice versa in other instances. The flow faces 1210, 1211 extend between opposing side faces 1220, 1221.

[0150] The laminated media configuration or pack 1201 shown as formed in FIG. 71 is sometimes referred to herein as a "blocked" laminated media pack. The term "blocked" in this context indicates that the configuration is formed into a rectangular block with all faces at 90 degrees to all adjacent wall faces. For example, in one example, the stack may be created with each strip 200 slightly offset from alignment with its adjacent strips, creating a parallelogram or angled block shape, with inlet and outlet faces parallel to one another, but not perpendicular to the top and bottom faces.

[0151] In one example, the media or media pack may be referred to as having a parallelogram shape in any cross section, meaning that any two opposing sides extend generally parallel to one another.

[0152] It is noted that a blocked stack configuration corresponding to FIG. 71 is described in the prior art of 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 Application No. 60 / 457,255, filed March 25, 2003, and U.S. Application No. 10 / 731,564, filed December 8, 2003 and published as 2004 / 0187689, each of which is incorporated herein by reference. It is noted that the stack configuration shown in U.S. Application No. 10 / 731,504, published as 2005 / 0130508, is a tilted stack configuration.

[0153] It should also be noted that in some instances, one or more stacks may be incorporated into a single media pack, and in some instances, the stacks may be produced with one or more flow faces having recesses therein, for example, as shown in U.S. Patent 7,625,419, which is incorporated herein by reference.

[0154] [C. A selected media or media pack configuration including multiple spaced coils of fluted media; Figs. 72-74] Alternative types of media configurations or packs, including flutes extending between opposing ends, may be used with selected principles in accordance with the present disclosure. Examples of such alternative media configurations or packs are depicted in Figures 72-74. The media of Figures 72-74 are similar to those depicted and described in German Utility Model DE 20 2008 017 059U1 and may be found in configurations available under the trademark "IQORON®" from Mann & Hummel.

[0155] Referring to FIG. 72, a media or media pack is generally indicated at 1250. The media or media pack 1250 includes a first media loop, an outer pleated (ridged) media loop 1251, and a second media loop, an inner pleated (ridged) media loop 1252, each having pleat tips (or ridges) extending between opposite flow ends. The view of FIG. 72 is toward the media pack (flow) end 1255. The depicted end 1255 may be the inlet (flow) end or the outlet (flow) end, depending on the flow direction selected. For many configurations using the characterized principles, having the media pack 1250 configured into a filter cartridge such that end 1255 is the inlet flow end.

[0156] Still referring to Fig. 72, the outer pleated (ridged) media loop 1251 is configured as an oval shape, although other configurations are possible. At 1260, pleat end closures, for example molded in place, are depicted closing the ends of the pleats or ridges 1251 at the media pack ends 1255.

[0157] The pleats or ridges 1252 (and associated pleat tips) are surrounded by and spaced from the loop 1251, thus further depicting the pleated media loop 1252 in a somewhat oval configuration. In this example, the ends 1252e of the individual pleats or ridges 1252p within the loop 1252 are sealed and closed. The loop 1252 also surrounds a center 1252c that is closed by a central strip 1253 of material, typically molded in place.

[0158] During filtering, when end 1255 is the inlet flow end, air enters gap 1265 between the two loops of media 1251, 1252. The air then flows through either loop 1251 or loop 1252 as it moves through media pack 1250 while filtering.

[0159] In the depicted example, loop 1251 is configured to extend from end 1255 and angle inwardly towards loop 1252. Spacer 1266 is also shown supporting centering ring 1267 that surrounds the end of loop 1252 for structural integrity.

[0160] In FIG. 73, end 1256 of cartridge 1250 is visible, opposite end 1255. Here, the interior of loop 1252 is seen, surrounding open gas flow region 1270. When air is flowed through cartridge 1250 in the general direction from end 1255 toward end 1256, the portion of the air passing through loop 1252 enters central region 1270 and exits therefrom at end 1256. Of course, in FIG. 72, air that enters media loop 1251 during filtering will generally pass around (over) the perimeter 1256p of end 1256.

[0161] 74 shows a schematic cross-sectional view of cartridge 1250. Selected identified and described features are designated with like reference numerals.

[0162] 72-74 and the above description, it will be understood that the described cartridge 1250 is generally a cartridge having a media leading edge extending longitudinally between opposing flow ends 1255, 1256.

[0163] 72-74, the media pack 1250 is depicted as having an elliptical, and specifically a racetrack-shaped, perimeter. Many of the example air filter cartridges below are depicted in this manner as well, since they also have an elliptical or racetrack-shaped configuration. However, the principles may be embodied with a variety of alternative perimeter shapes.

[0164] [D. Other examples of media changes, Figures 75 to 80] 75-80, schematic and fragmentary cross-sectional views are provided of some examples of additional alternative variations in media types that may be used in selected applications of the principles characterized herein. Specific examples are described in U.S. Patent Application 62 / 077,749, filed November 10, 2014, and owned by Donaldson Company, the assignee of the present disclosure. In general, each of the configurations of Figures 9-12 represents media types that may be stacked or coiled into configurations with straight-through flow and opposite inlet and outlet flow ends (or faces).

[0165] An exemplary media configuration 1301 from U.S. Patent Application 62 / 077,749 (2658) is shown in Figure 75. An embossed sheet 1302 is secured to a non-embossed sheet 1303, which are then stacked and coiled into a media pack with seals along opposing edges of the type previously described with respect to Figure 65 herein.

[0166] Figure 76 shows an alternative example media pack 1310 from U.S. patent application Ser. No. 62 / 077,749, in which a first embossed sheet 1311 is secured to a second embossed sheet 1312 and then formed into a stacked or coiled media pack configuration with edge seals generally consistent with Figure 65 herein.

[0167] Edge sealing may be performed at either the upstream or downstream end, or in some instances, both. It may be desirable to avoid common adhesives and sealants, especially where the media is likely to encounter chemicals during filtering.

[0168] In Fig. 77, a fluted sheet X is depicted in cross section with various embossments that engage with a facing sheet Y. As mentioned above, these may be separate or may be several sections of the same sheet of media.

[0169] FIG. 78 further illustrates a schematic diagram of such an arrangement between the fluted sheet X and the facing sheet Y.

[0170] FIG. 79 shows an example of an additional variation of this principle between fluted sheet X and facing sheet Y. This is meant to help understand how a wide variety of approaches are possible.

[0171] FIG. 80 shows yet another example of a possible variation of the fluted sheet X and the facing sheet Y.

[0172] 81 and 82 depict an exemplary media configuration 6401 in which a fluted sheet 6402 is secured to a facing sheet 6403. The facing sheet 6403 may be a flat sheet. The media configuration 6401 may then be stacked or coiled into a media pack with seals along opposing edges of the type previously described herein for FIG. 1. In the illustrated embodiment, the flutes 6404 of the fluted sheet 6402 have an undulating line of ridges that includes a series of peaks 6405 and saddles 6406. The peaks 6405 of adjacent flutes 6404 may be aligned or offset as shown in FIGS. 81 and 82. Additionally, the peak height and / or density may increase, decrease, or remain constant along the length of the flutes 6404. The ratio of peak flute height to saddle flute height may vary from about 1.5, typically 1.1, to about 1.

[0173] It should be noted that there is no particular requirement that the same media be used for the fluted sheet section and the facing sheet section. Different media may be desired for each to achieve different effects. For example, one may be a cellulosic media and the other may be a media containing some non-cellulosic fibers. They may have different porosities or different structural characteristics to achieve the desired results.

[0174] A variety of materials may be used. For example, the fluted sheet section or the facing sheet section may comprise a cellulosic material, a synthetic material, or a mixture thereof. In some embodiments, one of the fluted sheet section and the facing sheet section comprises a cellulosic material and the other of the fluted sheet section and the facing sheet section comprises a synthetic material.

[0175] The synthetic material(s) may include polymeric fibers such as polyolefin, polyamide, polyester, polyvinyl chloride, polyvinyl alcohol (with various degrees of hydrolysis), polyvinyl acetate fibers, etc. Suitable synthetic fibers include, for example, polyethylene terephthalate, polyethylene, polypropylene, nylon, rayon fibers, etc. Other suitable synthetic fibers include fibers made from thermoplastic polymers, cellulosic and other fibers coated with thermoplastic polymers, and multicomponent fibers in which at least one component comprises a thermoplastic polymer. Monocomponent and multicomponent fibers may be manufactured from polyester, polyethylene, polypropylene, and other conventional thermoplastic fibrous materials.

[0176] 75-82 are intended to generally illustrate that a variety of alternative media packs may be used in accordance with the principles of the present specification. Attention is also directed to U.S. Patent Application No. 62 / 077,749, which is incorporated herein by reference, for general principles regarding the construction and application of several alternative media types.

[0177] [E. Additional Media Pack Configurations Including Pleated Media with Flutes; Figures 83-86] 83-86 depict additional examples of alternative types of media configurations or packs, involving filtration media having flutes extending between opposing ends or flow faces in a straight-through configuration. The flutes may be considered inlet flutes if configured to admit dirty air via the inlet flow face, and outlet flutes if configured to allow filtered air to flow out via the outlet flow face.

[0178] The filtration media 6502 shown in FIGS. 83-85, which is similar to the filtration media shown in U.S. Patent No. 8,479,924 and U.S. Patent No. 9,919,256 assigned to Mann+Hummel GmbH, is illustrated in a configuration illustrating how the filtration media 6502 can be formed into a media pack configuration 6504.

[0179] The media pack configuration 6504 may be considered to have relatively long or deep pleats from the inlet flow face 6506 to the outlet flow face 6508, and may have various pleat depths as shown. As the pleat depth of the media pack increases, the filtration media tend to collapse against each other, thereby causing masking. Masking is undesirable because masking tends to cause the masked filtration media to no longer be available for filtration, thereby reducing the dust holding capacity and flow rate through the media pack, and may increase pressure loss across the media pack. To reduce masking and help the filtration media retain its shape, it is known to apply support structures to the pleated media. In FIGS. 84 and 85, support sections or spacers 6510 are provided. It is understood that FIGS. 84 and 85 are depicted in a folded configuration 6512 with pleat folds 6514, but are expanded or separated to illustrate how the filtration media 6502, as well as the support sections or spacers 6510, can be configured.

[0180] 84 and 85, the filtration media 6502 extends between a first side 6516 and a second side 6518. Although only one support section 6510 is shown on each pleat surface 6520, it is understood that multiple support sections 6510 may be disposed along each pleat surface 6520. Thus, when the filtration media 6502 is arranged in a media pack as shown in FIG. 83 as a media pack 6504, the volume between each support section 6510 may be considered as a flute extending between the inlet flow surface 6506 and the outlet flow surface 6508. As shown in FIG. 84, opposing support sections 6510 may be disposed on each flow surface 6520 such that they contact or engage each other to help maintain the shape of the media pack while limiting the amount of filtration media contacted by the support sections 6510. Additionally, by providing the support sections 6510 with adhesive properties, the support sections 6510 may be provided such that when the filtration media 6502 is placed in the media pack 6504, opposing support sections 6510 adhere to one another.

[0181] The support section 6510 may be configured with a cross section at the inner pleat 6522 that increases in cross section toward the outer pleat 6524. In this context, the phrase "inner pleat" refers to the side of the media that forms an acute angle and the phrase "outer pleat" refers to the side of the media that forms an obtuse angle when the media is placed in the media pack. Furthermore, references to varying the cross section of the support section 6510 may be in terms of one or both of the height that the support section extends away from the media to which it is bonded and the width along the media to which it is bonded in a direction across adjacent flutes toward or away from other support sections. Varying the shape of the support section 6510 can help maintain the shape of the media pack and the resulting flutes and can help reduce the amount of media that would otherwise be contacted by the support section 6510 if the support section 6510 was not configured with a tapered shape. In addition, the support section 6510 may be configured in a non-tapered configuration. As shown in FIG. 85, the support section 6510 may be provided to extend beyond the outer fold 6524, although it is not required that the support section 6510 extend beyond the outer fold. In addition, if desired, the support section 6510 may be provided to extend into the inner fold 6522, although it is not required that the support section 6510 extend into the inner fold 6522.

[0182] The support sections 6510 may be applied to the filtration media 6502 as an adhesive, where the adhesive is extruded onto the filtration media 6502 forming the support sections 6510. Prior to the point where the adhesive is fully cured, the filtration media 6502 may be folded into a media pack configuration 6504. The media pack configuration 6504 may or may not vary in pleat depth. By forming the media pack configuration 6504 before the adhesive is fully cured, the opposing support sections 6510 may be bonded or adhered to one another, thereby forming flutes extending between the inlet flow face 6506 and the outlet flow face 6508.

[0183] It is to be understood that the filtration media 6502 may have variations, such as corrugations, extending across the media. The direction of the variations, such as corrugations, may be parallel or perpendicular to the pleat fold direction.

[0184] The filtration media 6602 depicted in FIG. 86 is similar to the filtration media depicted in U.S. Publication No. 2018 / 0207566 assigned to Champion Laboratories, Inc. as another example of a media pack configuration 6604 having inlet and outlet flutes in a direct-flow configuration.

[0185] The filtration media pack configuration 6604 may be formed by folding the filtration media 6602 to form an inlet flow face 6606 and an outlet flow face 6608. The pleat tips 6610 form the inlet flow face 6606 and the pleat tips 6612 form the outlet flow face 6608. The adhesive beads 6616 and 6618 may be continuous or discontinuous and extend along the filtration media 6602 in a plurality of lines extending across the filtration media 6602 from the media first side 6620 to the media second side 6622. The adhesive beads 6616 and 6618 along the media first side 6620 and along the media second side 6622 may be thickened, if desired, and positioned to provide an edge seal along the media first side 6620 and the media second side 6622. By providing that the adhesive beads 6616 and 6618 adhere to one another when the filtration media 6602 is folded, the inlet flutes 6630 and the outlet flutes 6632 can be formed in the straight-through media pack configuration 6604.

[0186] A similar type of filtration media pack configuration is commercially available under the name Enduracube from Baldwin Filters, Inc. The filtration media pack available from Baldwin Filters, Inc. under the name Enduracube is configured with a pleated configuration that forms inlet and outlet flutes extending between inlet and outlet flow faces.

[0187] [F. Additional Media Types] Preferably, many of the techniques characterized herein apply when the media is oriented to filter between the opposing flow ends of the cartridge and has flutes or pleat tips extending in a direction between the opposing ends. However, this is not the only possibility. The techniques characterized herein for the definition of the seal configuration may be applied to a filter cartridge having opposing flow ends with media arranged to filter the fluid flow between the ends, even if the media does not include flutes or pleat tips extending in a direction between the ends. The media may be, for example, a depth media, pleated in alternating directions, or a non-pleated material.

[0188] However, the technology characterized herein is certainly advantageous for use with cartridges having a relatively deep extension between flow ends, 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, that are configured to provide a high loading during use. These types of systems are typically configured with media having pleated tips or flutes extending in a direction between opposing flow ends.

[0189] Also, the technology described herein has typically been developed for advantageous applications and configurations including media packs having a straight-through flow configuration. However, it is noted that the technology may be advantageously applied in other systems. For example, the technology may be applied where a cartridge includes media surrounding a central interior, the cartridge having an open end. Such configurations may involve a "forward flow" where the air to be filtered passes through the media into the central open interior and out the open end, or may involve a "backward flow" where the air to be filtered passes through the open end and then reverses and passes through the media. A variety of such configurations are possible, including pleated media and alternative types of media. Configurations that may be used include cylindrical, conical, and the like.

[0190] [IV. Summary] The principles described herein may be applied to a variety of filter assemblies. An example is described in which the principles are applied to (air) gas filter assemblies, such as air filters used to treat the intake air flow of an engine. The principles may be applied to a variety of alternative gas filtration configurations, and in some examples may be applied with liquid filter assemblies.

[0191] As can be seen, the principles, techniques, and features described herein may be applied to a variety of systems. Not all of the identified advantageous features need to be incorporated into an assembly, system, or component to obtain some benefit in accordance with the present disclosure. For example, the disclosed air filter cartridge 300, 300', 300" may have the disclosed seal member without having a handle. Further, the disclosed filter cartridge 200, 200', 200" may have a first portion of a catch arrangement, e.g., a locating feature, without having a handle, and vice versa. In addition, although the seal member 330, 330' has been described in some instances as being supported about (by) the shell 320, 320', the seal member 330, 330' may be supported directly on the periphery of the media pack 210, 210' itself. Additionally, the sealing arrangements 330", 331" of air cleaner 100" may be used with air cleaner 100, 100' in combination with the catch arrangements disclosed for those embodiments. Additionally, the catch arrangement of any one of air cleaner 100, 100', 100" may be used with any other one of air cleaner 100, 100', 100".

Claims

1. 1. A filter cartridge for an air purifier housing, comprising: (a) a media pack defining a periphery extending between an inlet flow end and an outlet flow end; (b) a shell circumferentially disposed around at least a portion of the periphery of the media pack; (c) a sealing member circumferentially disposed about the shell; The sealing member is (i) a radially oriented first seal arrangement that forms a seal between the filter cartridge and the air cleaner housing; (ii) a second radially oriented seal arrangement, separate from the first radially oriented seal arrangement, that forms a seal between the filter cartridge and another filter cartridge; the first seal arrangement is axially located between the second seal arrangement and the outlet flow end of the media pack. Filter cartridge.

2. 10. The filter cartridge of claim 1, wherein the seal member further includes a radially oriented third seal arrangement, the third seal arrangement forming a seal between the filter cartridge and the air cleaner housing.

3. 3. The filter cartridge of claim 1 or 2, wherein the first seal arrangement is an outward radially directed seal arrangement.

4. 3. The filter cartridge of claim 1 or 2, wherein the second seal arrangement is an outward radially directed seal arrangement.

5. 3. The filter cartridge of claim 1 or 2, wherein at least one of the first seal arrangement and the second seal arrangement includes a lip seal.

6. 3. The filter cartridge of claim 1 or 2, wherein the first seal arrangement is positioned radially closer to the longitudinal axis of the media pack than the second seal arrangement.

7. (a) a housing defining an interior volume; (b) a first filter cartridge disposed within the interior volume of the housing; and (c) a second filter cartridge disposed within the interior volume of the housing downstream from the first filter cartridge; The second filter cartridge includes a seal member, the seal member comprising: (i) a radially oriented first seal arrangement that forms a seal between the second filter cartridge and the housing; (ii) a second radially oriented seal arrangement that forms a seal between the second filter cartridge and the first filter cartridge; the first seal arrangement is axially located between the second seal arrangement and the outlet flow end of the media pack; Air purifier assembly.

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