Secure filter elements and filter assemblies

Abstract

The present disclosure relates to a filter element comprising a filter media pack extending along a longitudinal axis, a seal, and a support structure supporting the seal. The seal includes at least a first segment and a second segment adjacent the first segment, with at least a portion of the second segment axially spaced from the first segment. The filter media pack further includes a mating structure for engaging a complementary mating structure of a housing of a filter system, the support structure including a first circumferential radial surface and a second circumferential radial surface circumferential about the longitudinal axis, the mating structure of the filter element disposed on the first circumferential radial surface, and the seal disposed on the second circumferential radial surface.

Description

[Technical field]

[0001] The present disclosure relates generally to a filter element for filtering a fluid and to a filter assembly including a filter element and a housing for receiving the filter element. More particularly, the present disclosure relates to a filter element that is removably insertable into a housing of a filter system.

[0002] This application was filed as a PCT international patent application on April 21, 2023, which claims the benefit of and priority to European Patent Office Application Serial No. 22169544.8, filed April 22, 2022, which is incorporated by reference in its entirety. [Background technology]

[0003] Filter elements, also called filter cartridges, that filter fluids, which may be liquids or gases, including, for example, air, are used in a variety of filtering applications.

[0004] Typically, the filter element is one that is removed from the filter system housing and replaced at regular intervals, or when filter performance falls below a critical threshold.

[0005] Typically, the filter element comprises a filter media pack containing a filter media that removes contaminants as fluid passes through the filter media. Commonly used and commercially available filter media are, for example, pleated media or fluted media, also referred to as Z filter media.

[0006] The filter element further comprises a seal that seals against the interior wall of the filter system housing in addition to the filter media pack, thereby preventing the fluid being filtered from bypassing the filter media pack.

[0007] More sophisticated filter assemblies, such as automotive air filter assemblies, include two filter elements: a primary filter element, also referred to as the main filter element, and a secondary filter element, also referred to as the safety filter element.

[0008] The safety filter element backs up the main filter element, thus protecting the vehicle's engine, for example, while the primary filter is removed from the housing during service.

[0009] The safety filter element also protects the engine from hidden damage to the primary filter element, such as damage from cleaning, or from malfunction due to incorrect installation of the primary filter element or installation of an incorrectly sized primary filter element.

[0010] The life of the safety filter element is generally much longer than the life of the main filter element, for example 2 to 4 times longer. Therefore, the replacement intervals for the primary and secondary filter elements are different. For example, when replacing the main filter element, it is important to keep the safety filter element in place to protect the engine from dust and other materials that may damage it during maintenance operations. Summary of the Invention

[0011] Generally, when performing maintenance operations, it is important that new filter elements are correctly installed, e.g., oriented and secured, into the housing of the filter system. Furthermore, there is a need to provide filter elements and components that can be assembled in a simple and quick manner, thereby facilitating maintenance operations.

[0012] Thus, there is room for improving filter elements while facilitating maintenance procedures and ensuring secure and correct installation of the filter elements within the housing of the filter system.

[0013] It is an object of the present disclosure to provide a filter element for filtering a fluid that ensures quick and reliable installation of the filter element into a housing of a filter system and improves the serviceability of the filter element.

[0014] The present disclosure is defined in the accompanying independent claims. The dependent claims define advantageous embodiments.

[0015] According to a first aspect of the present disclosure, a filter element for insertion into a housing of a filter system is disclosed. In an embodiment, the filter element is, for example, a filter element for air purification.

[0016] The filter element includes a filter media pack for filtering fluid, a seal for preventing fluid from bypassing the filter media pack when the filter element is installed in a filter system, and a support structure for supporting the seal. The filter media pack includes a circumferential radial side extending along a longitudinal axis from a first axial end to a second axial end opposite the first axial end. The filter element is characterized in that the seal includes at least a first segment and a second segment adjacent the first segment, at least a portion of the second segment being axially spaced from the first segment. The filter element is further characterized in that it includes a coupling structure that interacts with a complementary coupling structure disposed within a housing of the filter system. The support structure for supporting the seal includes first and second circumferential radial surfaces that circumferentially extend along the longitudinal axis, the coupling structure of the filter element being disposed on the first circumferential radial surface, and the seal being disposed on the second circumferential radial surface.

[0017] When the terms "axially" or "axially spaced apart" are used, it should be interpreted as relative to the longitudinal axis, i.e., separation measured along the longitudinal axis.

[0018] Advantageously, the support structure, which simultaneously supports the seal and the coupling structure, allows for providing a reliable seal between the filter element and the housing of the filter system. The seal with offset seal segments allows for avoiding features, such as ribs, grooves, or recesses, on the inner surface of the housing, which would otherwise prevent a regular planar seal from sealing the space between the filter element and the inner surface of the housing. Furthermore, the coupling structure provides a uniform and reproducible pressure distribution at the seal, i.e. at each segment of the seal.

[0019] Furthermore, the combination of a seal having at least one seal segment axially separated from the adjacent seal segment and a coupling structure improves the serviceability of the filter element. In fact, due to the axial separation of the seal segments, the seal is only gradually compressed or, in the case of a lip seal, bent when the filter element is inserted into the housing and, for example, a rotational movement is performed on the filter element. When the filter element is inserted and rotation is started, only one or a limited number of segments, for example the second segment, are compressed or bent, and only when further rotation reaches the final sealing position, all segments, i.e. the first and second segments, are compressed or bent. This gradual compression of the seal allows the filter element to be smoothly installed in the housing of the filter system.

[0020] Using a seal having axially spaced segments, the sensor can be advantageously located in close proximity to the seal, thereby allowing for proper monitoring of the pressure differential between the inlet and outlet sides of the filter element.

[0021] Advantageously, by providing a seal including at least a first segment and an offset second segment, only a limited number of orientations are possible for the filter element to be installed in its sealed position, thereby allowing the filter element to be reproducibly reloaded.

[0022] In an embodiment, the seal is a lip seal including at least one circumferential sealing lip.

[0023] Advantageously, lip seals can be used in combination with coupling structures. Indeed, the use of a lip seal with a second segment extending axially from a first segment facilitates the rotational and translational movements with the filter element during installation of the latter in the housing of the filter system, since the flexibility of the sealing lip allows the lip seal to bend temporarily and appropriately inwards during the rotational movement. The amount of bending required during the rotational movement is variable and depends on the shape of the sealing surface of the housing. The sealing surface of the housing has, for example, a surface contour adapted to match the segment shape of the seal and to avoid the installation of an incorrect filter element.

[0024] Advantageously, when a filter element with a lip seal is mounted in a housing of a filter system, the higher the underpressure, the stronger the lip seal is seated in its sealing position and therefore the stronger the sealing effect.

[0025] In an alternative embodiment, the seal comprises a polyurethane seal, such as, for example, a foamed polyurethane seal.

[0026] According to a second aspect of the present invention, there is provided a filter assembly comprising a filter element and a housing encasing the filter element.

[0027] The housing includes a tubular framework disposed within the housing, the tubular framework having a first circumferential wall. A mating structure is disposed on the first circumferential wall of the tubular framework that is complementary to the mating structure of the filter element. The housing further includes a second circumferential wall forming a sealing surface configured to receive a seal of the filter element.

[0028] According to a preferred embodiment, the coupling structure of the filter element and the coupling structure of the housing are arranged and adapted to lock relative movement between the filter element and the housing, both axially and radially, when the filter element is fully installed in the housing. [Brief description of the drawings]

[0029] These and additional aspects of the present disclosure will now be described in further detail, by way of example only, with reference to the accompanying drawings in which:

[0030] [Figure 1a] 1A-1D are schematic perspective views of an embodiment of a filter element according to the present disclosure, showing a first end and a second end of the filter element, respectively. [Figure 1b] 1A-1D are schematic perspective views of an embodiment of a filter element according to the present disclosure, showing a first end and a second end of the filter element, respectively. [Figure 1c] FIG. 1b is a schematic side view of the filter element of FIG. [Figure 1d] FIG. 1c is a schematic cross-sectional view of the filter element shown in FIG. 1a, the cross-section being taken along the plane AA shown in FIG. [Figure 1e] FIG. 1b is a schematic top view of the filter element shown in FIG. [Figure 2a] FIG. 1b is a schematic cross-sectional view showing the insertion of the filter element shown in FIG. 1a into a housing of a filter system by performing rotational and translational movements on the filter element. [Figure 2b] FIG. 1b is a schematic cross-sectional view showing the insertion of the filter element shown in FIG. 1a into a housing of a filter system by performing rotational and translational movements on the filter element. [Figure 2c] FIG. 1b is a schematic cross-sectional view showing the insertion of the filter element shown in FIG. 1a into a housing of a filter system by performing rotational and translational movements on the filter element. [Figure 2d] FIG. 2b is an enlarged view of a portion of FIG. [Figure 3a]1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3b] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3c] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3d] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3e] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3f] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3g] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 3h] 1 illustrates generally an embodiment of a seal according to the present disclosure including a first segment and a second segment. [Figure 4a] 1 illustrates generally an embodiment of a seal according to the present disclosure including two first segments and two second segments. [Figure 4b] 1 illustrates generally an embodiment of a seal according to the present disclosure including two first segments and two second segments. [Figure 4c] 1 illustrates generally an embodiment of a seal according to the present disclosure including two first segments and two second segments. [Diagram 5] 1 shows a schematic of a portion of a filter media pack and a seal including a first segment and a second segment. [Figure 6a] FIG. 2 is a schematic perspective view of an embodiment of a lip seal of a filter element according to the present disclosure. [Figure 6b] FIG. 6b is a schematic side view of the seal of FIG. 6a. [Figure 6c]FIG. 6b is a schematic cross-sectional view of the seal shown in FIG. 6a, the cross-section being taken along the plane BB shown in FIG. 6b. [Figure 7a] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7b] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7c] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7d] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7e] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7f] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7g] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 7h] 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, in which the filter media pack includes an internal cavity. [Figure 8a] FIG. 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, where the filter media pack is a straight-through filter media pack. [Figure 8b] FIG. 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, where the filter media pack is a straight-through filter media pack. [Figure 8c] FIG. 1 is a schematic cross-sectional view of an embodiment of a filter element according to the present disclosure, where the filter media pack is a straight-through filter media pack. [Figure 9] FIG. 2 is a schematic perspective view of a portion of one embodiment of a housing for a filter system. [Figure 10a] 2a-2c depict a housing according to an alternative preferred embodiment of the present disclosure, similar to the housing described in connection with FIGS. 2a-2c and further including a filter element centering tower. [Figure 10b] 2a-2c depict a housing according to an alternative preferred embodiment of the present disclosure, similar to the housing described in connection with FIGS. 2a-2c and further including a filter element centering tower. [Figure 11a] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 11b] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 11c] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 11d] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 11e] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 11f] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 11g] 13 illustrates various alternative embodiments of an end cap for a second axial end of the filter element. [Figure 12a] 1 shows a further preferred embodiment according to the present disclosure. [Figure 12b] 1 shows a further preferred embodiment according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The present disclosure will be described in terms of specific embodiments, which are illustrative of the present disclosure and are not to be construed as limiting. It will be understood by those skilled in the art that the present disclosure is not limited by what has been specifically shown and / or described, and that alternative or modified embodiments may be developed in light of the overall teachings of the present disclosure. The drawings described are only schematic and non-limiting.

[0032] Use of the verb "to comprise" and its respective conjugations does not exclude the presence of elements other than those listed. The use of the articles "a", "an" or "the" preceding an element does not exclude the presence of a plurality of such elements.

[0033] Moreover, in this specification and claims, terms such as first, second, etc. are used to distinguish between similar elements and not necessarily to describe any order in time, space, ranking, or otherwise. The terms so used are interchangeable under appropriate circumstances, and it is to be understood that the embodiments of the disclosure described herein are capable of operation in orders other than those described or illustrated herein.

[0034] References throughout this specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in one or more embodiments of the present disclosure. Thus, the phrases "in one embodiment" or "in an embodiment" appear in various places throughout this specification. All may, but do not necessarily, refer to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0035] The words "preferred" and "preferably" refer to embodiments of the invention that may offer certain advantages, under particular circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0036] [Filter Element] The filter element for filtering the fluid is a serviceable component, i.e., a component that is removable and replaceable from the housing of the filter system. The filter element may be, for example, an air filter element for cleaning an air stream for an automobile or other filter system in which an air stream is cleaned.

[0037] 1a-1e, 7a-7h, and 8a-8c, various views of example embodiments of filter elements according to the present disclosure are shown. These filter elements 1 can be interpreted as either a main or primary filter element, or as a safety or secondary filter element that backs up the main filter element.

[0038] The filter element 1 includes a filter media pack 10 for filtering fluid, a seal 30 for preventing fluid from bypassing the filter media pack when the filter element is installed in a filter system, and a support structure 20 for supporting the seal 30.

[0039] In an embodiment, the support structure 20 is sealingly attached to the filter media pack 10. For example, this attachment between the support structure 20 and the filter media pack 10 may be by adhesive, heat welding, or any other suitable means.

[0040] The filter element according to the present disclosure is characterized in that the seal 30 includes at least a first segment S1 and a second segment S2 adjacent to the first segment S1. At least a portion PS2 of the second segment S2 is axially spaced from the first segment S1.

[0041] Additionally, the second segment S2 may be referred to as an offset segment because it is axially offset from the first segment.

[0042] "Axially" should be interpreted as relative to the longitudinal axis Z. Thus, axially spaced should be interpreted as spaced along the longitudinal axis Z.

[0043] A portion PS2 of the second segment S2 that is axially spaced from the first segment S1 means that the portion PS2 of the second segment is located at a different axial position compared to the axial position of the first segment S1.

[0044] In other words, there is at least a portion SP2 of the second segment S2 that is separated from the first segment S1 by a non-zero axial separation distance ΔD measured along the longitudinal axis Z. The cross-sectional views of the filter element shown in Figures 1c, 5, 7a-7h, and 8a-8c generally illustrate the non-zero axial separation distance ΔD between the first and second segments of the seal 30.

[0045] By use of the term "segment," it is intended only to denote a portion of the seal, regardless of the overall shape of the seal. Also, the portion of the second segment axially spaced from the first segment need not be entirely straight, planar, curved, or of any particular shape, unless otherwise specified. Detailed examples of embodiments of seals having different shapes are discussed further below.

[0046] The fact that there is a non-zero axial separation distance ΔD between a portion of the first segment S1 and the second segment S2 does not preclude that in an embodiment there may be an additional non-zero separation distance measured in a direction perpendicular to the longitudinal axis Z between the same or another portion of the first segment S1 and the second segment S2. In other words, in an embodiment, the second segment may be spaced apart from the first segment both axially, i.e., parallel to the longitudinal axis Z, and radially, i.e., perpendicular to the longitudinal axis Z.

[0047] The filter element according to the present disclosure is further characterized in that the filter element 1 is provided with a mating structure that engages with a complementary mating structure on the housing of the filter system.

[0048] For example, as shown in Figures 7a-7h and 8a-8c, the support structure 20 includes a first circumferential radial surface 22a orbiting the longitudinal axis Z. The filter element bonding structures 40a, 40b, 50 are disposed on the first circumferential radial surface 22a. The support structure 20 further includes a second circumferential radial surface 22b, 23a orbiting the longitudinal axis Z, and the seal 30 is disposed on the second circumferential radial surface 22b, 23a. Thus, a single support structure 20 is used to support both the seal 30 and the bonding structures.

[0049] The first orbiting radial surface 22a and the second orbiting radial surface 22b should not be construed as the same surface but as two different surfaces, i.e. two different and distinguishable surfaces.

[0050] The coupling structure, in combination with the seal having offset segments, allows a secure coupling between the filter element and the housing of the filter system, whereby a uniform and reproducible sealing force can be applied to each of the seal segments. Also, the risk of incorrectly installing the filter element in the housing of the filter system is strongly reduced or eliminated. Furthermore, the seal is only gradually compressed when installing the filter element in the housing of the filter system, facilitating installation of the filter element.

[0051] In an embodiment, the first orbiting radial surface 22a is parallel to the second orbiting radial surface 22b.

[0052] In an embodiment, the first circumferential radial surface 22a and / or the second circumferential radial surface 22b are parallel to the longitudinal axis Z. For example, in the filter configurations shown in Figures 7a-7c, 7g, 7h and 8a-8c, the first circumferential radial surface 22a and the second circumferential radial surface 22b are shown to be parallel to the longitudinal axis Z.

[0053] On the other hand, in the embodiment shown in Figures 7d to 7f, the first circumferential radial surface 22a, i.e. the surface supporting the bonding structure, is parallel to the longitudinal axis, while the second circumferential radial surface 23a, i.e. the surface supporting the seal, is inclined at an angle θ (or α) to the longitudinal axis Z.

[0054] More generally, in an embodiment, the second circumferential radial surface 23a supporting the seal 30 is inclined relative to the first circumferential radial surface 22a supporting the mating structure.

[0055] In an embodiment, the second orbiting radial surface 23a is inclined at an angle θ with respect to the longitudinal axis Z, where 5°≦θ≦85°, preferably 20°≦θ≦60°, and more preferably 30°≦θ≦50°. In an embodiment in which the second orbiting radial surface 23a is inclined with respect to the first orbiting radial surface 22a, the same ranges for the angle θ apply.

[0056] In an embodiment, the support structure 20 includes a first circumferential radial wall 22 circumferential about the longitudinal axis Z. The first circumferential radial wall 22 includes a first side and a second side opposite the first side, the first side corresponding to a first circumferential radial surface 22a supporting the coupling structure. In an embodiment, the second side of the first circumferential radial wall 22 corresponds to a second circumferential radial surface 22b supporting the seal 30, as shown in Figures 7a to 7c, 7g, 7h, and 8a to 8c. Thus, in these embodiments, the seal is located on one side of the circumferential radial wall 22 and the coupling structure is located on the opposite side.

[0057] Advantageously, because the seal 30 has a second segment S2 axially spaced from the first segment S1, when, for example, a protrusion is provided on one side of the first encircling radial wall 22 and the seal 30 is located on the other side of the first encircling radial wall 22, the relative positions of the protrusion and the seal segments can be defined such that the seal avoids potential sink marks of the protrusion, such as injection moulding sink marks on surface 22b, due to the presence of the protrusion on surface 22a, thereby improving the sealing performance of the seal 30.

[0058] In an embodiment, the first side, i.e., first radial surface 22a, and the second side, i.e., second radial surface 22b, of the first circumferential radial wall 22 are the radially inner and radially outer sides, respectively, of the first circumferential radial wall 22.

[0059] In other embodiments, as shown for example in Fig. 7h, the first side or first radial surface 22a and the second side or second radial surface 22b of the first circumferential radial wall 22 are respectively the radially outer and inner sides of the first circumferential radial wall 22. In other words, depending on the embodiment, the first circumferential radial surface 22a supporting the coupling structure is either the inner radial surface or the outer radial surface.

[0060] For example, in embodiments in which the filter element attachment structure is a pin, e.g., a bayonet pin, the pin is disposed radially inward of the first circumferential radial wall 22. In other embodiments, the pin, e.g., a bayonet pin, is disposed radially outward of the first circumferential radial wall 22.

[0061] In embodiments, such as those in which seal 30 is coupled to first circumferential radial wall 22, the seal is a radial seal that seals radially to the housing of the filter system, e.g., the seal is radially compressed when the filter element is installed in the housing of the filter system.

[0062] In embodiments in which the seal 30 is mounted radially outward of the first circumferential radial wall 22, the seal 30 is an outwardly directed radial seal.

[0063] In the case of embodiments in which the second circumferential radial surface 23a supporting the seal 30 is inclined, the support structure 20 not only includes the first circumferential radial wall 22 but also includes a second circumferential radial wall 23 circumferential about the longitudinal axis Z, the second circumferential radial wall 23 being inclined with respect to the longitudinal axis Z. In these embodiments, the surface side of the second circumferential radial wall 23 corresponds to the second circumferential radial surface 23a. Examples of such second circumferential radial walls 23 are shown diagrammatically in Figures 7d to 7f. In these embodiments, as described above, the first side of the first circumferential radial wall 22 has a first side corresponding to the first circumferential radial surface 22a supporting the coupling structure.

[0064] Advantageously, when the filter element is mounted in a filter system housing using angled radial walls to support the seal, the seal 30 acts partly as a radial seal and partly as an axial seal, improving sealing performance.

[0065] In an embodiment, at least a portion of the first circumferential radial wall 22 of the support structure 20 forms a tubular element extending along the longitudinal axis Z. The tubular portion is configured to drain filtered fluid from the filter media pack.

[0066] In an embodiment, as shown in Figures 7a-7g and 8a-8b, at least a portion of the first circumferential radial wall 22 of the support structure 20 has a cylindrical shape. In this manner, the first circumferential radial wall 22 forms a tubular element extending along the longitudinal axis Z and is configured to drain filtered fluid from the filter media pack.

[0067] As shown in Figures 1a and 1d, in some embodiments, the first circumferential radial wall 22 forms a tubular element. The ends of the circumferential radial wall 22 are contoured or stepped and follow a shape that matches the shape of the first and second segments of the seal.

[0068] In an embodiment, the inner and / or outer parts of the first circumferential radial wall are parallel to the longitudinal axis Z. For example, if the first circumferential radial wall 22 has the shape of a tube, both the inner and outer parts of the first circumferential radial wall are parallel to the longitudinal axis Z. In an embodiment, the cross section of the first circumferential radial wall 22 in a plane perpendicular to the longitudinal axis Z may have the shape of, for example, a circle or an ellipse.

[0069] In embodiments, the support structure 20 and / or the bonding structure are formed or at least partially formed from a thermoplastic material, preferably the thermoplastic material is any of the following materials or mixtures and combinations thereof: acrylonitrile butadiene styrene, polypropylene, polyamide, polyethylene terephthalate, polylactic acid, polyethylene, polycarbonate, polystyrene, or polyvinyl chloride.

[0070] In embodiments, the seal 30 is formed or at least partially formed from any of the following materials, or mixtures or combinations thereof: rubber, thermoplastic elastomer (TPE), thermoset elastomer, thermoplastic vulcanizate, or polyurethane. Most disclosed embodiments utilize or are illustrated with one or more lip seals, preferably including TPE. However, FIG. 11b shows an example using a polyurethane seal 30.

[0071] In an embodiment, the support structure 20 forms a unitary body, which may be achieved, for example, by a molding manufacturing process.

[0072] In embodiments, the seal 30 may be removably coupled to the support structure 20, for example, by providing a seal receiving groove in the support structure. In other embodiments, the seal 30 is permanently attached to the support structure 20, for example, by adhesive, injection molding, or any other means.

[0073] In an additional embodiment, both the support structure 20 and the seal 30 form a single body manufactured by a multi-component injection molding manufacturing process.

[0074] In a preferred embodiment, the support structure 20, seal 30 and bonding structure of the filter element form a single body manufactured by a multi-component injection molding manufacturing process, resulting in a robust filter element obtained in a cost-effective manner.

[0075] The support structure 20 is sealingly attached to the filter media pack, which in embodiments may be a permanent attachment formed, for example, by adhesive or heat welding.

[0076] The seal 30 may be removably coupled to the second orbiting radial surface 22b, 23a, or (or) the seal may be permanently coupled to the second orbiting radial surface.

[0077] In an embodiment, the filter element includes a closed end cap 25 and an open end cap at the first axial end 11 and the second axial end 12 of the filter media pack, respectively. In an embodiment, as shown, for example, diagrammatically in Figures 7a and 7b, the first circumferential radial wall 22 includes axial sides that form a flange member 21 that is attached to the second axial end 12 of the filter media pack to form an open end cap at the second axial end 12 of the filter media pack. The flange member 21 is a flange that includes a central opening.

[0078] In the embodiment shown in Figures 1c, 1d and 8c, the support structure 20 includes a flange member 21 that is configured to attach to the second axial end 12 of the filter media pack and form an open end cap at the second axial end 12 of the filter media pack. The flange member is thus, for example, a flange that includes a central opening for discharging filtered fluid. In an embodiment, the flange member 21 is attached to the axial end of the first circumferential radial wall 22. The flange member 21 may extend radially inwardly or radially outwardly, or both, and accordingly may have radially inwardly and radially outwardly extending portions.

[0079] According to a preferred embodiment, the seal 30 includes a seal extension 31, which partially or completely covers one or more surfaces defined by the flange member 21, such as the surface of the radially outwardly extending portion thereof. For example, the seal 30 may extend over both the upper and lower surfaces of the flange member 21, such as both the upper and lower surfaces of the radially outwardly extending portion thereof, thereby preferably further covering the radially outer surface of the flange member 21, such as shown in Figures 11c to 11g. For example, the seal 30 preferably further covers the radially outer surface of the radially outwardly extending portion of the flange member 21.

[0080] According to an alternative preferred embodiment, the seal 30 does not include such a seal extension 31, but is applied solely or primarily to the second circumferential radial surface 22b. In such an embodiment, the seal preferably does not cover the surface of the radially outwardly extending portion of the flange 21.

[0081] In embodiments where the filter element is a safety filter element, i.e., a secondary filter element backing up a primary filter element, the flange member 21 of the support structure 20 further includes one or more wing members 24, as shown in Figures 1a and 1e. These wing members 24 are to be construed as alignment members that align the primary filter element with respect to the safety filter element.

[0082] In a preferred embodiment of the present disclosure, the end cap or seal support structure 20 of the filter element 1 includes a shoulder or flange 26 that projects radially inward, for example at an axial height corresponding to the flange member 21. Such shoulder or flange 26 provides an additional stop surface that (at least in part) defines the axial position of the filter element 1 within the filter housing 100. The shoulder 26 has a limited radial extent (only a few mm or 1 mm) so as not to increase the restriction of the filter element. The shoulder or flange 26 preferably abuts against the inner liner of the filter element 1.

[0083] According to a preferred embodiment, shoulder or flange 26 corresponds to or includes a radially inwardly projecting portion of flange 21 .

[0084] 12a and 12b show a further preferred embodiment of the present disclosure. It comprises a support structure 20 or end cap, which further comprises a third circumferential radial surface 22c. A second or additional seal 30A is disposed on the third circumferential radial surface 22c. The third circumferential radial surface 22c and the second circumferential radial surfaces 22b, 23a are provided on axially opposite sides of the flange member 21, for example on axially opposite sides of the radially outwardly extending portion of the flange member 21. One or both of the seal 30 and the additional seal 31 (additional seal 30A, seal extension 31) can be embodied as described for the seal 30. According to a preferred embodiment, the seal 30 and the additional seal 30A are axially spaced apart. Preferably, they are adapted and configured to have a first seal that seals against the filter housing and a second seal that seals against another filter element.

[0085] [Bond structure] Various types of mating structures for the filter element that can be engaged with complementary mating structures on the housing of the filter system may be utilized.

[0086] In an embodiment, the mating structure of the filter element includes one or more protrusions 40a, 40b, 40c, 40d for engaging protrusion-receiving elements of a complementary mating structure of the housing of the filter system.

[0087] The protrusions are disposed on a first circumferential radial surface 22a of the support structure 20. In an embodiment, the protrusions protrude radially from the first circumferential radial surface 22a.

[0088] In an embodiment, the protrusions are either pins, knobs, ribs, embossments, pivots, nipples, or combinations thereof.

[0089] In a preferred embodiment, the projections extend radially inwardly, thereby forming respective undercuts, for example.

[0090] With reference to Figures 1e, 7a-7f, 7h, and 8a-8c, the protrusions are represented as pins 40a, 40b, 40c, and 40d that protrude radially from the first orbiting radial surface 22a. For example, Figure 7a depicts one pin 40a protruding from the first orbiting radial surface 22a, Figure 7b depicts two pins 40a and 40b, and Figure 1e depicts an embodiment having four pins 40a, 40b, 40c, and 40d. Additionally, the pins may be referred to as tabs.

[0091] 11a-11g show various alternative embodiments of the end cap at the second axial end of the filter element, illustrating potential shapes of the projection or pin 40. For example, the projection 40 may comprise a cylindrical, possibly hollow, pin (FIGS. 11a, 11b). Alternatively, the projection may comprise a rib extending longitudinally parallel to the axis of the filter element (FIG. 11c). Alternatively, the projection 40 may comprise a hemispherical knob (FIG. 11e). As a further alternative, the projection 40 may be generally cross-shaped, with a vertical extension portion extending longitudinally parallel to the filter element axis and a horizontal extension portion perpendicular to the vertical extension portion (FIG. 11f). As a further alternative, the projection 40 may be generally U-shaped, with the U-shape having, for example, an axis extending parallel to the filter element axis, with a U-shaped opening oriented, for example, away from the filter element (FIG. 11d).

[0092] In a preferred embodiment, the seal support structure 20 includes a continuous, stepped or contoured axial rim or end face 27. Preferably, the seal is disposed adjacent to or abuts and follows the axial end face 27. Thus, the axial end face 27 may be embodied in different shapes as disclosed for the seal in the "Example Seals" section of this disclosure.

[0093] In a preferred embodiment, the undulating or stepped axial end face 27 has a maximum amplitude or height difference (preferably corresponding to a maximum height difference or amplitude of the seal 30). The undulating or stepped axial end face may have a series of local maximum heights (peaks) and minimum heights (valleys). It can be seen that the end face includes alternating valleys and hills defining lobes L (see e.g. Figures 11a to 11e, where the valley levels are indicated by dotted lines) that extend axially.

[0094] Preferably, all of the protrusions are located on the first circumferential radial surface 22a, e.g., the inner cylindrical surface of the end cap. Preferably, but not necessarily, at least one, some or all of the protrusions 40 are located adjacent to and / or abutting the axial end face 27. Preferably, the protrusions 40 are located at positions corresponding to one or more local or global maximum heights (peaks) of the axial end face 27. Preferably, the protrusions 40 are located at positions corresponding to each local or global maximum height (peak) of the axial end face 27.

[0095] According to preferred embodiments, the axial height of one, some or each of the protrusions 40 is less than 150%, or less than 125%, or less than 100%, or less than 90%, or less than 75%, or less than 50%, or less than 35% of the axial height of the respective axially extending lobe L.

[0096] In another view, the projections 40 are preferably arranged to extend radially inwardly and are disposed in or primarily or completely within respective axially extending lobes defined by the axial end surface 27, which is preferably contoured or stepped. Figure 11g shows an example in which the axial end surface 27 extends beyond the projections 40 such that the projections do not extend to the axial ends of the surface 27, as is the case in the embodiment shown in Figures 11a to 11f. However, the projections 40 of the embodiment shown in Figures 11a to 11f may in some instances be inset from the end surface in the same manner as shown in Figure 11g.

[0097] According to a preferred embodiment, the location of the upper (i.e., axially inwardly facing) surface of one, some, or each of the projections 40 is located (axially) at a distance from the axial end face 27. This distance is less than 150%, or less than 125%, or less than 100%, or less than 90%, or less than 75%, or less than 50%, or less than 35% of the axial height of each axially extending lobe L.

[0098] Preferably, each protrusion forms or defines a respective undercut, the latter allowing for fixing the position of the filter element within the corresponding housing in the axial direction (e.g., by hooking after a corresponding housing feature, such as a feature of slot 110, or a similar feature).

[0099] Preferably, the undercut surface provides an additional locking engagement with the housing to ensure that the filter element remains securely in place during use.

[0100] The shape and location of the protrusions are preferably designed and predetermined to optimize the locking engagement while minimizing the effort required to install and remove the filter element.

[0101] In an embodiment, the coupling structure of the filter element is a bayonet coupling structure, and the protrusion of the coupling structure is, for example, a bayonet pin configured to engage with a corresponding bayonet slot of the housing of the filter system, the bayonet slot typically having an arc shape to allow the bayonet pin to rotate and move within the slot.

[0102] In practice, bayonet coupling generally requires a combination of rotational and translational movement about the longitudinal axis of the filter element to securely couple the filter element to the filter system housing. Depending on the geometry of the bayonet slot, a rotation of between 30° and 90° is typically required.

[0103] In other embodiments, the coupling structure is configured to form a closure between the coupling structure of the filter element and the complementary coupling structure of the housing of the filter system by translational movement parallel to the longitudinal axis, i.e., no rotational movement. In these embodiments, the engagement between the coupling structure of the filter element and the coupling structure of the housing of the filter system can be, for example, a snap-fit ​​connection.

[0104] In an embodiment, instead of protrusions, the mating structure of the filter element includes one or more protrusion receiving elements 50 that engage with protrusions of a complementary mating structure of the housing of the filter system.

[0105] In embodiments, the protruding receiving element is a slot 50 or groove disposed in the first circumferential radial surface 22a, as shown for example in Figure 7g. For these embodiments, the complementary structure on the filter housing includes, for example, a pin.

[0106] Typically, when the coupling structure of the filter element includes a slot or groove, the slot or groove may have an arc shape to form a bayonet coupling, In an embodiment, the slot or groove may have a locking end configured to lock the pin when the pin reaches the end of the slot or groove.

[0107] The number of protrusions, or alternatively the number of protrusion receiving elements, in the coupling structure of the filter element may vary from embodiment to embodiment. By providing more than one protrusion or protrusion receiving element, the sealing force acting on the seal is more evenly distributed. In an embodiment, the coupling structure of the filter element includes two or more protrusions, for example two or more pins 40a, 40b. The coupling structure preferably includes three or more protrusions, for example three or more pins 40a, 40b, 40c, and more preferably includes four or more protrusions, for example four or more pins 40a, 40b, 40c, 40d.

[0108] In an alternative embodiment, the filter element's bonding structure includes two or more protruding receiving elements 50, preferably three or more protruding receiving elements, and more preferably four or more protruding receiving elements. The protruding receiving elements may be, for example, slots or grooves.

[0109] Preferably, in order to apply uniform pressure to the various segments of the seal, the number of protrusions, e.g., pins, or the number of protrusion receiving elements, e.g., slots, is determined in relation to the number of second segments S2 of the seal 30, i.e., the number of displacing segments.

[0110] In an embodiment in which the filter element bonding structure includes a plurality of protrusions 40a, 40b, 40c, 40d and a plurality of first segments S1 and second segments S2, the number of protrusions is selected to be equal to or greater than the number of second segments S2.

[0111] Similarly, in embodiments in which the filter element bonding structure includes a plurality of protrusion receiving elements 50 and a plurality of first segments S1 and second segments S2, the number of protrusion receiving elements is selected to be equal to or greater than the number of second segments S2.

[0112] [Example of sticker] As mentioned above, the seal according to the present disclosure includes at least a first segment S1 and a second segment S2, characterized in that at least a portion PS2 of the second segment S2 is spaced apart from the first segment S1 in the axial direction, i.e., with respect to the longitudinal axis Z. In other words, in the direction of the longitudinal axis Z, there is a non-zero axial separation distance ΔD, ΔD1, ΔD2 between at least a portion PS2 of the second segment S2 and the first segment S1.

[0113] To illustrate examples of different shapes of seals including such second segments offset from the first segment according to the present disclosure, Figures 3a to 3h show schematic diagrams of different embodiments of such a seal 30. These schematic diagrams are to be interpreted as if the seal were cut and placed on a flat plane. In this first set of examples, the seal 30 includes one first segment S1 and one second segment S2, each having a first circumference or length φ1 and a second circumference or length φ2, respectively. The sum of the first and second circumferences (or lengths) is equal to the total circumference φ of the seal 30.

[0114] In embodiments, as shown in Figures 3a, 3b and 3h, the second segment S2 includes a central segment portion S2,c and two transition segment portions S2,t1 and S2,t2 adjacent to the central segment portion S2,c. The central segment portion S2,c is oriented parallel to the first segment S1. In these embodiments, the two transition segment portions S2,t1 and S2,t2, or at least a portion of the two transition segment portions, are oriented at an oblique angle to the first segment S1 and also at an oblique angle to the central segment portion S2,c. Such an offset second segment S2 having two transition segment portions may be referred to as a trapezoidal segment. This type of seal may be more generally referred to as a stepped seal. As shown in the figures, in these embodiments, the second segment S2 includes a portion PS2, i.e., the central segment portion S2,c, axially separated from the first segment S1 by a separation distance ΔD.

[0115] In embodiments in which the first segment S1 is parallel to the central portion S2,c of the second segment S2, the separation distance ΔD is also the maximum axial separation distance ΔD between the first and second segments, which may also be referred to as the step height.

[0116] In embodiments, the transition portions S2,t1 and S2,t2 may have the same circumferential length, as shown generally in Figure 3a, while in other embodiments the circumferential lengths of the transition portions may be different, i.e. the slopes of the transition portions are different, as shown, for example, in Figure 3b.

[0117] The shape of the seal shown in Fig. 3h is the same as that shown in Fig. 3a, i.e., the stepped seal as described above, but in Fig. 3h it is explicitly shown that the seal has a height H measured along the longitudinal axis Z. Preferably, in the embodiment, the height H of the seal 30 measured along the longitudinal axis Z is selected to be smaller than the maximum separation distance ΔDMAX between the first segment S1 and the second segment S2. This avoids, for example, an incorrect filter element having a flat seal being installed in the filter system.

[0118] Referring to FIG. 3c, an additional embodiment of seal 30 is shown in which at least a portion PS1 of a first seal segment S1 is parallel to a portion PS2 of a second seal segment S2.

[0119] In the embodiment shown in Fig. 3d, the second segment S2 also includes a central portion S2,c and two adjacent transition portions S2,t1 and S2,t2. However, in this embodiment, the first segment is not parallel to the central portion S2,c, as in the embodiment shown in Fig. 3a and 3b. Also, in this embodiment shown in Fig. 3d, a maximum separation distance ΔDmax can be identified as the maximum separation distance between the first and second segments, measured along the longitudinal axis Z. As shown diagrammatically in Fig. 3d, a part PS2 of the second segment, i.e. the central portion S2,c, is separated from the first segment S1 by a separation distance ΔD in the axial direction. In this embodiment, the maximum separation distance ΔDmax can also be interpreted as the step height.

[0120] Referring to Fig. 3e, an embodiment of a seal having a triangular shape is shown, i.e., the first and second segments have a triangular shape. Again, the first segment S2 includes at least a portion PS2 axially spaced from the first segment. Depending on which portion of the portion PS2 is selected, the separation distance to the first segment may vary between a first separation distance ΔD1 and a second separation distance ΔD2. Furthermore, Fig. 3e shows a maximum separation distance ΔDmax between the first segment S1 and the second segment S2.

[0121] With reference to Figures 3f and 3g, wave-type seals are shown in which the seal 30 has a wave shape. In these types of embodiments, first and second segments S1, S2 can be specified in which at least a portion PS2 of the second segment S2 is axially spaced from the first segment S1. An example of an arbitrary selection of such a portion PS2 is shown diagrammatically in Figures 3f and 3g, but of course any other selection is possible, i.e. selecting the PS2 segment portion narrower or wider. In the case of wave-type seals, the maximum separation distance between the first and second segments can be specified as being equal to ΔDmax. In a preferred embodiment, the height H of the seal 30 is lower (smaller) than the maximum separation distance ΔDmax.

[0122] In an embodiment, the seal 30 includes a plurality of first segments S1 and a plurality of second segments S2, each of the first segments being interleaved with one of the second segments. Figures 4a and 4b show an example of an embodiment including two first segments S1 and two second segments S2. Figures 6a and 6b show an example of an embodiment of the seal including three first segments S1 and three second segments S2.

[0123] When a seal includes a plurality of first segments and a plurality of second segments, the separation distance ΔD between adjacent first and second segments is not necessarily the same for all pairs of first and second segments. With reference to the embodiment shown in FIG. 4a and FIG. 6a-6c, the separation distance ΔD is the same for all pairs of first and second segments. In other embodiments, a pair of first and second segments S1 and S2 may be separated by a first separation distance ΔD1, as shown in FIG. 4b, for example. Meanwhile, another pair of first and second segments S1 and S2 may be separated by a second separation distance ΔD2 different from the first separation distance.

[0124] An example of a stepped seal configuration for a filter media pack is shown in Figure 5. In this example, the seal 30 includes one first segment S1 and one second segment S2. Both portions of the first segment S1 are at the same axial distance D1 from the second axial end 12 of the filter media pack 10, while each portion of the second segment S2 is at a distance from the second axial end 12 that varies between the first axial distance D1 and a second axial distance D2 that is greater than the first axial distance D1.

[0125] In embodiments, the portions of the first segment S1 of the seal 30 are both located at the same axial distance D1 from the second axial end 12 of the filter media pack, while the portions of the central segment portion S2,c of the second segment S2 are both located at the same second axial distance D2 from the second axial end 12 of the filter media pack, the second axial distance D2 being different from the first axial distance D1. Typically, in these embodiments, the second segment S2 further includes two transition segment portions S2,t1 and S2,t2 adjacent the central segment portion S2,c, as described above. For each transition segment, a portion of the segment is located at an axial distance that varies between the first axial distance D1 and the second axial distance D2 from the second axial end of the filter media pack. The first and second axial distances are measured in a direction parallel to the longitudinal axis Z.

[0126] In an embodiment, as shown in Figures 3a to 3h, the maximum separation distance ΔDmax between the first segment S1 and the second segment S2 measured along the longitudinal axis Z is between 5 mm and 200 mm, more preferably between 5 mm and 150 mm.

[0127] In an embodiment, the seal 30 is of the type commonly referred to as a lip seal or wiper seal. Such a lip seal 30 includes at least one circumferential sealing lip 30a, 30b, 30c. The embodiment of the filter element shown in Figures 1a-1d includes a seal having two circumferential sealing lips 30a, 30b. The embodiment of the seal 30 shown in Figures 6a-6c is an example of a lip seal 30 that includes three circumferential sealing lips 30a, 30b, 30c.

[0128] In embodiments in which the lip seal includes two or more circumferential sealing lips 30a, 30b, 30c, the sealing lips are generally disposed in a spaced parallel relationship.

[0129] In an embodiment, the circumferential sealing lips 30 a , 30 b , 30 c are disposed at an oblique angle relative to the first circumferential radial wall 22 .

[0130] In an additional embodiment, the circumferential sealing lip of the lip seal has a small inclination relative to the base of the lip seal, thus providing a preferred twist direction.

[0131] The lip seal in combination with the joint facilitates the execution of rotational and translational movements by the filter element during installation of the filter element into the housing of the filter system, since the flexibility of the sealing lip allows the stepped lip seal to temporarily and appropriately flex inward during rotational movement.

[0132] [Filter media pack] Filter elements according to the present disclosure are not limited to any particular filter media pack.

[0133] Typically, the filter media pack 10 of a filter element 1 according to the present disclosure includes a circumferential radial side 15 that extends along a longitudinal axis Z from a first axial end 11 to a second axial end 12 opposite the first axial end 11.

[0134] In an embodiment, the filter media pack 10 is rotationally symmetric about the longitudinal axis Z. For example, the circumferential radial side 15 of the filter media pack 10 may have a cylindrical shape.

[0135] In other embodiments, the filter media pack may have a non-cylindrical shape, for example, the cross-section of the filter media pack has an oval or peanut shape.

[0136] In an embodiment, for example as shown in Figures 7a to 7g, the filter media pack 10 has an interior cavity 17 extending between a first axial end 11 and a second axial end 12. The filter media pack may, for example, have the shape of a hollow cylinder.

[0137] In those embodiments in which the filter media pack 10 has an internal cavity 17, the filter element includes a closed end cap 25 attached to the first axial end 11 and an open end cap attached to the second axial end 12. As shown in Figures 7a-7g, this open end cap at the second axial end 12 of the filter media pack is formed by a support structure 20. For example, a first circumferential radial wall 22 of the support structure 20 corresponds to a radial wall of the open end cap.

[0138] In embodiments in which the filter media pack 10 includes an internal cavity 17, after the filter element is installed in the housing of the filter system, the fluid to be filtered (the subject fluid) traverses the filter media in a direction transverse to the longitudinal axis Z. For example, the fluid to be filtered traverses through the circumferential radial side 15 of the filter media pack toward the internal cavity 17, and the filtered fluid exits the filter media at the second axial end 12 of the filter media pack 10 through the open end cap.

[0139] In an embodiment, the filter media pack having an internal cavity is a pleated filter media pack.

[0140] Typically, the pleated filter media has a plurality of pleats arranged in a closed loop, e.g., annular shape. In this way, a hollow filter body is formed extending in the direction of a longitudinal axis Z. The hollow filter body has a first opening and a second opening at a first end and a second end of the hollow filter body, respectively. The pleats are formed, for example, by folding a sheet of filter paper.

[0141] The outer tips of the plurality of pleats form a circumferential periphery of the hollow filter body, and the circumferential radial side 15 of the filter media pack 10 corresponds to this circumferential periphery formed by the outer tips of the pleats. The first axial end 11 and the second axial end 12 of the filter media pack 10 correspond to the first and second ends, respectively, of the hollow body. In an embodiment, typically the fold lines of the pleated filter media are oriented substantially parallel to the longitudinal axis Z.

[0142] In another embodiment, as shown in Figures 8a to 8c, the filter media pack 10 is a so-called straight-through filter media pack, i.e., the filter media performs filtration of a fluid by the fluid traversing the filter media pack in a flow direction from a first axial end 11 defining an inlet flow face to a second axial end 12 defining an outlet flow face for the filter media pack.

[0143] In an embodiment, the straight-through filter media pack 10 includes fluted filter media, also known as Z-filter media. An example of a commercially available Z-filter media is known under the name PowerCore®, manufactured by Donaldson Company.

[0144] In embodiments, the fluted filter media may be formed by a coiled layer of filter material.

[0145] In an embodiment, the filter media pack is obtained by coiling a layer of filter material, the circumferential radial side 15 of the filter media pack being formed by the surface of the outer layer of the coiled filter media.

[0146] In embodiments, the filter media may be formed by coiled layers of fluted filter material, each of which includes inlet and outlet flutes oriented substantially parallel to the longitudinal axis Z. By coiling the layers of fluted filter media, a filter media pack is formed. The circumferential radial side 15 of the filter media pack is formed by the surface of the outer layer of the coiled fluted filter media.

[0147] Generally, in embodiments comprising a coiled layer of fluted filter material, each layer of the coiled fluted material includes a set of inlet flutes and a set of outlet flutes. The set of inlet flutes are open at an axial inlet side of the filter body to receive unfiltered fluid, and the inlet flutes are closed at or toward an axial outlet side of the filter body. Meanwhile, the set of outlet flutes are closed at or toward the axial inlet side and open at the axial outlet side to allow filtered fluid to exit the filter body. In this way, the fluid is forced to follow a Z-shaped trajectory to flow from the axial inlet side to the axial outlet side of the filter media pack.

[0148] In additional embodiments comprising a coiled layer of filter material, the outer layer of the coiled filter material is at least partially covered with a covering comprising a separate material, such as a polymer, cellulose, or inorganic material. The covering may be implemented as, for example, a wrap, a sleeve, or a coating. The covering may include, for example, a plastic wrap. The covering is to be construed as a protective cover. In this manner, at least a portion of the periphery of the filter media pack is formed by the covering. The covering may be, for example, glued to the outer layer of filter material or may be an adhesive tape. In an embodiment, the covering may be heat welded to the outer layer of the coiled layer of filter material, as further described below.

[0149] In an embodiment, as shown in Figure 8b, the support structure 20 further forms a protective cover around the filter media pack 10. For example, in this embodiment, the support structure 20 may be a cylindrical shell with a portion of the shell corresponding to the first circumferential radial wall 22 with the pins 40a protruding from the inside of the first circumferential radial wall 22.

[0150] [Filter Assembly] According to an additional aspect of the present disclosure, there is provided a filter assembly including the filter element 1 described above and a housing 100 enclosing the filter element 1. Figures 2a-2c show an example of an embodiment of a filter assembly according to the present disclosure including a filter element 1 and a housing 100.

[0151] In an embodiment, the housing 100 includes a tubular framework 150 disposed within the housing, the tubular framework 150 having a first circumferential wall, and a coupling structure complementary to the coupling structure of the filter element 1 is disposed on the first circumferential wall of the housing. For example, the first circumferential wall may be a radially outer wall of the tubular framework 150.

[0152] The housing further includes a second circumferential wall defining a seal surface 130 configured to receive the seal 30 of the filter element. A portion of the housing of the filter system is shown in FIG. 9 illustrating the seal surface 130 that matches the shape of the stepped seal of the filter element. In this example, a rib 120 is used to define a stepped seal surface 130 that corresponds to the shape of the stepped seal of the filter element to be inserted into the housing. The rib inhibits installation of an incorrect filter element, for example having a different seal shape.

[0153] 2a-2c is a bayonet coupling structure, in which the coupling structure of the filter element includes bayonet pins 40a, 40b, 40c, 40d and the coupling structure of the housing of the filter system includes bayonet slots 110. The pins are configured to engage with the slots 110 after entering the slots through their respective slot openings 1102. When the filter element is inserted into the housing and subjected to rotational and translational movements, the filter element 1 is coupled to the housing 100 by interaction of the bayonet coupling structure of the filter element 1 with the complementary bayonet coupling structure of the housing 100.

[0154] The process of inserting a filter element into a housing through rotational and translational movement of the filter element 1 is described using Figures 2a to 2c. As shown in Figure 2a, rotational and translational movement begins when the bayonet pin of the filter element is inserted into the beginning of a slot of a bayonet-type complementary coupling structure inside the housing. In Figure 2b, the filter element is further rotated such that the filter element 1 translates longitudinally until the bayonet pin 40 reaches the end of the slot 110 as shown in Figure 2c. In a preferred embodiment, the slot 110 further includes respective slot locking features 1101 near the ends of the slot, such as small bumps 1101 on the underside of the slot 110. This allows the respective projections 40 to pass when the filter element 1 is installed, but at least partially prevents the projections 40 from moving back out as a result of, for example, machine vibration (see Figures 2a, 2b, 2d).

[0155] 10a and 10b show a filter housing 100 similar to that described in connection with FIGS. 2a-2c, and further includes an alignment structure or tower 1001. The alignment structure or tower 1001 is disposed upstream of the housing outlet 100X and projects into the interior volume of the housing 100. The tower 1001 preferably includes a rounded tapered end portion 1001e that provides a guide surface that initially guides each filter element during installation before the filter element 1 is locked or mated with the housing 100.

[0156] In an embodiment, the filter assembly includes both a primary filter element and a safety filter element to back up the primary filter element in the event of failure. The safety filter element may be the stepped seal and coupling structure filter element described above.

[0157] In those embodiments including a safety filter element, the housing 100 encases both the primary filter element and the safety filter element. Also in this embodiment, the housing includes a tubular framework 150 disposed inside the housing and having a first circumferential wall. A coupling structure 110, complementary to the coupling structures 40a, 40b, 40c, 40d of the filter element 1, is disposed on the first circumferential wall of the tubular framework. The housing further includes a second circumferential wall forming a sealing surface 130 configured to receive the seal 30 of the filter element.

[0158] [Detailed features] The following is described in the form of embodiment clauses. The embodiment clauses include characterizations that indicate various options, features, and combinations of features that can be used in accordance with the teachings of the present disclosure. Alternative characterizations of the given embodiment clauses that are consistent with the above description herein are possible. In summary, according to the present disclosure, for example, the following embodiment clauses can be claimed:

[0159] 1. A filter element for insertion into a housing of a filter system, comprising: a filter media pack for filtering a fluid, the filter media pack including a circumferential radial side extending along a longitudinal axis from a first axial end to a second axial end opposite the first axial end; a seal that prevents fluid from bypassing the filter media pack when the filter element is installed in a filter system; and a support structure for supporting the seal. A filter element, The seal includes at least a first segment and a second segment adjacent to the first segment, with at least a portion of the second segment axially spaced from the first segment; The filter elements are a mating structure for mating with a complementary mating structure disposed within a housing of the filter system; the support structure includes a first circumferential radial surface circumferential about the longitudinal axis and a second circumferential radial surface circumferential about the longitudinal axis, the filter element coupling structure being disposed on the first circumferential radial surface and the seal being disposed on the second circumferential radial surface. Filter element. 2. The filter element according to embodiment 1, wherein the coupling structure of the filter element includes one or more protrusions that engage with a protrusion-receiving element of a complementary coupling structure of a housing of the filter system; Or alternatively, the mounting structure of the filter element includes one or more projection receiving elements that engage projections of a complementary mounting structure of the housing of the filter system. 3. The filter element of embodiment 2, wherein the one or more protrusions project radially from the first circumferential radial surface. 4. The filter element according to embodiment 2 or 3, wherein the one or more protrusions are any of a pin, a knob, a rib, an embossment, a pivot, a nipple, or a combination thereof. 5. The filter element according to any one of embodiments 2 to 4, wherein the bonding structure of the filter element comprises two or more protrusions, preferably three or more protrusions, and more preferably four or more protrusions. 6. The filter element of any one of embodiments 2 to 5, wherein the seal comprises a plurality of first segments and a plurality of second segments, and the bond structure of the filter element comprises a plurality of protrusions, the number of protrusions being equal to or greater than the number of second segments. 7. The filter element of embodiment 2, wherein the one or more projection receiving elements are any of a slot, a groove, or a combination thereof. 8. The filter element according to embodiment 2 or 7, wherein the bonding structure of the filter element comprises two or more protrusion receiving elements, preferably three or more protrusion receiving elements, and more preferably four or more protrusion receiving elements. 9. The filter element of embodiment 2, 7 or 8, wherein the seal comprises a plurality of first segments and second segments, and the filter element's bond structure comprises a plurality of protruding receiving elements, and the number of protruding receiving elements is equal to or greater than the number of second segments. 10. The filter element of any one of the preceding claims, wherein the first circumferential radial surface is parallel to the second circumferential radial surface. 11. The filter element of any one of the preceding embodiments, wherein the first circumferential radial surface and / or the second circumferential radial surface are parallel to the longitudinal axis. 12. The filter element of any one of embodiments 1 to 11, wherein the support structure includes a first circumferential radial wall circumferentially about the longitudinal axis, the first circumferential radial wall including a first side and a second side opposite the first side, the first side corresponding to the first circumferential radial surface. 13. The filter element of embodiment 12, wherein the second side of the first circumferential radial wall corresponds to the second circumferential radial surface. 14. The filter element of embodiment 13, wherein the first and second sides of the first circumferential radial wall are radially inner and outer sides of the first circumferential radial wall, respectively; Or alternatively, the first and second sides of the first circumferential radial wall are respectively radially outer and radially inner sides of the first circumferential radial wall. 15. The filter element of any one of the preceding claims, wherein the second circumferential radial surface is inclined relative to the longitudinal axis. 16. The filter element of any one of the preceding claims, wherein the second circumferential radial surface is inclined relative to the first circumferential radial surface. 17. The filter element of any one of embodiments 1 to 9, wherein the first circumferential radial surface is parallel to the longitudinal axis and the second circumferential radial surface is inclined relative to the longitudinal axis. 18. The filter element of any one of embodiments 15 to 17, wherein the second circumferential radial surface is inclined at an angle θ, where 5°≦θ≦85°, preferably 20°≦θ≦60°, and more preferably 30°≦θ≦50°. 19. The filter element of any one of embodiments 15 to 17, wherein the inclined second circumferential radial surface has a conical shape. 20. The filter element of any one of embodiments 15 to 19, wherein the support structure includes a first circumferential radial wall circumferential about the longitudinal axis and a second circumferential radial wall circumferential about the longitudinal axis; the first circumferential radial wall includes a first side and a second side opposite the first side, the first side corresponding to the first circumferential radial surface; The second circumferential radial wall is inclined relative to the longitudinal axis, and a surface side of the second circumferential radial wall corresponds to the second circumferential radial surface, the filter element. 21. The filter element of any one of embodiments 12 to 14 or 20, wherein at least a portion of the first circumferential radial wall of the support structure forms a tubular element extending along the longitudinal axis and is configured to drain filtered fluid from the filter media pack. 22. The filter element of any one of embodiments 12 to 14 or 20, wherein at least a portion of the first circumferential radial wall of the support structure has a cylindrical shape. 23. The filter element of any one of embodiments 12 to 14 or 20, wherein the support structure forms an open end cap attached to a second axial end of the filter media pack, and preferably the first circumferential radial wall corresponds to a radial wall of the open end cap. 24. The filter element of embodiment 23, wherein the first circumferential radial wall includes a flange member that is attached to a second axial end of the filter media pack and forms an open end cap on the second axial end of the filter media pack. 25. The filter element of any one of embodiments 12 to 14 or 20, wherein the support structure includes a flange member configured to attach to a second axial end of the filter media pack and form an open end cap at the second axial end of the filter media pack, and preferably the flange member is bonded to an axial end of the first circumferential radial wall. 26. The filter element of any one of embodiments 1 to 25, wherein the filter media pack has an internal cavity extending between a first axial end and a second axial end of the filter media pack, and the filter element includes a closed end cap attached to the first axial end. 27. The filter element of any one of the preceding claims, wherein the filter media pack comprises pleated or fluted filter media. 28. The filter element of any one of the preceding claims, wherein the seal is formed or at least partially formed from any of the following materials, or mixtures or combinations thereof: rubber, thermoplastic elastomer, thermoset elastomer, silicone, thermoplastic vulcanizate, or polyurethane. 29. The filter element according to any one of the first to second embodiments, the support structure and / or the bonding structure are formed or at least partially formed from a thermoplastic material; Preferably, the thermoplastic material is any of the following materials or mixtures and combinations thereof: acrylonitrile butadiene styrene, polypropylene, polyamide, polyethylene terephthalate, polylactic acid, polyethylene, polycarbonate, polystyrene, or polyvinyl chloride. 30. The filter element of any one of the preceding embodiments, wherein the support structure forms a unitary body, preferably manufactured by an injection molding manufacturing process. 31. The filter element of any one of the preceding claims, wherein the support structure and the seal form a single body manufactured by a multi-component injection molding manufacturing process. 32. The filter element of any one of the preceding claims, wherein the support structure, seal, and bonding structure of the filter element form a single body manufactured by a multi-component injection molding manufacturing process. 33. The filter element of any one of the preceding claims, wherein a portion of the second segment axially spaced from the first segment is parallel to at least a portion of the first segment. 34. The filter element of any one of the first to third embodiments, wherein the second segment of the seal comprises a central segment portion and two transition segment portions adjacent to the central segment portion; A filter element wherein a central segment portion of the second segment is oriented parallel to the first segment and at least a portion of the two transition segment portions are oriented at an oblique angle relative to the first segment. 35. The filter element of any one of embodiments 1 to 34, wherein the seal includes a plurality of first segments and a plurality of second segments, each of the first segments being arranged alternately with one of the second segments. 36. The filter element of any one of the preceding claims, wherein the seal comprises at least one circumferential sealing lip. 37. The filter element of embodiment 36, wherein the circumferential sealing lip is disposed at an oblique angle relative to the first circumferential radial wall. 38. The filter element according to any one of embodiments 36 or 37, The seal includes two or more circumferential sealing lips disposed in spaced parallel relationship, the filter element. 39. The filter element of any one of embodiments 1 to 38, wherein a portion of the second segment axially spaced from the first segment is axially spaced apart by a non-zero axial separation distance measured along the longitudinal axis. 40. The filter element of any one of embodiments 1 to 39, wherein the maximum separation distance between the first and second segments measured along the longitudinal axis is between 5 mm and 200 mm, more preferably between 5 mm and 100 mm. 41. The filter element of any one of the preceding claims, wherein the seal height measured along the longitudinal axis is less than the maximum separation distance between the first and second segments measured along the longitudinal axis. 42. The filter element according to any one of the preceding embodiments, wherein the filter element has a bayonet coupling structure. 43. The filter element of any one of the preceding claims, wherein the support structure is sealingly attached to the filter media pack. 44. The filter element of any one of the preceding claims, wherein the seal is sealingly attached to the second circumferential radial surface. 45. A filter element according to any one of claims 1 to 44; and a housing enclosing the filter element, the housing comprising: (i) a tubular frame structure disposed inside the housing and having a first circumferential wall, the tubular frame structure having a coupling structure complementary to the coupling structure of the filter element disposed on the first circumferential wall of the tubular frame structure; (ii) a second peripheral wall forming a sealing surface configured to receive a seal of the filter element; Filter assembly. 46. ​​A main filter element; A safety filter element that backs up the failure of the main filter element, the safety filter element being the filter element according to any one of embodiments 1 to 44; and a housing enclosing the primary filter element and the safety filter element, the housing comprising: (i) a tubular frame structure disposed inside the housing and having a peripheral wall, the tubular frame structure having a coupling structure complementary to the coupling structure of the filter element disposed on the peripheral wall of the tubular frame structure; (ii) a second peripheral wall forming a sealing surface configured to receive a seal of the filter element; Filter assembly. 47. The filter assembly according to embodiment 45 or 46, wherein the coupling structure of the filter element and the complementary coupling structure of the housing are configured to form a bayonet closure. [Explanation of symbols]

[0160] 1 Filter Element 10 Filter Media Packs 11 First axial end of filter media pack 12 Second axial end of filter media pack 15 Circumferential radial side of filter media pack 17 Internal Cavity 20 Seal support structure 21 Flange member 22 first circumferential radial wall of seal support structure 22a First orbit radial surface 22b, 23a Second orbit radial surface 22c Third orbit radial surface 23 Second circumferential radial wall of seal support structure 24 Wing member 25 Closed End Cap 26 Shoulder 27 Axial end face of seal support structure 30 Seals 30A additional seal 31 Seal extension 30a, 30b, 30c Circumferential seal lip 40, 40a, 40b, 40c, 40d Pins or protrusions 100 Housing 100X Housing Exit 1001 Alignment Tower 110 Slots 1101 Slot Lock Feature 1102 Slot opening 120 Ribs 130 Housing sealing surface 150 Tubular frame structure of housing Lobes extending along the L axis

Claims

1. A filter element (1) for insertion into the housing of a filter system, A filter medium pack (10) for filtering fluids, the filter medium pack (10) includes a circumferential radial side surface (15) extending along the longitudinal axis (Z) from a first shaft end (11) to a second shaft end (12) opposite to the first shaft end, A seal (30) is provided to prevent the fluid from bypassing the filter medium pack when the filter element is installed in the filter system, The system includes a support structure (20) that supports the seal (30). It is a filter element, The seal (30) is at least one circumferential seal lip (30a, 30b, 30c) and includes at least a first segment (S1) and a second segment (S2) adjacent to the first segment (S1), wherein at least a portion (PS2) of the second segment (S1) is axially separated from the first segment (S1). Filter element (1) is, The coupling structure of the filter element is provided to engage with a complementary coupling structure located within the housing of the filter system by rotational and translational movement, the coupling structure includes one or more protrusions (40a, 40b, 40c, 40d) that engage with the protrusion receiving elements of the complementary coupling structure in the housing of the filter system, preferably, the protrusions among the one or more protrusions (40a, 40b, 40c, 40d) are any of pins, knobs, ribs, embossing, pivots, nipples, or a combination thereof, or alternatively, the coupling structure of the filter element includes one or more protrusion receiving elements (50) that engage with the protrusions of the complementary coupling structure in the housing of the filter system, the one or more protrusion receiving elements are any of slots (50), grooves, or a combination thereof. The support structure (20) includes a first radial surface (22a) that orbits the longitudinal axis (Z) and a second radial surface (22b, 23a) that orbits the longitudinal axis (Z), the coupling structure of the filter element is located on the first radial surface (22a), and the seal (30) is located on the second radial surface (22b, 23a). Filter element.

2. The filter element according to claim 1, comprising a plurality of first segments (S1) and a plurality of second segments adjacent to each of the first segments, wherein the number of protrusions is equal to or greater than the number of second segments.

3. The filter element according to claim 2, wherein one or more of the protrusions project radially from the first radial surface (22a).

4. The filter element according to any one of claims 1 to 3, wherein the support structure (20) includes a first radial wall (22) that orbits the longitudinal axis (Z), the first radial wall (22) includes an inner portion and an outer portion opposite to the inner portion, the inner portion corresponding to the first radial surface (22a), the outer portion corresponding to the second radial surface (22b), or alternatively, the inner portion corresponding to the second radial surface (22b) and the outer portion corresponding to the first radial surface (22a).

5. The filter element according to any one of claims 1 to 3, wherein the first radial surface (22a) is parallel to the longitudinal axis (Z), and the second radial surface (22b) is inclined with respect to the longitudinal axis (Z).

6. The support structure (20) includes a first radial wall (22) that orbits the longitudinal axis (Z) and a second radial wall (23) that orbits the longitudinal axis (Z), The first radial wall (22) includes a first side and a second side opposite to the first side, the first side corresponding to the first radial surface (22a), The filter element according to claim 5, wherein the second radial wall (23) is inclined with respect to the longitudinal axis (Z), and the surface side of the second radial wall (23) corresponds to the second radial surface (23a).

7. The second segment (S2) of the seal (30) comprises a central segment portion (S2, c) and two transition segment portions (S2-t1, S2-t2) adjacent to the central segment portion (S2, c), The filter element according to any one of claims 1 to 3, wherein the central segment portion (S2, c) of the second segment (S2) is oriented parallel to the first segment (S1), and at least a portion of the two transition segment portions (S2-t1, S2-t2) is oriented obliquely to the first segment (S1).

8. A filter element (1) according to any one of claims 1 to 3, The system comprises a housing (100) that encloses the filter element, and the housing is (i) A tubular frame structure (150) having a first circumferential wall and arranged inside the housing (100), wherein a coupling structure (110) that is complementary to the coupling structure (40a, 40b, 40c, 40d) of the filter element (1) is arranged on the first circumferential wall of the tubular frame structure (150), (ii) A second circumferential wall that forms a sealing surface (130) configured to receive the seal (30) of the filter element, Filter assembly.

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