FILTER ASSEMBLY, ITS COMPONENTS AND FEATURES, AND METHODS OF USE AND ASSEMBLY - Patent application

Abstract

To provide a filter cartridge with an improved filter structure.SOLUTION: A filter cartridge includes: (a) a filter medium having first and second end parts; and (b) a housing seal structure arranged on the first and second end parts, and (i) includes a housing seal surface which is the housing seal surface 571 which defines a non-circular structure and faces to a radius direction and has at least two parts 571x protruding to an outer side in the radius direction and at least one part 571y protruding to an inner side in the radius direction, wherein at least the two parts protruding to the outer side in the radius direction and at least the one part protruding to the inner side in the radius direction are defined on the housing seal surface facing to the radius direction, and the housing seal surface facing to the radius direction is a face engaging with a housing so as to provide sealing when being used, and (ii) the parts protruding to the outer side in the radius direction have a different curvature from a curvature of the part protruding to the inner side.SELECTED DRAWING: Figure 49

Description

[Technical field]

[0001] The present disclosure relates to a filter assembly, e.g., an air cleaner assembly, its components and features, and methods of assembly and use. The filter assembly includes a housing that houses a removable and replaceable filter cartridge. The filter cartridge is advantageously configured with an optional housing seal arrangement. Various features of the filter housing and / or cartridge that can provide advantages are described. Methods of assembly and use are described. Optional and advantageous resonator / sonic choke arrangements are described. [Background technology]

[0002] In many systems it is desired to filter air or other gases. A typical application is the filtration of the intake air of an internal combustion engine. Another application is the filtration of a crankcase ventilation filter assembly. Usually such a system comprises a filter assembly housing a serviceable filter cartridge. After a period of use, the filter media inside the filter housing needs to be serviced by cleaning or complete replacement. In the case of an air cleaner filter assembly or crankcase ventilation filter assembly, for example, used with an internal combustion engine of a vehicle, the filter media is usually a removable and replaceable component, typically called a filter element or filter cartridge, i.e. the serviceable component. The filter cartridge is configured to be removably sealed in the air cleaner during use.

[0003] It would be desirable to improve filter construction with respect to assembly, serviceability, and use. Summary of the Invention

[0004] A filter assembly (such as an air cleaner assembly or a crankcase ventilation filter assembly), its components and features are described. Methods of assembly and use are also described. The filter assembly generally comprises a housing in which a filter cartridge is removably disposed. For example, one example of a filter cartridge is shown having a housing seal surface that is a radially facing surface having a plurality of radially outwardly projecting portions spaced apart by radially inwardly projecting portions.

[0005] In the particular example construction shown, the housing optionally includes a connection portion, advantageously with a portion of the connection portion located between two housing seals disposed on the cartridge.

[0006] Selected principles of the present application may be applied to filter cartridges that do not include two housing seals, but instead include one effective housing seal. In one construction, the radially oriented sealing surface comprises a plurality of spaced apart lobes or outwardly projecting (e.g., convex) portions separated by optional non-linear portions, such as opposing inwardly projecting (e.g., concave) portions.

[0007] In the particular example shown, the housing seal is provided with a generally circular radially facing surface.

[0008] In a particular application of the technology described herein, a filter cartridge is provided that includes two housing seals, each generally radially oriented, but with different perimeters, typically one housing seal having a substantially larger perimeter than the other housing seal. In such applications, both seals may be circular, although other shapes are possible, as described and illustrated.

[0009] It is not required that an air cleaner assembly, its components or features include all of the detailed features described herein in order to obtain any benefit according to the present disclosure. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic side view of an air cleaner assembly according to the present disclosure. [Diagram 2] 2 is a second schematic side view of the air cleaner assembly of FIG. 1 as viewed from the right side of FIG. [Diagram 3] FIG. 3 is a third schematic side view of the air cleaner assembly of FIGS. 1 and 2 with some portions shown in cross section to show internal details. [Figure 3A] FIG. 3A is an enlarged, fragmentary, schematic, cross-sectional view showing a selected portion of FIG. [Figure 4] FIG. 4 is a schematic outlet end perspective view of a filter cartridge usable in the air cleaner assembly of FIGS. 1-3. [Diagram 5] FIG. 5 is a schematic side view of the filter cartridge shown in FIG. 4 with some portions shown in cross-section to show internal details. [Figure 6] FIG. 6 is a schematic plan view showing a molded portion of the first open end of the filter cartridge of FIG. [Figure 7] 7 is a schematic cross-sectional view of the molded portion of FIG. 6 taken along line 7-7 of FIG. [Figure 8] FIG. 8 is a schematic enlarged fragmentary view of the same portion of the molded portion of FIG. [Figure 9] FIG. 9 is a schematic outlet end view of the support components of the filter cartridge of FIG. [Figure 10] FIG. 10 is a schematic side view of the support component of FIG. [Figure 11] FIG. 11 is a schematic end view showing the components of FIG. 10 as viewed towards the left end of FIG. [Figure 12] FIG. 12 is a second schematic end view showing the components of FIGS. 9 and 10 as viewed towards the opposite end from FIG. [Figure 13]FIG. 13 is the same portion of the enlarged schematic view shown in FIG. [Figure 14] FIG. 14 is an enlarged schematic cross-sectional view of the same portion shown in FIG. [Figure 15] FIG. 15 is an enlarged, fragmentary, schematic, cross-sectional view showing selected portions of the support component shown in FIGS. [Figure 16] FIG. 16 is an enlarged, fragmentary schematic diagram showing a selected portion of FIG. [Figure 17] FIG. 17 is a schematic perspective view showing a housing portion of the assembly of FIGS. 1 to 3. FIG. [Figure 18] FIG. 18 is a schematic side view of the housing portion shown in FIG. [Figure 19] FIG. 19 is a schematic end view of the housing portion of FIGS. [Figure 20] 20 is a schematic cross-sectional view of the housing portion of FIG. 19 taken along line 20-20 of FIG. [Figure 21] FIG. 21 is an enlarged, partially schematic diagram showing a selected portion of FIG. [Figure 22] FIG. 22 is a schematic perspective view showing the flow tube components of the assembly of FIGS. 1-3. [Diagram 23] FIG. 23 is a schematic side view showing the components of FIG. [Figure 24] FIG. 24 is a schematic plan view showing the components of FIGS. 23 and 24. [Diagram 25] FIG. 25 is a schematic cross-sectional view taken generally along line 25-25 of FIG. [Figure 26] FIG. 26 is an enlarged schematic fragmentary view showing a selected portion of FIG. [Figure 27] FIG. 27 is an enlarged schematic cross-sectional view taken generally along line 27-27 of FIG. [Figure 28] FIG. 28 is an enlarged schematic fragmentary view of the same portion shown in FIG. [Figure 29] FIG. 29 is a schematic end view of the second end cap molding of the cartridge of FIG. [Diagram 30]30 is a schematic cross-sectional view of the molded portion of FIG. 29 taken generally along line 30-30 of FIG. [Diagram 31] FIG. 31 is a schematic end perspective view of a second housing portion of the assembly of FIGS. 1-3. [Diagram 32] 32 is a schematic cross-sectional side view of the housing portion of FIG. 31 taken along line 32-32 of FIG. [Diagram 33] FIG. 33 is a schematic side view of a second embodiment of an air cleaner assembly according to the present disclosure, but without showing certain molded-in-place molding portions of the cartridge end caps so that details of the internal structure are visible, and a cross-sectional view taken along line 33-33 in FIG. 33A. [Figure 33A] 33A is an end plan view of the access cover of the assembly shown in FIG. 33, with line 33-33 indicating the cross section of FIG. 33. FIG. [Figure 33B] FIG. 33B is an enlarged, fragmentary view showing the identified portion of FIG. [Figure 33C] FIG. 33C is a schematic cross-sectional view similar to FIG. 33 including an illustration of the molded-in-place portions of the two end caps, but showing selected variations of the second embodiment of the air cleaner assembly. [Figure 33D] FIG. 33D is an enlarged, fragmentary schematic diagram showing a selected portion of FIG. 33C. [Figure 33E] FIG. 33E is a perspective view of a housing that can be used with the variations of FIGS. 33C and 33D. [Diagram 34] FIG. 34 is a schematic closed end view of a filter cartridge using the assembly of FIG. [Figure 34A] 34A is a schematic outlet end perspective view of the filter cartridge of FIG. 34. FIG. [Figure 34B] FIG. 34B is a schematic closed end perspective view of the alternative filter cartridge of FIGS. 33C and 33D. [Figure 34C] FIG. 34C is a schematic outlet end perspective view of the filter cartridge of FIG. 34B. [Diagram 35]FIG. 35 is a schematic side view of the filter cartridge shown in FIG. 34 with portions removed and in cross section to show internal details. [Figure 35A] FIG. 35A is a schematic side view of the filter cartridge of FIG. 34C. [Figure 35B] FIG. 35B is a schematic cross-sectional view of the filter cartridge of FIG. 35A. [Diagram 36] FIG. 36 is a schematic open end plan view of the filter cartridge of FIG. [Figure 36A] FIG. 36A is a top view of the outlet end of the filter cartridge of FIGS. 35A and 35B. [Figure 37] FIG. 37 is a schematic closed end perspective view of the filter cartridge of FIG. [Figure 37A] FIG. 37A is a top view of the closed end of the filter cartridge of FIGS. 35A and 35B. [Figure 38] FIG. 38 is a schematic outlet end plan view showing the internal components of the filter cartridge of FIG. [Figure 39] FIG. 39 is a schematic side view showing the components of FIG. 38. [Diagram 40] FIG. 40 is a schematic outlet end plan view showing the components of FIG. [Diagram 41] FIG. 41 is a schematic end view showing the components of FIG. 39 as viewed towards the opposite end from that shown in FIG. [Diagram 42] FIG. 42 is an enlarged, partially schematic, cross-sectional view showing the components shown in FIG. [Diagram 43] FIG. 43 is an enlarged, partially schematic, sectional view of the same portion shown in FIG. [Diagram 44] FIG. 44 is a schematic partial plan view showing a part of FIG. [Diagram 45] FIG. 45 is a schematic perspective view showing an outlet tube component usable with the assembly of FIG. [Diagram 46] FIG. 46 is a schematic side view showing the outlet tube of the component of FIG. [Figure 47]FIG. 47 is a schematic cross-sectional side view showing the components of FIGS. 45 and 46 taken generally along line 47-47 of FIG. [Figure 48] FIG. 48 is a schematic end plan view showing the components shown in FIGS. [Figure 49] FIG. 49 is a schematic cross-sectional view taken generally along line 49-49 of FIG. [Figure 50] FIG. 50 is an enlarged schematic fragmentary view of the same portion shown in FIG. [Figure 51] FIG. 51 is a schematic side view showing the assembly shown in FIG. [Figure 52] FIG. 52 is a schematic cross-sectional view taken generally along line 52-52 of FIG. [Figure 53] FIG. 53 is a schematic perspective view showing the housing components of the assembly of FIG. 51. [Figure 54] FIG. 54 is a schematic plan view showing the housing components of FIG. [Figure 55] FIG. 55 is a schematic end plan view of the housing components of FIG. 53. [Figure 56] FIG. 56 is a schematic cross-sectional view taken generally along line 56-56 of FIG. [Figure 57] FIG. 57 is a schematic enlarged partial view of the same portion shown in FIG. [Figure 58] FIG. 58 is a schematic plan view of mold components that can be used to form a portion of the cartridge of FIG. 34A. [Figure 59] FIG. 59 is a schematic cross-sectional view of the mold components of FIG. 58 taken along line 59-59 of FIG. [Figure 60] FIG. 60 is a schematic enlarged fragmentary view showing a portion of FIG. [Figure 61] FIG. 61 is a schematic enlarged fragmentary view showing a portion of FIG. [Figure 62] FIG. 62 is a schematic enlarged portion of FIG. [Figure 63] FIG. 63 is a schematic enlarged fragmentary view showing a portion of FIG. [Figure 64]FIG. 64 is an exploded schematic view showing the relationship of the inner filter support of FIG. 38 to the mold of FIG. [Figure 65] FIG. 65 is a schematic developed cross-sectional view showing the structure shown in FIG. [Figure 66] FIG. 37 is a schematic diagram illustrating an alternative seal arrangement to that shown in FIG. 36. [Figure 67] FIG. 67 is a schematic diagram illustrating a second seal arrangement which is an alternative to the seal arrangement shown in FIG. [Figure 68] FIG. 68 is a schematic diagram illustrating a third alternative seal arrangement to that shown in FIG. [Figure 69] FIG. 69 is a schematic diagram illustrating a fourth seal arrangement which is an alternative to the seal arrangement shown in FIG. [Figure 70] FIG. 70 is a schematic diagram illustrating a fifth seal arrangement which is an alternative to the seal arrangement shown in FIG. [Figure 71] FIG. 71 is a schematic side perspective view of a third embodiment of an air cleaner assembly in accordance with the present disclosure. [Figure 71A] FIG. 71A is a schematic perspective view showing an air cleaner assembly according to a variation of the embodiment of FIG. [Figure 71B] FIG. 71B is a schematic side view showing a modification of FIG. 71A. [Figure 71C] FIG. 71C is a schematic side perspective view showing a further modification of the structure of FIG. [Figure 72] FIG. 72 is a schematic cross-sectional view showing the air cleaner of FIG. [Figure 72A] FIG. 72A is an enlarged, fragmentary schematic view showing a portion of FIG. [Fig. 72B] FIG. 72B is a schematic cross-sectional view taken generally along line 72B-72B of FIG. 71B, showing a variation of the view of FIGS. 72 and 72A. [Fig. 72C] FIG. 72C is a schematic cross-sectional view showing the structure shown in FIG. 71C. [Figure 73] FIG. 73 is a schematic cross-sectional view showing selected housing flow tube and filter cartridge features of the assembly of FIGS. [Figure 74] FIG. 74 is a schematic side view showing filter cartridge components usable in the assembly of FIGS. 71-73. [Fig. 74A] FIG. 74A is a schematic side view of a filter cartridge used in the variations of FIGS. 71A, 71B, and 71C. [Figure 75] FIG. 75 is an enlarged schematic cross-sectional view of the filter cartridge components shown in FIG. [Fig. 75A] FIG. 75A is an enlarged cross-sectional view of the variation of FIG. 74A taken generally along line 75A-75A of FIG. 74A. [Fig. 75B] A perspective view of the outlet end of the cartridge is shown in FIG. 75B. [Figure 76] FIG. 76 is an enlarged schematic end view of the open end of the cartridge of FIGS. 74 and 75. [Figure 76A] FIG. 76A is a schematic open end plan view of a variation of the filter cartridge of FIG. 75A. [Figure 77] FIG. 77 is an enlarged schematic end view of the closed end of the filter cartridge of FIGS. [Figure 77A] FIG. 77A is a schematic end view of the closed end of the alternative filter cartridge of FIGS. 74A and 75A. [Figure 78] FIG. 78 is a schematic open end perspective view of the filter cartridge of FIGS. 74 and 75. FIG. [Fig. 78A] FIG. 78A is a schematic open end perspective view of a variation of the filter cartridge shown in FIGS. 74A and 75A. [Fig. 78B] FIG. 78B is a closed end perspective view of a variation of the filter cartridge shown in FIGS. 74A, 75A, and 78A. [Figure 79] FIG. 79 is an enlarged, partial, cross-sectional schematic view showing selected portions of the filter cartridge shown in FIGS. [Figure 80]80 is an enlarged, fragmentary, cross-sectional schematic view of a portion of the filter cartridge shown in FIG. 79, excluding the molded end cap potting portion visible in FIG. [Figure 81] FIG. 81 is an enlarged schematic view generally similar to FIG. 76 with selected dimensional information provided. [Figure 82] 82 is an enlarged schematic end plan view of the molded end cap portion of the cartridge shown in FIG. [Figure 83] 83 is an enlarged schematic cross-sectional view of the molded end cap portion shown in FIG. 82. FIG. [Figure 84] FIG. 84 is an enlarged schematic outlet end perspective view of one of the filter cartridge components shown in FIGS. [Figure 85] FIG. 85 is a schematic cross-sectional side view showing the components shown in FIG. [Figure 86] FIG. 86 is an enlarged schematic outlet end view showing the components shown in FIGS. 84 and 85. [Figure 87] FIG. 87 is an enlarged schematic perspective view showing the housing tube components of the assembly shown in FIGS. [Figure 88] FIG. 88 is an enlarged schematic plan view showing the components shown in FIG. [Figure 89] FIG. 89 is an enlarged schematic fragmentary view showing the identified portions of FIG. [Figure 90] FIG. 90 is a schematic side view showing another support structure for use in a cartridge according to the present disclosure. [Figure 91] FIG. 91 is a schematic partial perspective view showing the support structure of FIG. [Figure 92] FIG. 92 is a second schematic partial view of the support structure of FIGS. 90 and 91. [Figure 93] FIG. 93 is a schematic side view illustrating a second alternative support structure in accordance with the present disclosure. [Figure 94] FIG. 94 is a schematic partial perspective view showing the support structure of FIG. 93. [Figure 95]FIG. 95 is a second schematic partial perspective view of the support structure of FIGS. 93 and 94. FIG. [Figure 96] FIG. 96 is a schematic perspective exploded view showing an additional variation of the support structure usable in the cartridge of the present disclosure. [Figure 97] FIG. 97 is a side view showing a modification of the support structure of FIG. [Figure 98] FIG. 98 is a schematic perspective view showing a modified example of the support structure of FIG. [Figure 99] FIG. 99 is a schematic end view showing a modification of the support structure of FIG. [Figure 100] FIG. 100 is a schematic cross-sectional view showing a modification of the support structure of FIG. [Figure 101] FIG. 101 is an enlarged fragmentary view showing a selected portion of FIG. [Figure 102] FIG. 102 is an enlarged schematic perspective view of another filter cartridge according to the present disclosure. [Figure 103] FIG. 103 is a schematic diagram showing a process for assembling a medium for use in the cartridge of FIG. [Figure 104] FIG. 104 is a schematic perspective view of a filter cartridge according to yet another application in which the principles of the present disclosure may be applied. [Figure 105] FIG. 105 is a schematic plan view of the filter cartridge shown in FIG. [Fig. 106] FIG. 106 is a schematic perspective view of a further variation of a filter cartridge applying selected principles of the present disclosure. [Figure 107] FIG. 107 is a side view of the filter cartridge shown in FIG. [Figure 108] FIG. 108 is a schematic perspective view of a filter cartridge for use in crankcase ventilation filtration as an application of the principles of the present disclosure. [Figure 109] FIG. 109 is a schematic plan view of the filter cartridge of FIG. [Figure 110]FIG. 110 is a schematic perspective view of a second filter cartridge for use in crankcase ventilation filtration in which principles of the present disclosure may be applied. [Figure 111] FIG. 111 is a schematic plan view of the filter cartridge shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] An exemplary filter assembly, its features and components are described and illustrated. Various specific features and components are described in detail. Many features and components may be applied to provide advantages. However, it is not specifically required to apply the various individual features and components throughout the assembly having every feature and every characteristic described to provide some benefit according to the present disclosure.

[0012] It should be noted that several embodiments are shown and described, and that the embodiments are not intended to be exclusive with respect to the features shown, i.e., selected features of one embodiment may be advantageously applied to one or more of the other embodiments, as appropriate.

[0013] In many examples, the filter assembly shown is an air cleaner assembly used, for example, to filter the intake air of an internal combustion engine. Additional embodiments are described in which the filter assembly is a crankcase ventilation filter assembly. In that case, the filter cartridge is used to filter crankcase blow-by gases, which typically contain both particulate and liquid contaminants. These two types of filter assemblies are generally referred to as "gas filter assemblies" since the carrier stage to be filtered is a gas (air or crankcase blow-by gas). Although the technology described herein is typically used in gas filtration applications, it can also be used to filter other substances, such as liquids, if desired.

[0014] I. General Features of an Exemplary Embodiment, FIGS. 1-3 1 generally indicates a filter assembly, e.g., an air cleaner or air cleaner assembly or structure, according to the present disclosure. The filter assembly (in this example, an air cleaner assembly) 1 comprises a housing 2. The housing 2 defines a sidewall 2s and includes a first body portion 3 and a second body portion or access cover 4. In the example shown, the access cover 4 is removably secured to the first body portion 3, although other configurations are possible. In the example shown, the cover portion 4 is attached to the body portion 3 by a latch structure 5, although other configurations are possible. The latch structure typically comprises a plurality of over-center latches 5x.

[0015] In general, the air (gas) cleaner 1 includes an air (gas) flow inlet structure 7. In the illustrated example, the air flow inlet structure 7 is an inlet tube, designated 7t, in the body portion 3. The particular inlet tube 7t illustrated is configured as a side tangential inlet; that is, the gas flow is directed tangentially along the inner wall of the housing 2, rather than directly toward the housing central axis X. Alternative inlet structures, locations and orientations are possible; however, the illustrated tangential inlet structure is convenient and advantageous for reasons explained below.

[0016] Reference number 8 indicates a dirt / water exhaust structure disposed in the housing 2, which includes a tube 9. In the illustrated example, the tube 9 is part of the access cover 4, but other configurations are possible. The tube 9 is covered by a pressure relief valve structure 10 which includes a duckbill valve of the type commonly used with air cleaners. See, for example, International Publication No. WO 2006 / 06241 A1 and U.S. Patent No. 6,419,718 B1, both of which are incorporated herein by reference. Alternative pressure relief valve structures may also be used.

[0017] The reference numeral 15 in the drawings designates an outlet or flow tube that is part of the housing 2 located in another portion of the housing body portion 3. Although the tube 15 can be formed integrally with the housing body portion 3, the tube 15 is typically a separate member that is snap-fit ​​or otherwise attached to the housing body portion 3 as described below.

[0018] During operation, air (gas) to be filtered enters the air cleaner assembly via inlet tube 7t. Eventually, the air passes through a filter media in a filter cartridge configuration disposed within the interior space 2i of the housing 2. After passing through the media of the air filter cartridge, the filtered air is directed to exit the housing via outlet tube 15, from which the filtered air is delivered to downstream equipment, such as an air intake of a turbo or engine system. (Note that, in some cases, the assembly 1 can include an optional safety or secondary filter cartridge (not shown) through which the air passes on its way from the filter cartridge to the outlet tube 15.) The particular air cleaner (filter) assembly 1 shown includes an optional precleaner stage, which is formed in part by directing air tangentially from inlet tube 7t into the interior space 2i of the housing 2. A portion of the air is then directed in a cyclone or spiral pattern around the interior space of the assembly 1 by the internal cyclone ramp 17, FIG. 2, which causes some of the moisture or dirt particles contained within the air stream to be spun against the inner surface of the side wall 2s. This material, separated from the air stream, eventually travels toward and enters tube 9, from which it is discharged through valve 10.

[0019] The particular air cleaner assembly 1 shown is configured to be mounted in a variety of orientations, such as with central axis X vertical or with central axis X horizontal. This is readily accomplished by orienting outlet pipes 9 downward at an angle of 30-60° to axis X at a lower corner of access cover 4 such that pipes 9 can face downward whether axis X is vertical or horizontal.

[0020] 1 and 2, the housing body portion 3 includes a mounting pad structure 11. The mounting pad structure 11 can be integral with other portions of the housing 2 as shown, or can be a separate member. The mounting pad structure 11 is used to help secure the housing 2 in place on the equipment with which the air cleaner 1 is intended to be used. By providing the mounting pad structure 11 on the housing body portion 3, the housing body portion 3 can be held by bolts to the equipment or other system during servicing, and the access cover 4 is removably secured to the body portion 3 for convenient servicing.

[0021] 2, outlet pipe 15 includes an optional tap 15t which can be used, for example, as a pressure tap for a restriction indicator (not shown) that is optionally used with air cleaner assembly 1.

[0022] As described thus far, the air cleaner assembly is similar to many conventional air cleaner assemblies, including those shown and described in International Publication No. WO 2006 / 06241 A1, International Publication No. WO 2009014988 and U.S. Pat. No. 6,419,718 B1, which are incorporated by reference herein.

[0023] Attention is now directed to Figure 3, which shows another elevational view of the air cleaner assembly 1 with some portions shown in cross section. With reference to Figure 3, one can see the filter cartridge 25 disposed within the interior space 2i of the housing. The filter cartridge 25 will be described in further detail below. In general, the cartridge 25 is a serviceable component that includes an elongated filter media 26 through which the air to be filtered passes before it can exit the assembly 1.

[0024] The term "serviceable component" as used herein and when referring to cartridge 25 means that cartridge 25 is removable and replaceable in air cleaner assembly 1. Thus, if media 26 becomes clogged during use, cartridge 25 can be removed and refurbished or replaced.

[0025] 3, it can be seen that the housing 2 includes an optional, but effective, shield structure 27 that surrounds a selected portion of the cartridge 25. The shield structure 27 includes a first shield portion 28 on the housing body portion 3 that is oriented to surround a portion of the cartridge 25 at that location and defines an annular space 29 between the shield 28 and an outer wall 30. Air entering through the inlet 7 is directed (in a cyclone pattern by the inner surface of the inclined surface 17) into the inlet annular space 29. The shield 28 inhibits debris and other material carried by the inlet air in the annular space 24 from directly impinging on the media 26 until at least a portion of the air moves in a cyclone pattern and passes the shield 28 in a direction toward the access cover 4.

[0026] In Fig. 3, reference numeral 33 denotes a second shield portion of the shield structure 27 on the access cover 4. The second shield portion 33 defines an annular space 34 between the shield 33 and a side wall 35 of the portion 4. Reference numeral 37 denotes an outlet or discharge opening on the side wall 2 leading from the housing interior space 2i to the interior space 9i of the tube 9. The discharge or outlet opening 37 communicates with the annular space 34. The shield 33 aids in removing debris and other material through the opening 37 into the debris discharge structure 8.

[0027] The use of a shield structure similar to shield structure 27 having one or more shields similar to shield portions 28 and 33 is common to many air cleaner designs. See, for example, International Publication No. WO 2006 / 06241 A1, International Publication No. WO 2009 / 014988, U.S. Patent Application No. 61 / 446,653, U.S. Patent Application No. 61 / 473,296, and U.S. Patent No. 6,419,718 B1, all of which are incorporated herein by reference. Similar features and principles may be used in the present disclosure.

[0028] Figure 3A shows an enlarged partial view of Figure 3. In Figure 3A, portions of the shield 28 and the annular space 29 are visible.

[0029] It should be noted that in many applications where a "dual stage" or "two stage" air (gas) cleaner is desired, having a first precleaner stage to separate moisture and larger particles from the air before it is delivered to the filter cartridge 25 (second stage), the shield structure 27 and debris ejection structure 8 are used consistently, however, such features are generally optional features and many of the principles of this disclosure are also applicable to air cleaners that do not include such a two stage configuration or a precleaner stage.

[0030] It should be noted that the particular air cleaner assembly 1 shown does not include a safety filter or cartridge disposed downstream of the media 26 and prior to the outlet 50. Many of the principles described herein are equally applicable to systems that use such a safety filter or cartridge.

[0031] II. Features related to housing seal structure - General A. Overview As previously indicated, the features pointed out and described above with respect to Figures 1-3A in relation to general air cleaner construction and operation are well known features, and configurations of those features have been used in a variety of systems. Certain unique features of the air cleaner of Figures 1-3A relate to certain features of the filter cartridge 25, and in particular the engagement of the filter cartridge with other portions of the air cleaner assembly 1. This section describes selected features related in this regard.

[0032] Generally speaking, the cartridge 25 is a serviceable component, i.e., it is removed and replaced during the useful life of the air cleaner 1. A releasable seal is required between the cartridge 25 and the housing 2 to ensure that unfiltered air does not pass through the cartridge 25 and instead enters the outlet tube 15, which could cause engine damage. A releasable sealing engagement between the filter cartridge 25 and the housing 2 that achieves this purpose is generally characterized herein as a housing seal arrangement.

[0033] 3, the filter cartridge 25 generally includes a filter media 26 extending between a first media end 41 and an opposing second media end 42. The first media end 41 is engaged with a first end cap or first end piece 45. The second media end 42 is engaged with a second end cap or second end piece 46. Thus, the media 26 extends between the opposite end caps (or end pieces) 45, 46.

[0034] In the illustrated example, the filter media 26 is configured to surround the open filter interior space 26i approximately centered on the central axis X of the air cleaner 1 and cartridge 25, although other configurations are possible using selected techniques described herein. The media 26 may be pleated, although other configurations are possible. The media 26 may be configured in a cylindrical pattern as shown, although other configurations are possible as needed. For example, the media 26 may extend somewhat conically between the ends 41, 42. The media may also be configured to have non-circular inner and / or outer peripheries, such as elliptical or other cross-sectional shapes.

[0035] The second end member or end cap 46 is typically a closed end member or end cap that extends completely over the media 26 at the second end 42, thereby enclosing the second end 42 of the media 26 and the filter interior space 26i, although other constructions are possible using selected techniques described herein. That is, in the illustrated example, the end member or end cap 46 is a closed end member or end cap, i.e., an end cap that does not have an opening therethrough that communicates with the open filter interior space 26i.

[0036] In contrast, first end member or end cap 45 is an open end member or end cap. That is, first end member or end cap 45 surrounds and defines a central opening 50 that, in this example, communicates with the media via open filter interior space 26i. In normal use, opening 50 is an air flow exhaust opening that allows filtered air to exit the media, e.g., from open filter interior space 26i. (In other applications where gas flows in the reverse direction during filtration, opening 50 may be an inlet opening. Typically, opening 50 is a gas flow opening.) In the illustrated example, the first end member 45 extends completely over the entire media 26 of the cartridge 25 from the outer periphery 26x to the inner periphery 26o. Typically, the first end member 45 has a single central opening 50 therethrough.

[0037] To insert or remove the cartridge 25, the access cover 4 is removed from the housing body portion 3 to provide access to the interior space 2i. The filter cartridge 25 must then be suitably removably sealed to the housing 2 to prevent unfiltered air from flowing into the outlet tube 15. To enable this, the cartridge 25 is provided with a first primary (or housing) seal arrangement 55.

[0038] Attention is now directed to Fig. 3A, an enlarged partial view of the same portion of Fig. 3, with respect to the first housing or primary seal arrangement 55, as well as other features of the first end cap 45. As can be seen in Fig. 3A, the primary seal arrangement 55 defines a radially oriented seal or seal surface 55s oriented to engage a portion of the air cleaner assembly 1, designated generally by the numeral 58, to provide a releasable seal. It is noted that Fig. 3A is a schematic view, and the seal material forming the seal surface 55s is shown in a state that is not distorted by engagement with the structure 58. From this, it can be seen how there is typically much interference between the seal material of the seal arrangement 55 and the surface 58 during sealing, although other configurations are possible, as will be explained in more detail below.

[0039] 3A, it will be appreciated that the surface 55s of the primary seal structure 55 that forms a seal with the structure 58 may be referred to as a radially oriented surface. In this case, the primary seal structure 55 is referred to as a radially oriented seal. As used herein, "radial" means that the seal or seal surface (as well as the compression of the seal surface during sealing) is generally defined relative to (i.e., around) the central axis X in a direction toward or away from the central axis X. The particular surface 55s of the illustrated example faces radially outward relative to the central axis X, and thus the seal structure 55 may be characterized as "radially outwardly oriented." However, in accordance with certain principles of the present disclosure, radially inwardly oriented seals may also be used.

[0040] It should be noted that in the illustrated example, the housing seal arrangement 55 includes a portion of the end cap 45. More generally, any housing seal arrangement that is attached to a filter cartridge is configured to releasably seal against the housing, regardless of whether that particular housing seal arrangement includes a portion of the end member.

[0041] The preferred and effective housing seal arrangements described herein are generally "non-clamping" or "clampless" housing seal arrangements, meaning that the housing seal arrangement is formed when the cartridge is inserted into the housing without the need for tightening clamps or connectors of any kind.

[0042] The particular features of the primary seal arrangement 55 of the illustrated example are described in further detail below.

[0043] Generally, for the particular structure shown in Figure 3A, the surface 58 with which the seal structure 55 removably engages to form the primary seal structure 55 comprises a seal flange 60 facing axially inwardly of the housing 2, toward the access cover 4, Figure 3. For this particular example shown, the seal flange 60 is part of the flow tube, in the illustrated example the outlet tube 15.

[0044] 3A, in the example construction shown, the outlet (flow) tube 15 is a separate component formed from the housing portion 3. In the particular example construction shown, the flow tube 15 is snap-fitted into the end 3x of the housing portion 3, forming a connection 62 between the two components. Connection 62 is a location where water or other materials may enter the interior space 2i of the housing 2. Some potential problems in this regard are advantageously solved by an optional second (housing) seal arrangement 65.

[0045] Typically, when an engine system (the equipment in which the air cleaner assembly 1 is used) is operated, a vacuum or suction of air occurs at the tube 15 in Figure 3, which draws air through the air cleaner 1 and into the engine or other equipment system. That is, typically, air may be drawn from the surrounding environment into the interior space 2i of the housing 2. If the second seal 65 is provided, this suction would cause such a draw at the connection 62 during normal operation.

[0046] Generally, the second seal arrangement 65 defines a seal surface 66 on the cartridge 25 that removably engages a seal surface 67 on the housing portion 3. The seal surface 66 is generally radially oriented and is therefore a radial seal. In the illustrated example, the seal surface 66 is a radially outwardly facing (peripheral) surface that is surrounded by the seal surface 67 on the housing portion 3 when installed.

[0047] It can be seen that the connection 62 communicates with the interior space 2i of the housing 2 at a location between the primary seal structure 55, which is isolated from the rest of the housing 2 by the cartridge 25, and the second seal structure 65. As a result, there is no internal suction acting on the connection 62 at that location to draw water and / or associated materials into the interior space 2i, and therefore the risk of drawing a vacuum at the connection 62 is prevented. It should be noted that in the illustrated embodiment, the second seal structure 65 is not provided to accommodate a large pressure difference across it and / or to avoid unfiltered air entering the (outlet) tube 15. The second seal structure 65 is therefore said to be a secondary seal, i.e. a seal with a lower sealing force, which compresses less than the primary seal structure 55. As will be understood from the detailed description below, in certain preferred configurations, the sealing material of the second seal structure 65 will typically compress somewhat when the cartridge 25 is installed, but not as much as the sealing material of the primary seal structure 55.

[0048] In the next section, the features of the first seal arrangement 55 and the optional second seal arrangement 65 are described in further detail.

[0049] B. End member features including first seal structure 55 and second seal structure 65, FIGS. 3 and 3A 3 and 3A, for the particular assembly 1 shown, cartridge 25 is configured such that first (end) member 45 is a molded-in-place (end) member 70 to which a portion (e.g., one end) 41 of media 26 is fixed, e.g., embedded. This is a typical configuration, but alternative configurations are possible according to selected principles of the present disclosure. In a typical construction, end member (cap) 70 completely covers and closes end 41 of media 26 from outer periphery 26x of the media to inner periphery 26o of the media. If media 26 is pleated, outer periphery 26x is the outer pleat tip and inner periphery 26o is the inner pleat tip.

[0050] Typically, the end cap 70 is manufactured from a flexible, compressible end cap material formed from a foam such as foamed polyurethane. Possible materials are described below.

[0051] For the particular cartridge 25 shown, the first seal structure 55 and the second seal structure 65 are formed as an integral part of the molded-in-place portion of the end cap 70, although other structures are possible, as will be described in more detail below in conjunction with the discussion of Figures 4-8.

[0052] Before referring to Figures 4-8, attention is again directed to Figure 3A. The end member (cap) 70 includes an axially outer end surface 72 having a recess, receiving portion or receiving groove 73. The size and location of the recess, receiving portion or receiving groove 73 is selected to receive the flange 60 and a portion of the housing part 3, designated by reference numeral 3x, which project into the recess, receiving portion or receiving groove 73 when the cartridge 25 is installed. That is, a portion of the connection portion 62 projects into the recess, receiving portion or receiving groove 73. In the illustrated example, the radially innermost surface 73i (the surface facing radially outward) of the recess, receiving portion or receiving groove 73 forms the sealing surface 55s of the primary seal structure 55. In the illustrated example structure, the radially outermost surface 73o (the surface facing radially inward) of the recess, receiving portion or receiving groove 73 preferably does not form any seal at all. Typically, this surface 73o does not radially engage the housing part 3 or the flange 58 at all, but other structures are possible. It should be noted that end cap 70 in Figure 3A has a portion 70k that does not surround media 26 at end 41. In this example, this is the typical configuration since end 41 of the media is embedded in end member (cap) 70. Region 70k may engage a portion of the housing, but is not typically significantly compressed, so in many cases it does not participate in sealing the housing, although alternative configurations are possible.

[0053] 3A, the sealing surface 66 of the secondary seal structure 65 is part of the outer periphery 70p of the end member (cap) 70. Thus, the sealing surface is sometimes referred to as a circumferential radial seal. Also, in the illustrated embodiment, the portion of the sealing surface 66 that is compressed during sealing preferably does not surround the media 26, although other configurations are possible.

[0054] 4, a schematic perspective view of cartridge 25 is shown looking generally toward outlet end 75 and end member (cap) 70. As previously mentioned, cartridge 25 generally includes media 26 extending between first end member (cap) 45 and second end member (cap) 46 and circumscribing cartridge central axis X. Generally, when cartridge features are referred to as being radially oriented, it is meant that the features are oriented generally outwardly or away from a central axis, in this example cartridge central axis X. When features are referred to as being axially or "axially" oriented, it is generally meant that the features are oriented generally in alignment with a central axis, e.g., cartridge central axis X (not necessarily parallel to the central axis). When a seal is characterized as being "radially outwardly" oriented, it is meant that the seal or sealing surface is oriented generally radially away from a central axis, such as cartridge central axis X.

[0055] 4, it can be seen that the end member (cap) 45 includes a molded portion 70m, which in this example defines an open central opening 50 through which (filtered) air is discharged from the cartridge 25. The end member (cap) 70 (and thus the molded portion 70m) is an integrally molded end member (cap) defining a recess, receiving portion or receiving groove 73. A radially inner portion of the recess, receiving portion or receiving groove 73, designated by reference numeral 73i in the figures, forms in part a sealing surface 55s. It can be seen that the surface 55s faces generally radially outwardly and forms a radially outwardly facing seal. It can be seen that the radially outer surface 73o of the recess, receiving portion or receiving groove 73 defines a radially inwardly facing surface, i.e., a surface facing the axis X. As previously mentioned, in the particular cartridge shown, the surface 73o is not a sealing surface, although other configurations are possible.

[0056] It is noted that it is possible for the sealing surface 55x to surround the protrusion and not be a sidewall of a recess, receiving portion or receiving groove, such as the recess, receiving portion or receiving groove 73. However, in the particular embodiment shown, it is advantageous for the sealing surface 55x to be the sidewall 73i of the recess, receiving portion or receiving groove 73.

[0057] 4, reference numeral 66 denotes a sealing surface of a second (optional) sealing arrangement 65, which in the illustrated example is part of the outer periphery of a molded part 70 which engages with the housing part 3 when the cartridge 25 is installed to form the second seal 65 therewith.

[0058] 5, several portions are shown in cross section to show internal details of cartridge 25. For purposes of discussion in this section, particular attention is paid to first end member (cap) 45. As previously mentioned, in an exemplary preferred construction, end member (cap) 45 includes a molded portion 70m (or end cap 70) disposed at end 41 of media 26. Sealing surface 66 of second seal structure 65 and sealing surface 55s of primary seal structure 55 can be seen. Groove 73 is also shown in cross section.

[0059] The sealing pressure of seal structures 55 and 65 at surfaces 55s and 66, respectively, is preferably adjusted by forming each seal from a radially compressible material and preferably (optionally) by embedding a relatively rigid radial support structure in end member (cap) 70. For primary seal structure 55, the radial support is indicated at 80. For secondary seal structure 65, the radial support is provided by support 81 embedded in end member (cap) 70.

[0060] Typically, the support structure that supports the seal structure 55, 65 is a "preform" embedded in the molded portion 70m of the end piece (cap). For purposes of this description, "preform" means a pre-molded component or preform component that is used in conjunction with the support structure to assemble the cartridge 25. Typically, the preform component is molded from plastic, although other materials are possible. Typically, the preform component is secured to a structure that extends toward the second end cap 46, although other structures are possible.

[0061] The support 80 is typically embedded in a sealing material forming the primary seal 55 in a position such that the compression of the surface 55s in the radial direction toward the central axis X is assisted by the support 80 such that the amount of radial compression of the end member (cap) in the region between the surface 55s and the support 80 is at least 10%, typically at least 15%, preferably no more than about 35% maximum compression, and typically in the range of about 20% to 30% maximum compression. Typically, to achieve this, the support 80 is spaced from the surface 55s by a maximum distance of no more than 20 mm, typically no more than 15 mm, and typically the width of the spacing is in the range of about 5 to 14 mm. In this regard, the width of the spacing refers to the maximum spacing, i.e. the separation distance, between the support 80 and the portion of the surface 55s that would be radially furthest from the support 80 if the surface 55s were not distorted by compression.

[0062] In contrast, as previously indicated, in the illustrated example cartridge 25, the optional second seal structure 65 does not participate in the ingress of dirt and water into the outlet tube 15, but serves to isolate the connection portion 62 of FIG. 3A from the interior space 2i of the housing 2, so that the amount of compression (if compression occurs) of the second seal structure 65 is typically less than that of the first seal structure 55. It is possible to provide the second seal structure 65 with a support 81, but the support 81 is optional. In some cases, the second seal surface 66 may be aligned with the surrounding housing portion so as to achieve an alignment with relatively little compression (if compression occurs). Typically, in use, the optional support 81 is located at a distance not greater than about 10 mm, typically not greater than about 8 mm, and usually within the range of 1 to 6 mm, from the radially outermost portion of the surface 66 that compresses when the cartridge 25 is installed. Typically, these dimensions are selected so that the total amount of compression of the sealing material in area 66x, i.e., face 66, compressed toward support 81 is a maximum of no more than about 25%, usually no more than 20%, typically at least 3%, often at least 5%, usually no less than 5% and no more than 20%, although other configurations are possible.

[0063] 5, it can be seen that in the illustrated construction, the portion of surface 66 which forms the radially outward seal includes a portion which extends toward end cap 46 beyond the deepest portion of groove 73. This is optional, but may be considered a preferred configuration. That is, in the exemplary embodiment, there may be an optional radial overlap between surface 66 and portions of surface 55x, but at least a portion of surface 66 extends toward end member (cap) 42 farther than any portion of surface 55s. This amount of extension (in use) is at least 1 mm, typically at least 2 mm, and in some cases at least 4 mm.

[0064] Before discussing further the features of the sealing structure of end member (cap) 70, attention is directed to Figure 5 for a brief description of selected additional features, which are described in more detail later in this specification.

[0065] Attention is first directed to end member (cap) 46 disposed at end 42 of media 26. In the particular construction illustrated, end cap 46 is a molded-in-place end cap that completely covers end 42 of media 26 and closes off open interior space 26i. The particular molded-in-place end member 46 illustrated is formed from a material similar to that used for molded portion 70, although other materials are possible if desired.

[0066] 5, attention is now directed to support 90. Support 90 in the illustrated example is a central support extending between end members 41, 42 and surrounded by media 26, and in fact, in the illustrated example, is embedded in end cap 45 (i.e., molded portion 70m) and end cap 46. Optional advantageous features of the particular support 90 illustrated are described in more detail later in this specification.

[0067] Referring to FIG. 6, an end view of molded portion (end piece or end cap 70) 70m is shown. In this specification, the face of end molded portion 70m facing the viewer of FIG. 6 is generally referred to as axial end face 72. In the illustrated example, axial end face 72 primarily comprises outer ring 72x and inner ring 72i (see FIG. 5) on either side of receiving groove 73. At the outer periphery of ring 72x, cartridge 25 includes a plurality of insets, generally of two types: insets 93, which are artifacts generally formed by standoffs at the bottom of the mold where molded portion 70m will be formed, and insets 94, which are generally formed from portions of the bottom surface of the mold that are used to help center the media pack in the mold during formation of molded portion 70m. Note that in the illustrated example, standoff artifacts 93 include selected ones of centering artifacts 94.

[0068] Attention is now directed to FIG. 7, which shows a cross-sectional view taken generally along line 7-7 of FIG. 6. In FIG. 7, the mold-in-place molding material of the end member (cap) 46 or molded portion 70m is shown. That is, FIG. 7 is a schematic view, and the various supports 80, 81 are not shown. FIG. 7 is intended to show the configuration of features formed from the resin typically used to mold the end member (cap) 70. Referring to FIG. 7, reference numeral 66 indicates a peripheral portion of the molded portion 70 for forming a secondary seal. Between portion 66 and end 72x, the outer peripheral surface of molded portion 70m further includes an inwardly stepped or inwardly tapered region 95. This region is typically sized to cooperate with an adjacent portion of the adjacent housing portion during installation so as not to be compressed generally toward the central axis X during installation, although other configurations are possible. Typically, region 95 is preferably sized to form a generally linear fit between the portion of housing 2 surrounding region 95 during installation. This linear fit preferably continues for a length of at least 4 mm. Alternative configurations are possible, such as requiring some amount of compression (e.g., slight) in this region and / or varying the axial length of the face. Region 95 cooperates with region 66 to not only inhibit retraction at connection 62 in FIG. 3A, but also to help stabilize cartridge 25 within housing 2.

[0069] Attention is now directed to FIG. 8, which shows an enlarged fragmentary view of a selected portion of molded portion 70m of FIG. 7. In FIG. 8, receiving groove 73 can be seen. Radially inner surface 73i (the radially outwardly facing surface) of groove 73 includes a lower portion 73i adjacent a bottom portion 73b configured to form the most compressed portion of the radially outwardly facing radial seal of primary seal structure 55. As shown at 98, the outer portion of surface 73i is beveled to facilitate guiding cartridge 25 along flange 60 during installation. As can be seen, radially outer surface 73x has a bevel 73t at its outer end to similarly facilitate mating along flange 60 and a portion of housing portion 3t during installation. Following a further general description of cartridge 25 and housing 2 below, seal structures 55 and 65 will be described in more detail.

[0070] III. Additional Details of Cartridge 25 Assembly and Internal Structure Attention is now directed to Figure 9, where support 90 is shown in perspective view. Support structure 90 generally comprises a liner portion 100 and an outlet end support portion 101. In the example assembly shown, outer end support portion 101 and liner portion 100 are non-removably secured to one another, although other constructions are possible. Typically, the portions are integrally molded from plastic, although other constructions are possible.

[0071] The outlet end support section 101 includes an inner central support or hub 105, an optional circumferential ring 106 surrounding and spaced from the hub 105, and an open lattice structure 108 extending between the hub 105 and the circumferential ring 106. The lattice structure 108 includes a plurality of spaced apart struts, ribs or support members 110 that extend between the circumferential ring 106 and the hub 105 and secure the circumferential ring 106 in place. Although the circumferential ring 106 is optional, it is advantageous to have one. The circumferential ring 106 provides structural support for the ends of the strips, ribs or support members 110. However, the circumferential ring 106 is not required in all applications of the present disclosure.

[0072] The posts, ribs or support members 110 are also optional, but may be beneficial in that they aid in assembly of the cartridge and also provide areas for providing mechanical interlocking between the molded-in-place portions of the end caps and the preform portions of the support structure 90.

[0073] 9, the peripheral ring 106 includes an edge 114. The edge 114 is generally the portion of the ring 106 that protrudes furthest into the molded portion 70m during formation of the cartridge 25. For the particular assembly shown, the edge 114 is preferably optionally defined by a plurality of spaced apart tabs 115 having grooves or recesses 116 therebetween. Generally, the recesses 116 serve to facilitate the flow of resin along the ring 106 in the region of the edge 114 and the tabs 115 when the end cap 70 is formed. While the tabbed configuration is preferred, other configurations are possible.

[0074] The peripheral ring 106 further includes an optional seal support region 118. Generally, if the seal support region 118 is used, in the assembled cartridge 25, the seal support region 118 constitutes the optional support 81 of FIG. 3A for the second seal structure 65.

[0075] Typically, the support portion 101 is configured such that when installed, no portion of the peripheral ring 106 surrounds the media, although other configurations are possible.

[0076] 9, the hub 105 includes an inner surface 105i and an outer surface 105x. In the illustrated example cartridge 25, the outer surface 105x forms the seal support 80 of the primary rib seal structure 55.

[0077] It should be noted that the support 90 further includes an optional inner ring 120 spaced radially inward from the hub 105. A trough 120t is formed between the inner ring 120 and the hub 105 into which resin can flow during formation of the cartridge. Several openings 121 are shown in Figure 9 to allow resin to flow into the trough 120.

[0078] 10, a side view of support 90 is shown. Support 90 in FIG. 10 can also be seen to include optional end ring 106 defining tab 115 (optional), recess 116 and seal support area 118, as previously described. Also seen is opening 121 through ring 120 to facilitate resin flow.

[0079] 10, support 90 includes an optional media centering ring 125. Media centering ring 125 is positioned such that an inner periphery of media 26 engages support 90 along and around ring 125 when media 26 (or a media pack) is positioned on support 90 to form a cartridge, to facilitate formation of the proper media shape prior to molding of end cap 70.

[0080] Assembly of cartridge 25 generally involves positioning the media pack on support 90, typically by forcing the media pack over end 127 until media end 41, FIG. 3, engages end portion 101, generally in region 128, FIG. 10. Media centering ring 125 allows media 26 to assume the proper circumferential shape about end support 100. Ring 125 also supports media 26 in the completed cartridge 25. Each end cap 45, 46, FIG. 5, can be molded in place over the combination of media pack 26 and support 90. During formation of end cap 45, resin flows through recess 116 and opening 121 and into the space between supports 110, thereby ensuring mechanical fixation of support 100 in place and ensuring complete sealing of end 41 of media 26, whether or not the media 26 is pleated. Additionally, the mold may be configured to form sealing surfaces 55s and 66 and groove 73 in end member (cap) 45.

[0081] It should be noted that the media pack pressed into the support 90 may have an outer liner or may not have an outer liner, or may have an inner liner or may not have an inner liner. Typically, the media pack is a pleated media, and therefore does not include an inner or outer liner when pressed into the support 90. Typically, the media is pleated and may include corrugations extending generally perpendicular to the pleat tips to facilitate holding the pleats open during use. As is commonly known in the art, various techniques can be readily used to fold the pleat tips. An example of this technique can be found in media packs bearing the trademark "Pleatloc" of Donaldson Company Inc., Minneapolis, Minnesota, the assignee of the present application.

[0082] In FIG. 11, an end view of the support 90 as viewed generally towards the end structure 100 is shown.

[0083] In FIG. 12, an end view of support 90 as viewed generally toward end 127 is shown.

[0084] 13 shows an enlarged fragmentary view of a portion of FIG. 11. Generally, one of a number of end tabs 127x at end 127 is visible. Tab 127 helps mold end cap 46 securely in place.

[0085] FIG. 14 shows the same portion of FIG. 11 in an enlarged, partial cross-sectional view.

[0086] 15 shows a partial cross-sectional view of a portion of the support 90. The trough 120t can be seen, and a portion of the opening 121 between the ring 120 and the hub 105 can be seen.

[0087] In FIG. 16, an enlarged fragmentary view of a portion of the end support structure 101 of the support 90 is shown.

[0088] 16, a particular preferred configuration of the end supports 101 is shown. In particular, for the lattice structure 108, which in this example includes ribs 110, the ribs 110 preferably extend from adjacent the inner hub 105 to adjacent the outer ring 106 and are angled away from the media end 41 (not shown in FIG. 16). This angle or divergence from the media is illustrated in FIG. 16 by the angle CS. Thus, when the media is pressed into the support 90, the media end 41 generally engages the support structure 101 at the projection 128 in FIG. 16 such that the ribs 110 diverge away from the media 26. In practice, the media end 41 is generally aligned with the line 111t in FIG. 16. The angle CS has the advantage of creating a flow area for the resin as it flows across the end of the media pack. Generally, the angle CS is at least 0.5°, typically at least 1°, and often greater. Typically, the angle CS is in the range of greater than or equal to 1° and less than or equal to 3°, although alternative values ​​are possible.

[0089] The particular cartridge 25 shown includes an optional resonator or sonic choke, although other configurations are possible. The optional resonator or sonic choke comprises a portion 140, FIG. 10, of the support 90. In more general terms, the support 90 includes an end perforated liner portion 141 at the support portion 100 opposite the support portion 101. When the media 26 is positioned around the liner 90, the perforated liner portion 141 acts as an inner liner 142 adjacent the media end 42. An opening 143 in the inner liner portion 142 provides an air flow path that ultimately leads to the outlet opening 50, FIG. 4.

[0090] 10 and 16, between the support portion 101 and the perforated end portion 142, several features are provided to form an optional sonic choke or resonator portion 140. First, portion 160 is provided with a funnel portion leading to the throat 161 as an intermediate region between the end portion 142 and the throat 161. From the throat 161 to the engagement position with the end portion 101, an expanding cone-shaped portion or funnel portion 162 is provided. The portion 160, the throat 161 and the portion 162 together define the sonic choke or resonator portion 140. This inhibits the transmission of noise from the external engine system when the cartridge 25 is in use.

[0091] 10, the optional resonator / sonic choke structure shown may optionally differ in some ways from the structure described in U.S. Pat. No. 6,419,718 B1. Referring to FIG. 10, the area extending from the liner 141 toward the throat 161 is provided with a tapered portion 160 having two opposing curved portions when viewed from the outside and / or in the cross section shown in FIG. 10. The first portion 171 is curved including a concave portion curved radially inward and a convex portion curved radially outward. The area 171 is also provided with an opening structure 172 for air flow. In practice, due to the opening structure 172, typically at least 40% of the area 171 is open, and typically at least 50% is open.

[0092] Between region 171 and throat 161 is region 173 which is formed to have a curved shape including a generally radially outwardly curved side, so that the intermediate region from region 142 towards throat 161 defines (in cross section) a slight S-shaped curve on one side of support 90. It should be noted that in the particular construction shown, region 173 has the advantage of being solid and unperforated, although alternative constructions are possible.

[0093] Typically, the throat 161 has a cross-sectional dimension of at least 25 mm, usually no more than 35 mm, and often in the range of 26 to 31 mm. The throat 161 is configured to provide a suitable resonator effect without unduly restricting airflow during use.

[0094] Typically, the conical region 175 slopes outwardly at an angle of about 3°-4° on either side relative to the central axis, thereby defining a conical expansion angle of about 6°-8°, designated DB in Figure 10. A typical conical expansion angle is about 7°.

[0095] In general, portions 160, 161 and 162 create a sonic choke or resonator effect which serves to inhibit noise transmission from the engine through the air-inducting structure of the air cleaner to the outside environment. The sonic choke or resonator is also configured to avoid undesirable restriction of air flow from the surrounding environment into the air cleaner and through filter cartridge 25. In particular, it has been found that aperture structure 161 in region 162 facilitates this while also aiding the flow of air from the region of media 26 surrounding solid portion 162 of the resonator into tube 162 and out through aperture 50 in FIG. 3.

[0096] The features of support 90 and region 100, including support portion 101 and sonic chokes, can be further understood by examining FIGS.

[0097] 29 and 30, the second end cap 46 is shown. As previously indicated, the second end cap 46 may be a molded-in-place end cap, although other constructions are possible. In FIG. 29, an end plan view of the end cap 46 is shown. In FIG. 30, a cross-sectional view is shown along line 30-30 of FIG. 29. In FIG. 30, the second end cap 46 is shown in schematic form without showing the portion of the media 26 and liner 90 embedded in the second end cap 46. It can be seen that the end cap 46 has an outer axial (or end) surface 46x with a plurality of projections or bumpers 46y. The projections or bumpers engage the access cover 4 to help support the cartridge 25 firmly within the housing 2 during installation.

[0098] Periphery portion 46p, FIG. 30, is sized to be positioned within housing shield portion 33, FIG. 3, and supported therein to prevent cartridge 26 from undesirably moving too far.

[0099] With regard to the construction of the cartridge 25, there is no particular requirement as to the order in which the two end caps 45, 46 are formed by molding after the media pack 26 has been properly positioned on the support 90.

[0100] With the above in mind, it will be appreciated that some variations are possible in the application of the present disclosure. For example, the support structure 81 need not be integral with the intermediate support of the media. That is, if desired, the support structure 81 may not be directly attached to or integrally formed with any structure around which the media is positioned. For example, the support structure 81 and any inner liner may be provided separately and each incorporated into the cartridge during manufacture, for example, embedded in a molded-in-place end cap material. Additionally, the cartridge may not have an inner liner, or the media may surround an inner liner that is not configured as a sonic choke. Additionally, referring to FIG. 9, the structure of the support structure supporting the inner seal, for example, 105, need not be directly coupled to the optional support used to support the outer seal, for example, 118. If a ring supporting the outer seal is used, it may be possible to completely separate the ring from the structure supporting the inner seal.

[0101] Furthermore, it is not specifically required that the support structure or various portions of the support structure be constructed from the same material. For example, the inner liner could be constructed from an expanded metal construction and both or one of the seal supports could be constructed from plastic.

[0102] IV. Selected Housing Section and Outlet Pipe Features, FIGS. 17-28 and 31-32 17 to 28 and 31 to 32 show in detail various characteristic structures of the housing 2 and the outlet pipe 15. In this chapter, these characteristic structures will be described.

[0103] Referring to Figure 17, a typical appearance of the housing portion 3 when molded from plastic is shown. Features previously described are shown as inlet tube 7t, side wall 3s and mounting pad 11. Also shown is rim 3r which would engage latch structure 5 of access cover 4 of Figure 2. External features of the housing which define inner angled surface 17 can also be seen.

[0104] Shown is the end 3x of the housing portion 3. Also shown is a lining opening 200 through which a portion of the outlet tube 15 would protrude in use. The lining opening 200 is provided with an optional interference corrugation or interference tooth structure 201 which acts as an indexing structure to facilitate positioning of the outlet tube 15 as described below.

[0105] Still referring to FIG. 17, the housing portion 3 shown may conveniently be molded from plastic if desired, although the housing portion 3 may be constructed from other materials.

[0106] In Figure 18, a side view of the housing portion 3 is shown. In Figure 19, an end plan view of the housing portion 3, looking generally towards the end 3x, is shown. In Figure 19, an opening 200 can be seen having an interference region (in this example formed by a rib or tooth region 201) with optional toothed or indexing region 201 optionally including a number of outwardly deflectable tabs 202. Additionally, the tangential position of the inlet tube 7t relative to the side wall 3s and the central axis X can also be seen.

[0107] In Figure 20, a cross-sectional view is shown taken generally along line 20-20 of Figure 19. In addition to the features previously described, reference numeral 210 denotes a protruding structure extending axially from end 3x into interior space 2i of housing 2. It is this protrusion 210 that engages a portion of the outlet tube to form a connection upon installation. Protruding structure 210 includes a plurality of optional tabs 202 having optional ribs or toothed structures along a radially inner portion of protruding structure 210.

[0108] 20, attention is now directed to inner sidewall region 211. This region 211 includes a support portion 212 that forms a sealing surface 67 for engaging surface 66 of optional secondary seal structure 65 of Figures 3 and 3A. In region 211, surface 212 generally includes a first end region 213 that is configured to linearly align with cartridge 26 of Figure 3A (in use) and an optional opposing second end region 214 that generally provides for optional compression of the seal material in region 66 during installation of cartridge 26 of Figure 3A.

[0109] In Figure 21 there is shown an enlarged fragmentary view of a portion of Figure 20. Areas 213 and 214 are visible.

[0110] 22 shows a perspective view of the outlet tube 15. The outlet tube 15 includes a connector region 220 which engages with the housing part 3 during use. The outlet tube 15 further includes a gas flow tube region 221 and an outlet 222. It is noted that the particular outlet tube 15 shown is an L-shaped tube, i.e. the conduit through the outlet tube is bent. Alternative configurations are possible.

[0111] Referring to FIG. 22, an optional pressure tap 15t on the previously mentioned pipe section 221 is shown.

[0112] 22, it can be seen that connector portion 220 includes two ring portions, an outer ring 224 and an inner ring 225. Rings 224, 225 are described in further detail below.

[0113] 22, the connector region 220 is provided with a peripheral ring portion 228 having an optional teeth / projection region 229. The teeth / rib region 229 is generally sized to mate with the optional teeth / rib region 201 of the housing portion 3. Thus, the L-shaped tube 221 can be rotated to a particular angle relative to the housing portion 3 and the tube 221 will remain in that orientation (indexed position) until the force applied by the twisting motion becomes overwhelming.

[0114] 23 shows a side view of the outlet tube 220. It should be noted that the outlet tube 221 is provided with a rim 222r to facilitate the connection of a hose or other conduit.

[0115] Figure 24 is a plan view of the outlet tube 15. Figure 25 is a cross-sectional view taken generally along line 25-25 of Figure 24.

[0116] 25, as previously indicated, the connector portion 222 generally comprises a first ring portion 224 and a second ring portion 225. The first ring portion 224 generally includes features for securely coupling to the housing portion 3x. The first ring portion 224 generally forms the support 60 of the primary seal structure 55 of FIG. 3A, and the second ring portion 225 forms the outlet flow portion.

[0117] 25, it can be seen that the first ring portion 224 has an optional snap-fit ​​leading tip 226 and receiving portion 227. The tip 226 is forced into the opening 200, FIG. 17, until a snap fit occurs, and the portion of the housing portion 3 defining the opening 200 is located in the area 227. Comparing FIG. 25 with FIG. 3A, it can be seen that the outlet tube 15 can include an outer peripheral ring portion 227a and a base portion 227b on the first ring portion 224. In FIG. 3A, this ring 227a is shown as having an axial projection 227p. This axial projection 227p can engage around the axial outer projection 230, FIG. 3A, of the housing end 230 to facilitate a water seal. It should be noted that the ring 227a in FIG. 25 is shown without this optional projection 227p (shown in FIG. 3A).

[0118] FIG. 26 shows an enlarged fragmentary view of a selected portion of FIG.

[0119] FIG. 27 shows a cross-sectional view taken generally along line 27-27 of FIG.

[0120] Figure 28 shows an enlarged fragmentary view of a portion of Figure 27. In detail, one can see the rib portion 229. Furthermore, from Figure 27, it can be seen that there are opposing rib portions 229 on either side of the ring 224.

[0121] In Figure 31, the access cover 4, as it would be made from plastic, is shown without the latch 5 in place. In Figure 32, a cross-section of the access cover 4 is shown. The flange 33 can be seen. Slits or spaces 33x in the flange 33 allow water to escape from the flange 33 that may get inside the flange 33 during use.

[0122] V. Detailed Description of Selected Specific Characteristic Structures A. Primary seal feature 55 and recess, receiving portion or groove 73 7 and 8, a typical assembly will now be described with reference to the definition of the primary radial sealing surface 55s in the illustrated example with optional recess, receiving portion or receiving groove 73, although alternative constructions are possible. If recess, receiving portion or groove 73 is provided, the depth of recess, receiving portion or groove 73 at its deepest point from at least one or the other of faces 72x, 72i, usually both, is typically at least 5mm, usually at least 8mm, often 10-25mm, and typically adjacent bottom end 73b, the width of recess, receiving portion or groove 73 is at least 3mm, usually at least 5mm between opposed side walls 73x, 73i (ignoring any slope at its deepest point).

[0123] In other words, if the optional recess, receiving portion or receiving groove 73 is used, the inner and outer side walls 73i, 73x of the recess, receiving portion or receiving groove 73 are usually spaced apart by at least 3 mm, typically at least 5 mm, and often spaced apart by an amount in the range of 5 mm or more and 10 mm or less at the bottom of the groove 73. If the sealing surface formed by the recess, receiving portion or groove is circular, typically this spacing will not exceed a 15 mm separation at its widest point within 30% of the maximum depth of the groove 73, typically within 35% of the maximum depth of the groove 73, although other configurations are possible. However, it will be appreciated that the side walls 73x, 73i may also be angled inwardly toward each other at the deepest bottom 73b of the groove.

[0124] Where the sealing surface formed by optional recess, receiving portion or groove 73 is circular, typically at its outer end adjacent surface 72x, 72 in FIG. 8, the width of recess, receiving portion or groove 73 is at least 5 mm, typically 7 mm, and often between 7 and 25 mm.

[0125] The axial length of face portion 73r when compressed radially inwardly to the greatest extent when a radially outwardly facing seal is formed in the region of face portion 73r of recess, receiving portion or groove 73 in FIG. 8 will usually have an axial length of at least 5 mm, typically 8 to 20 mm, and will usually be spaced from one or the other of face portions 72x, 72i, typically both, by a distance of at least 4 mm, often within the range of 4 to 15 mm.

[0126] Referring to Figure 7, typically the portion of molded portion 70m defining radial sealing surface 55s is (when unstrained) at least 5mm thick, typically at least 7mm thick, and usually between 7 and 25mm thick, from opening 50 to surface 55s. Preferably surface 55s is not spaced more than 50mm from opening 50, although other constructions are possible. Also, typically support 80 of Figure 5 is recessed in this region not more than 20mm, typically not more than 15mm from the nearest portion of surface 55s before it is distorted by compression during installation, although other constructions are possible.

[0127] In general, even if a variety of cartridges of different sizes are used, the above features when the optional recess, receiving portion or receiving groove 73 is used are useful and acceptable in providing two structures: an effective first radial seal 55, and an area for receiving the axially protruding portions of both the outlet tube 15 and the engaging portion of the housing portion 3.

[0128] Typically, the molded portion 70m defining the radial seal surface 55x is configured such that when installed against the support 80, the material forming the radial seal surface causes the seal surface 55s to compress (radially up to) at least 10% of its thickness toward the first seal support 80, typically at least 15% of its unstrained thickness, and usually an amount in the range of 15-35% of its unstrained thickness. Typical examples would include compression in the range of 20% or more and 30% or less of its unstrained radial thickness.

[0129] B. Optional outer secondary seal surface 66 7 and 8, the outer surface 66 is typically at least 3 mm radially from the face 55s, often at least 5 mm, often at least 10 mm, usually at least 15 mm, and typically at least 20 mm in structures configured as shown. Typically, this separation distance is in the range of 20-80 mm, although other values ​​are possible.

[0130] Typically, the first radially oriented sealing surface has a maximum seal perimeter cross-sectional dimension that is at least 6 mm smaller than the second radially oriented sealing surface, often at least 10 mm smaller, more often at least 20 mm smaller, and typically at least 30 mm smaller in configurations such as those shown. When a circular sealing surface is defined, the "maximum seal perimeter cross-sectional dimension" is typically a diameter. Note that when a cartridge such as that shown is used, the first radially oriented sealing surface typically has a maximum seal perimeter cross-sectional dimension that is at least 30 mm smaller than the second radially oriented sealing surface.

[0131] When compression against the support 81 occurs, the second seal surface 66 is typically not spaced more than 8 mm from the support 80. Typically the material in this area will compress (radially) a maximum of at least 3% towards the second seal support, typically at least 5%, and often by an amount in the range of 5-20%.

[0132] It should be noted that, in the illustrated example, the majority of the sealing axial length of surface 66 that is compressed during installation is axially spaced from surface 72x farther away than the bottom end of receiving groove 73, although other configurations are possible. This is typical when cartridge 25 is assembled as described herein. Typically, surface 66 extends axially toward the opposite end 46 of cartridge 25 beyond bottom 73b of groove 73 a distance of at least 2 mm.

[0133] C. Materials that can be used to mold the end caps 45, 46 A variety of materials can be used for the end cap material 45, 46 when the end caps 45, 46 are molded in place to provide both an effective seal at the end of the media pack and an effective housing seal. Typically, a foam material is used having a Shore A hardness of not more than about 30, typically not more than about 22, and preferably not more than 20. Typically, the material selected has a hardness of not more than 28 lbs. / cu. ft (about 450 kg / m 3 ), and more preferably no more than about 22 lbs. / cubic ft (355 kg / m 3 ), typically about 18 lbs. / cu.ft (290 kg / m 3 ) in most cases, it has a "molded density" of 13-17 lbs. / ft (200-275 kg / m 3 ) is selected. In this specification, the term "molded density" is generally defined as weight divided by volume. A displacement test or a similar test can be used to determine the volume of a molded foam sample. When applying a volume test to absorb water by pressure into the pores of a porous material, it is not necessary to expel the air contained in the pores. Thus, the displacement test used to determine the volume of the sample will be an instantaneous drainage without the need to wait a long time to expel the air in the pores of the material. In other words, only the volume represented by the circumference of the sample needs to be used to calculate the molded density.

[0134] Typically, a resin is selected that will rise during cure and increase in volume during cure by an amount of at least 40%, typically 60%, and often 80% or more.

[0135] Commercially available foamed polyurethanes can be used as the mold-in-place material for the end caps. A detailed description of usable polyurethanes can be found in the prior art, such as International Publication No. WO 2006 / 026241, which is incorporated herein by reference.

[0136] D. Media Pack The particular material selected for the media is a matter of the chosen application, and where the filter assembly is an air cleaner, any of the wide variety of media materials currently used in air cleaners can be used in accordance with the principles of the present disclosure.

[0137] The media pack may include only the media 26, or the media may be provided with an inner liner and / or an outer liner prior to being loaded into the cartridge 25. The media may be pleated, although other configurations are possible. The media may include hot melt media tip spacers or other media spacers as required. The media may be provided with pleat spacers formed from corrugations and / or folds in the media. The media may be provided in a variety of configurations, including cylindrical and conical, and may have a variety of shapes defining the inner and / or outer periphery, such as circular or elliptical.

[0138] E. Illustrative Construction Dimensions The principles described herein are applicable to a variety of systems having a variety of sizes and a variety of specific features. Example dimensions are provided for systems that can be used. However, these dimensions are merely illustrative and are not intended to impose any particular limitations on the broad range of application of the principles described. Examples of dimensions and angles indicated by letters for reference in the drawings are as follows: AA=112mm, AB=76.7mm, AC=56.5mm, AD=35.2mm, AE=186.4mm, AF=173.5mm, AG=205.2mm, AH=113.5mm, AI=24.5mm, AJ=42.7mm, AK=54.4mm, AL=269.8mm, AM=136.4mm, AN=47°, AO=280.3mm, AP=130.4mm, AQ=78.7mm, AR=129.5mm, AS=11mm, AT=5.5mm, AU= 30°, AV=radius 2mm, AW=diameter 130.42mm, AX=128.45mm, AZ=87.53mm, BA=78.74mm, BB=55.32mm, BC=radius 3mm, BD=3mm, BE=6mm, BF=25.5 mm, BG=53.4mm, BH=130.2mm, BI=1.5mm, BJ=6.62mm, BK=16mm, BL=radius 3mm, BM=radius 2mm, BN=radius 1mm, BO=radius 1mm, BP=radius 4mm, BQ=radius 2m m, BR=231.4mm, BS=121.1mm, BT=2mm, BU=6.4mm, BV=7°, BW=diameter 123.5, mm, BX=0.95mm, BY=18°, BZ=47.6°, CA=diameter 29.36mm, CB= Radius .5mm, CC=0.5°, CD=radius 0.5mm, CE=1.7mm, CF=radius 1.3mm, CG=radius 0.5mm, CH=6.5mm, CI=15.8°, CJ=95.6mm, CK=3.3mm, CL=18.9mm , CM=1.5mm, CN=radius 30mm, CO=radius 14.2mm, CP=0.2°, CQ=radius 3mm, CR=16mm, CS=2°, CT=15mm, CU=21.9mm, CV=12mm, CW=31.6mm, CX=1 5.8mm, CY=9mm, CZ=6mm, DA=105mm, DB=112mm, DC=40mm, DD=6mm, DE=15mm, DF=9mm, DG=80.7mm, DH=210mm, DI=55.8mm, DJ=54.9mm, DK=144.7mm, DL=124.4mm, DM=89mm, DN=12.7mm, DO=82.2mm, DP=80mm, DQ=33.1mm, DR=164.9mm, DS=1 69.6mm, DT=182.7mm, DU=10.9mm, DV=1.5mm, DW=1.5mm, DX=30°, DY=0.9mm, DZ=17mm, EA=81.2MM, EB=44.6m m, EC=110.6mm, ED=66mm, EE=89.2mm, EF=radius 24.7mm, EG=3.1mm, EH=45°, EI=89.2mm, EJ=82.21mm, EK=79.5 6mm, EL=74.5mm, EM=63.1mm, EN=52.9mm, EO=46.7mm, EP=50.8mm, EQ=55.2mm, ER=2.1mm, ES=1.6mm, ET=radius 0 .7mm, EU=6mm, EV=25.3mm, EW=2.5mm, EX=1.4mm, EY=8mm, EZ=17mm, FA=2mm, FB=45°, FC=2.5mm, FD=3mm, FE =2mm, FF=4.9mm, FG=radius 1mm, FI=120°, FJ=30°, FK=9.3mm, FH=radius 62.4mm, FL=125.5mm, FM=100mm, FN=60°, FO =Radius 1.5mm, FP=8.5mm, FQ=5mm, FR=Radius 3mm, FS=Radius 3mm, FT=72.3mm, FU=75.8mm, FV=29.5mm, FW=196.5mm, FX=4 0°, FY=186.4mm, FZ=120.5mm, GA=97.7mm, GB=1.5mm, GC=132.28mm, GD=168.9mm, GE=183.9mm, GF=54.9mm. .

[0139] F. Optional Resonator / Sonic Choke As previously indicated, in one embodiment of the present application, the filter cartridge 25 may be provided with an optional resonator / sonic choke (or sonic choke / resonator). One example of a sonic choke is provided that includes a throat, an expanding funnel portion between the throat and a first end member (cap) of the cartridge, a permeable liner portion adjacent the second end member (cap) of the cartridge, and an intermediate region between the throat and the liner portion. In the illustrated example, the intermediate region tapers downwardly toward the throat and includes an outwardly convex permeable portion adjacent the liner portion and an outwardly concave portion adjacent the throat.

[0140] In one illustrated example, the throat has an inside diameter of at least 25 mm, typically at least 26 mm, and often in the range of 26 mm or more and 35 mm or less.

[0141] In one illustrated example, the funnel portion is impermeable, although other configurations are possible. Generally, the funnel portion expands at an internal angle of at least 5°, and typically in the range of 6° or more and 8° or less, as it extends from the throat to the first end member (cap).

[0142] In the example construction shown, the outwardly concave portion of the mid-region is preferably impermeable, i.e., it is a solid wall, which provides advantages in terms of the combined noise suppression and airflow characteristics of the resonator / sonic choke.

[0143] Typically, the outwardly concave portion of the intermediate region has an outer radius of curvature of at least 25 mm, and typically has an outer radius of curvature in the range of not less than 26 mm and not more than 35 mm.

[0144] Typically, the outwardly convex portion of the intermediate region has a radius of curvature of at least 10 mm, and typically has an amount within the range of 12 mm or more and 18 mm or less.

[0145] Typically, the outwardly convex portion of the intermediate region is at least 40% open, typically at least 50%, and often 60% or more open. The term "open" refers to the amount of the outwardly convex portion that forms an opening, rather than a solid wall. This particular configuration facilitates the flow of air from the area of ​​the medium 26 immediately surrounding the impermeable conical portion into the interior space of the sonic choke and resonator, and then to the outlet end cap 50.

[0146] VI. Alternative Embodiments, Alternative Uses of Selected Principles, Figs. 33-70 A. Overview 33-57 show some optional alternative principles and features that may be applied to the structures of the present disclosure. Some of these features relate to alternative configurations of the primary seal that may be effectively implemented. While the alternative configurations of the primary seal may be used in combination with a secondary seal, benefits may also be obtained when used in structures that do not include a secondary seal.

[0147] FIGS. 58-65 show a preferred mold design and molding technique for manufacturing each portion of a filter cartridge of the type shown in FIGS.

[0148] 66-70 are schematic diagrams of alternative seal configurations that may be used in the filter cartridges and filter assemblies of the present disclosure.

[0149] B. Second embodiment and modified examples of FIGS. 33 to 57 Reference numeral 500 in Figure 33 generally denotes a filter (in this example, an air cleaner) assembly according to a second embodiment of the present disclosure. The filter assembly uses an effective primary seal modified between a filter cartridge and a housing. With reference to Figure 33, the air cleaner assembly 500 is shown in cross section and includes a housing 502 defining a housing body 503 and an access cover 504. The access cover 504 is removably secured to the housing body 503 by latch structure 505, not shown in Figure 33. See Figure 51.

[0150] The housing 502 defines an interior space 502i within which is disposed a removable and replaceable, i.e., serviceable, filter cartridge 510, which is described in more detail below. Note that in Figure 33, some of the end pieces (caps) of the cartridge 510 are not shown so that details of the internal structure can be seen, as will be understood with reference to the description of Figures 34 and 35 below.

[0151] 33, air cleaner assembly 500 includes a housing 502 with an end wall 511 from which an air flow tube 512 projects outwardly. Typically, tube 512 is a clean air outlet tube used similarly to tube 15 of FIG. 1, but if reverse flow is used, this tube would be an inlet tube. Tube 512 further includes an optional pressure tap 512x. As shown, tube 512 may be a separate structure from the rest of housing 502, in which case tube 512 is attached to the rest of housing 502 to form the overall housing of air cleaner assembly 500. Alternate structures are possible.

[0152] The illustrated housing 502 further includes an optional debris exhaust pipe arrangement 514 having a pressure relief valve arrangement 515 disposed therein.

[0153] Referring to FIG. 51, an optional mounting pad structure provided on the housing 502 is indicated at 516 .

[0154] Returning to Figure 33, reference numeral 517 denotes an air flow inlet ramp. A shield for body portion 503 is designated by reference numeral 518, and a shield for access cover portion 504 is designated by reference numeral 519. An opening 520 is disposed in access cover 504 to allow dirt and water to enter the interior space of exhaust pipe 514, designated by reference numeral 514i.

[0155] Reference numeral 521 in FIG. 51 denotes an inlet pipe of the air cleaner assembly.

[0156] 33A shows a top view looking towards the access cover 504. FIG. 33A shows a view at line 33-33 of FIG.

[0157] So far as described, assembly 500 is substantially similar to assembly 1. The identified features may be configured to operate in a similar manner to the similar features described above in connection with the assembly 1 embodiment.

[0158] 35, there is shown a side view of cartridge 510, partially cut away to reveal internal detail. Cartridge 510 is a serviceable component that may be used with air cleaner 500. In particular, once access cover 504 is removed from the remainder of housing 502, cartridge 510 may be inserted or removed for service.

[0159] Generally, referring to FIG. 35, the cartridge 510 includes a media 525 disposed about an open filter interior space 526 (and cartridge central axis X) and extending between a first end member (or end cap) 528 and a second end member (or end cap) 529, in this example, although other configurations are possible. Note that in FIG. 35, the end member 528 is disposed at the (open) outlet end of the cartridge 510 through which air (gas) can flow during operation. In FIG. 33, the cartridge 510 is in place without some portions of the end member (cap) 528, so that the preferred internal structure can be seen in detail. The portions of the end member (cap) 528 not shown in FIG. 33 are molded-in-place molded parts in a typical application of the principles described herein, although other configurations are possible.

[0160] Typically, at least a portion of end member 528 is molded in place and end 525x of media 525 is embedded in the portion, and at least a portion of end member 529 is molded in place and end 525y of media 525 is embedded in the portion, although other configurations are possible. Media 525 may be pleated media, although other configurations are possible. The media and media configuration are selected based on efficiency and useful life in use, but generally media and media features as described above or media and media features as used in various air (gas) filters can be used.

[0161] As shown, the media 525 is disposed about an inner liner or central support 527, which in the illustrated example includes an optional resonator / sonic choke structure 546, which may be of a structure generally as described above with respect to the cartridge 25 of FIG. 5.

[0162] End member 529, as shown, is typically a closed end member and may generally correspond to end member (cap) 42 of FIG.

[0163] End member 528 is an open end member having a central air flow opening 530 therethrough. End member 528 includes a first primary seal structure 533 and an optional secondary seal structure 534. Optional secondary seal structure 534 may be configured generally similar to seal structure 66 of Figure 5 described above, although other structures are possible, including the seal structures described in the embodiments described below.

[0164] As with the previously described embodiment, in the illustrated example, the primary seal structure 533 is configured as a radially outward facing radial seal or sealing surface that is axially overlapping with the media. However, the primary seal structure 533 may be configured as a radially inward facing seal if desired. The cartridge central axis is designated X, and radial as described herein refers to a direction toward (inner) or away from (outer) the axis X.

[0165] As with the previously described embodiments, the primary seal arrangement 833 is a "non-clamping," "non-clamping," or "clamp-less" seal arrangement in the sense that there is no additional clamp that must be tightened to achieve a positive engagement and seal. The seal is accomplished once the cartridge 510 is properly and properly installed within the housing.

[0166] 37, there is shown a closed end member 529 having a bumper 537 similar to bumper 464 of FIG 29 previously described. End member 529 is also shown in a bottom perspective view in FIG.

[0167] 34A shows an isometric view of cartridge 510 as viewed generally toward end member 528 and opening 530. FIG.

[0168] Attention is now directed to Figure 36, which is an end view of cartridge 510 as viewed generally toward end member 528. Reference numeral 533 denotes a radially oriented housing seal (or sealing surface) which forms a primary seal arrangement. It is noted that in the particular example shown, housing radial seal 533 faces generally radially outward with respect to cartridge central axis X of Figure 35, although other arrangements are possible.

[0169] 36, for the illustrated example cartridge 510, the primary seal 533 has a sealing surface that defines a non-circular configuration, preferably having alternating outwardly projecting (in this example outwardly convex) portions or lobes 533x spaced apart by non-linear (usually inwardly projecting, in this example concavely curved) portions 533y. The particular number of outwardly projecting (in this example convexly curved) sealing surface portions 533x and inwardly projecting (in this example concavely curved) portions 533y is not critical, at least to some advantage. Typically, the number of each portion is at least two, usually at least three, and sometimes four or more and eight or less, and often in the range of four to ten, such as six or more and eight or less, although other numbers are possible.

[0170] According to another definition, the sealing surface 533 may be characterized as having a plurality of spaced apart lobes or radially outwardly projecting (e.g., convex) portions 533x spaced apart from one another by (in this example non-linear, e.g., concave) portions 533y of the surface 533. Typically, there are at least two such outwardly projecting lobes or portions, and usually there are at least three, and sometimes there are four or more and eight or less, and preferably there are many such outwardly projecting lobes or portions in the range of four or more and ten or less (e.g., six or more and eight or less), although other numbers are possible.

[0171] 35 and 36, a recess, receiving portion or receiving groove 540 is disposed surrounding primary seal member or surface 533. Similar to groove 73, this recess, receiving portion or receiving groove 540 is a receiving portion disposed and defined to receive the protruding portions of housing end 511 and tube 512. See FIG.

[0172] For the particular cartridge 510 shown, the recess, receiving portion or receiving groove 540 is configured with inner walls that form a surface 533 that is preferably non-circular by definition as explained above. The outer wall 541 of groove 540 in FIG. 35 is preferably generally circular by definition about central axis X, although other shapes are possible.

[0173] In Figure 38, a central support 545 of cartridge 510 is shown. Support 545 can be formed and used as support 527 of Figure 35. It is similar to support 90 described above with reference to Figures 9-16 in relation to the embodiment of Figures 1-32, except that it has been modified to accommodate a non-circular seal 535. In the example shown, support 545 defines, in part, an optional sonic resonator / choke 546.

[0174] 38, the support 545 includes an end structure 548 with an inner seal support or hub 549 spaced from and surrounded by an outer support 550 secured by struts or an open lattice structure 551. The support 549 is embedded in the end member 528 (and seal structure 533) during use to assist in controlled compression during installation. Thus, the support 549 operates in many respects similarly to the support 105 of FIG. 9. The particular hub 549 shown includes a continuous wall having a non-circular shape preferably with a plurality of radially outwardly projecting (curved in this example) lobes or seal support portions 549x alternating with radially inwardly projecting (curved in this example) seal portions 549y. (Alternatively, in the illustrated example, hub 549 can be characterized as having a number of lobes 549x separated by radially inwardly projecting portions 549y that are non-circular and, in this example, non-straight.) The characteristics of various hub shapes that can be used for hub 549 are described in more detail below.

[0175] The number of radially outwardly projecting (e.g., curved or convex) portions 549x and inwardly directed (e.g., curved or concave) portions 549y, when shaped as shown, is appropriate for the associated seal configuration, and thus there are typically at least two of each, usually at least three or more, and sometimes four or more and up to eight of each, and preferably in the range of four or more and ten or less, such as six or more and up to eight of each.

[0176] 38, in the example shown, the non-circular seal support portion of hub 549 is solid and continuous, i.e., it does not include a side opening therethrough while extending beyond post 551 toward tip 549p. While this is a typical configuration, other configurations are possible.

[0177] The outer supports 550 and posts 551 may be substantially similar to the supports 108 and posts 110 shown in FIG.

[0178] It should be noted that support 545 typically includes an optional sonic choke structure 546 in the illustrated configuration, similar to the sonic choke structure described with respect to FIG.

[0179] In Fig. 39, a side view of support 545 is shown. A ring 554, similar to ring 125 in Fig. 10, can be seen. Resin flow openings 555, similar to flow openings 121, are shown. In short, with reference to Fig. 39, support 545 in the illustrated example is generally similar to support 90, except for the particular configuration of inner support (or hub) 549 in Fig. 38.

[0180] An end view of the structure 548 is shown in Figure 40. An opposite end view of the support 545 is shown in Figure 41.

[0181] In Figure 42, an enlarged partial cross-sectional view of support 548 is shown. Support portion 548 can be seen to include an inner axial flange 560 that defines a trough 561 similar to flange 120 and trough 120e in Figure 16. An opening 555 allows resin to flow into trough 561.

[0182] FIG. 43 shows an enlarged fragmentary view of a portion of FIG. 42. The radially inward region of the struts 551, similar to portion 128 of FIG. 16, is designated 564. It can also be seen that the struts 551 extend at an angle HF greater than 0° with respect to a plane perpendicular to the central axis X, similar to the angle CS described above with respect to FIG. 16. Referring to FIG. 33, the inclination of the struts 551 extending radially inwardly away from the media 525x can be seen. It should be noted that the media 525 is shown in FIG. 33 as not abutting any portion of the lattice structure 551. However, it is expected that in some cases some axial contact may occur between the media 525 and the lattice structure 551 at the radially innermost portion.

[0183] A partial view of the support 545 is shown in FIG.

[0184] 45 shows a flow (in this example, outlet) pipe arrangement 570 having an outlet pipe 512 with a pressure tap 512x. The outlet pipe 512 includes a sealing surface 571, which in the example shown is a radially inwardly facing sealing surface against which the seal 533 abuts to form a radially outwardly facing seal when the cartridge 510 is engaged. In many other respects, the structure 570 may be substantially similar to the pipe structure 15 of FIG. 22. Note that the projections 572 mounted on a ring 572r for rotational engagement with the housing 502 differ in shape, number and location from the portion 228 of FIG. 22. This is explained further below.

[0185] 45, the tube arrangement 570 has a plurality of radially spaced apart snap-fit ​​cam projections 573 disposed radially on a ring 572r. The ring 572r is the portion of the tube arrangement 570 that is pressed into the receiving opening and housing portion during use. The projections 573 provide a snap fit when pressed into place to prevent disengagement.

[0186] FIG 46 shows a side view of a tube arrangement or tube structure 570. FIG 48 shows a top view of the tube arrangement 570 of FIG 46. FIG 47 shows a cross-sectional view taken generally along line 47-47 of FIG 48. FIG 49 shows a cross-sectional view taken generally along line 49-49 of FIG 46. FIG 50 shows an enlarged partial view of the identified portion of FIG 49.

[0187] Attention is directed to FIG. 49. Note that the individual projections 572 on the tube 570 in the illustrated example are each positioned so that they are radially aligned with the thin extensions 574 of the wall 575, i.e., each hollow portion 576. This facilitates rotational locking of the portion 570 to the housing 502, since as the tube 570 is rotated and the projections 572 engage the toothed housing portion, a slight spring effect is created. This also helps to avoid deformations in the area 574 during assembly or pressure from the projections 572, which may affect the shape of the sealing surface area 571. For example, it is important to properly mold the surface 571 while the tube 570 is molded from plastic. The hollow portions 526 facilitate uniform cooling to minimize distortion of the surface 571. In FIG. 50, one of the hollow portions 576 can be easily seen in detail.

[0188] Generally, for the cartridge 510 shown in FIG. 35, the housing seal 533 is formed with a plurality of alternating seal surface portions that are non-circular sides of the groove 540 and project radially outwardly or radially inwardly (curved in the illustrated example). This forms a seal perimeter with non-circular alternating outwardly and inwardly projecting portions. With reference to FIG. 49, when the cartridge 510 is installed, the cartridge seal arrangement 533 is pressed into sealing engagement (with a radial seal) with a similarly shaped seal support 571 on the housing without the use of a separate clamp. In the particular example shown, the seal housing surface 571 is formed as part of the outlet tube arrangement 570.

[0189] In the case of the present example cartridge 510, the primary seal structure is configured as a radially inner surface or wall (outwardly facing surface 533) of a recess, receiving portion or receiving groove 540 of the end cap 528 of Figure 35. The recess, receiving portion or receiving groove 540 is configured to receive not only the protruding portion of the outlet tube where the seal occurs, but also the protruding portion of the housing side wall that is snap-fitted onto the tube. Thus, the connection between the outlet tube portion 570 and the housing end wall 511 in the housing is received in groove 540 of the cartridge 510, see Figure 33.

[0190] By comparing Figures 36, 38 and 49, it can be seen that when the seal arrangement includes alternating radially outwardly projecting portions 533x and radially inwardly projecting portions 533y, and the housing seal surface 571 of Figure 49 also includes alternating outwardly projecting portions 571x and radially inwardly projecting portions 571y, the surface portions 571y can project between the outwardly projecting portions 533x of the seal structure 533. This can aid in the rotational locking of the seal structure 533. Furthermore, when the cartridge 510 is installed, a positive and distinct tactile feel is provided to the operator that the cartridge 510 is correctly inserted and completely sealed. This allows for easy installation without leaving any leak paths in the primary seal 533. It is particularly advantageous to have at least four portions 533y in number, since proper engagement can be achieved with a relatively small amount of rotation of the cartridge.

[0191] It should be noted that in some applications, only the primary seal 533 is required, but in some cases, it may be advantageous to have a secondary seal, as will be discussed in the next section of this chapter.

[0192] 35, cartridge 510 includes a secondary seal 534, FIG. 35, which engages the side wall of the housing. Similar to secondary seal 65 and sealing surface 66, FIG. 4, secondary seal 534 may be supported by optional seal supports 581 embedded in the end cap material of cartridge 510. This optional support is provided by optional supports 550 in structure 545 shown in FIG.

[0193] Optional support 550 includes optional spaced apart tabs 531t, similar to the support of the embodiment of Figures 1-32. Indeed, with respect to the configuration of primary seal 533, the structure of Figures 33-50 is substantially similar to that of Figures 1-32.

[0194] The illustrated sealing configuration for primary seal 533 provides several advantages. Again, in this embodiment, it is not possible to rotate (outlet) tube 570 radially relative to housing body 503 after the tube 570 engages cartridge 510, thus providing a more reliable seal that is immune to rotational stresses and forces.

[0195] Furthermore, in seals that include multiple lobes or multiple projections, portions of the (typically curved) sealing surfaces of the various lobes or projections are tangentially oriented around a portion of the circumference, such seals being "self-aligning" seals. That is, portions of seal 533 are not perfectly radially oriented. Thus, after seal 533 is pressed into place, any imbalance in pressure on the lobes (projections) will cause the seal to rotate slightly, self-correcting for misalignment. Seal 533 is still referred to as a radial seal because the sealing compression is not in axial alignment with axis X (i.e., longitudinally of axis X), but rather is mostly in directions toward or away from axis X.

[0196] Additionally, as previously discussed, the unique configuration of seal 533 aids the inspection personnel in verifying that the correct cartridge 510 has been selected for the system, and also makes it fairly easy to recognize when the cartridge is not installed correctly, since the components can be selected such that the access cover cannot be closed until the lobes of the cartridge are properly aligned with the lobes of the outlet tube.

[0197] Possible seal configurations and their advantages are discussed in more detail below.

[0198] 51, a side view of assembly 500 is shown. From FIG. 51, it can be seen that housing 502 comprises portion 503 and access cover 504 secured together by latch structure 505. It can also be seen that outlet tube 512 comprises a portion of tube 570, inlet tube 521 and exhaust tube 514. Note section line 52-52 through housing portion 503, outlet tube 512 and a portion of cartridge 510, as will be understood from further description below.

[0199] Attention is now directed to Fig. 52, which shows a portion of cartridge 510 aligned with a portion of housing portion 503 so that a seal can occur, however the molded-in-place portion of end cap 528 is not shown in Fig. 52 so that construction details can be seen.

[0200] 52, attention is first directed to sealing face 571 and hub 549. It will be appreciated that the material forming sealing face 533, i.e., a portion of the molded-in-place portion of end member 528, may fill space 579 between these two components. It will be seen that outwardly directed projection 549x of hub 549 aligns with outwardly directed region 571x of face 571, and inwardly directed region 549y of hub 549 aligns with inwardly directed region 571y of wall 571. It will also be seen that a rotational blockage occurs to prevent rotation. Also, if any misalignment occurs during insertion of cartridge 510 into sealing face 571, an inspector can rotate cartridge 510 slightly to feel that the seal is locked into the correct engaged position.

[0201] 52, it can be seen that the individual projections 572 are engaged in a ratcheting or resistive manner by a toothed surface or region, or a ratchet surface or region 581, of the housing portion 503, as will be described in more detail below.

[0202] 53 shows a perspective view of the housing portion 503. An opening 580 is shown at end 511. The opening 580 includes a portion 580t with an array of notches, teeth or ratchet structures 581 and flexible tabs 582. When the tube structure 570 of FIG. 45 is inserted into the opening 580, members 572 engage the teeth 581 to help secure the tube 570 in a selected rotational position. The flexible tabs 582 help achieve a snap-fit ​​effect, similar to member 573 of FIG. 46. It should be noted that during initial installation, the tube can be rotated by hand to apply a force that overcomes the ratchet effect, so that if an L-shaped tube 512 is used, the tube can be rotated as needed. However, once the cartridge 510 is installed, the cartridge 510 will attempt to lock the tube 570 in a particular rotational position. This is due in part to the effect of the perimeter or secondary seal 534 on the cartridge 510, as previously described, which causes it to engage with the sidewall portions of the housing portion 503. Rotation of tube 570 is also prevented by axial pressure on cartridge 510 abutting end 511 while access cover 504 is pressed into place.

[0203] FIG. 54 shows a side view of the housing portion 503. FIG. 55 shows a plan view of the housing portion 503. FIG. 56 shows a cross-sectional view taken along line 56-56 in FIG. 55. FIG. 57 shows an enlarged partial view of the portion indicated in FIG. 56. In FIG. 57, reference numeral 590 indicates a sealing surface portion of the housing portion 503 that forms a seal with the secondary sealing surface 534 of the cartridge 510 in FIG. 35 when the cartridge 510 is installed. This is similar to the embodiment in FIGS. 1 to 32.

[0204] Attention is now directed to Fig. 33B, which shows an enlarged fragmentary view of a portion of Fig. 33. Fig. 33B illustrates the engagement of a portion of tube 570 with end 511 of housing portion 503. As with Fig. 33, Fig. 33B does not show some of the molded-in-place seal material of end cap 528 so that construction details can be seen.

[0205] In Fig. 33B, reference numeral 591 denotes a connection portion located between the tube 570 and the housing portion 502 and projecting into the recess, receiving portion or receiving groove 540 of the cartridge 510 of Fig. 35 during installation. Also shown in Fig. 33B is a structure effective to prevent water leakage at the connection portion 591. In particular, it can be seen from Fig. 33 that the tube 570 includes a radially projecting mounting ring portion 593 that engages the end portion 511 and a rim projection portion 595 that projects toward the end portion 511. The end portion 511 includes a recess 511r into which the rim portion 595 projects. Furthermore, the end wall 511 includes a projection ring 511p that projects from the tube 570 toward the ring portion 593 at a position surrounded by the rim projection portion 595. Upon snap-fit ​​engagement of tube 570 with housing portion 503 at end 511, the tortuous water flow path presented by ring protrusion 595 and protrusion ring 511p in recess 511r inhibits water from entering interior space 502i of housing 502. This effect is particularly desirable when housing 502 is oriented so that end 511 protrudes upwardly.

[0206] C. Assembly of Cartridge 510, Particularly End Member 528, FIGS. 58-65 In a preferred application in which the principles of the present disclosure are applied, end member 528 comprises a portion that is molded-in-place over a preform portion of cartridge 510. In particular, end member 528 comprises material that is molded-in-place over end 525x of media 525, various portions of support structure 545, and adjacent seal supports 549, 550 and posts 551. Methods and mold structures for achieving this are described in this section with reference to Figures 58-65.

[0207] 58 shows a top view of mold 600. Mold 600 includes a peripheral ring surface 601 that surrounds mold cavity 602. A central projection 603 is located in the center of mold cavity 602. During manufacture of cartridge 510, resin is dispensed into mold cavity 602, typically by rapid spinning to distribute the resin. Media (media pack) and support are then inserted into mold cavity 602 and the resin is molded to the media pack and support in a manner appropriate to form end cap 528.

[0208] 59 shows a cross-sectional view of mold 600. Note that cavity 602 contains ring 610 which will form groove 540 of FIG. 35 in molded cartridge end cap 528.

[0209] Radially outwardly of projection 610 is mold cavity portion 602x, the outer periphery of which, located at 602p, forms outer sealing surface 534, FIG. 35, in the molded material.

[0210] An inner mold cavity portion 602i is disposed radially inward of the support 610. An inner surface 610i of the projection 610 is configured to form the outwardly facing radial sealing surface 533, FIG.

[0211] In FIG. 60, an enlarged partial view of the cavity 602 and the central projection 603 is shown, which includes a periphery 603p having a first member mold rotational alignment structure generally designated 612. In the particular configuration shown, the mold rotational alignment structure 612 comprises a plurality of recesses or grooves 613 spaced radially from one another around the periphery of the projection 603 that are oriented and positioned in a generally vertical direction. The particular assembly shown uses six grooves, although other numbers are possible (usually more than two and less than ten). It is noted that the grooves are shown as being equally spaced radially around the center of the post 603, although other configurations are possible. The operation of the grooves 613 will be understood from the further description below.

[0212] 61 shows the same portion of the enlarged fragmentary view of FIG. 59. The portion shown is a cross-sectional view of one of the grooves 613.

[0213] Figure 62 shows a second identical portion of the partial cross-sectional view of Figure 59. A cross-sectional view of mold cavity 602 is shown, including the features previously shown.

[0214] Figure 63 shows an enlarged fragmentary view of a portion of Figure 58. The portion shown in Figure 63 shows mold standoffs 615 to facilitate molding. Referring to Figure 58, multiple such mold standoffs 615 are shown. The standoffs 615 leave artifacts in the end cap 528 (see FIG. 34A, item 617). The standoffs 615 function to ensure that the media and support are properly supported within the mold.

[0215] FIG. 64 shows a schematic of the process of inserting the cartridge structure into a mold for forming end cap 528. Note that the media is not shown in FIG. 64 for ease of viewing the details, but would be present during insertion. Referring to FIG. 64, a mold 600 is shown. The structure 545 is shown being lowered into the mold cavity 602. Prior to insertion, the media would be generally positioned around center 545c. The media would surround ring 554. Also, resin would typically be fed into cavity 602, typically toward region 619, by rapidly rotating mold 600 prior to insertion of the cartridge components.

[0216] It will be appreciated that the support 545 must be properly oriented radially in the mold relative to the outer mold section 620 which forms the sealing surface of the seal 533. A method for achieving this can be seen with reference to Figure 65.

[0217] 65, it can be seen that the cartridge support 545 includes an inner surface 545s having a second member mold rotational alignment structure 625 at a center 549c. The second member 625 includes a plurality of radially inwardly directed projections 626. The projections 626 are configured and positioned to engage with the members 612 of the central post 603. In the particular construction shown, the members 626 are projections configured as spaced apart vertical ribs oriented to be received within the recesses 613 while the support 545 is being lowered into the mold 600 (although other constructions are possible). Thus, the support 545 cannot be fully lowered into the mold 600 until the ribs 626 engage the receiving portions 613. This provides rotational indexing so that the hub 529 of the support 545 of FIG. 65 is properly rotationally aligned with the mold portion 520.

[0218] D. Some dimension examples In Figures 33 to 63, some example dimensions are presented as follows: GH=280.3mm, GI=128.3mm, GJ=92.4mm, GK=129.8mm, GL=45.4mm, GM=231.4mm, GN=102.1mm, GO=2mm, GP=6.4mm, GQ=7°, GR=117.5mm, GS=7°, GT=diameter 117.5mm, GU=2.8mm, GV=95.6mm, GW=3.3mm, GX=18.9mm, GY=1.5mm, GZ=14.62mm, HA=radius 30mm, HB=radius 14.2mm, HC=0.2°, HD=16mm, HE=radius 3mm, HF=2°, HG=1 4.8mm, HH=21.9mm, HI=diameter 77.93mm, HJ=radius 11.7mm, HK=radius 27.9mm, HL=radius 5.5mm, HM=diameter 60.41mm, HN=30°, HO=20mm, HP=81mm, HQ=55.5mm, HR=121.5mm, HS=48.9mm, HT=2.5mm, HU=45.8mm, HV=50.8mm, HW=54.2mm, HX=54.9mm, HY=88.46mm, HZ=96mm, HI=30°, H2=66mm, H3=diameter 59.9mm, H4=diameter 77.9mm, IA=1 11mm, IB=radius 14.2mm, IC=111mm, ID=30°, IF=1.5mm, IG=radius 0.5mm, IH=2.1mm, II=radius 1mm, IJ=diameter 7.5mm, IK=radius 2.7mm, IL=112mm, IM=105mm, IN=80.5mm, IO=40mm, IP=12mm, IQ=6mm, IR=15mm, IS=8.9mm, IT=15.8mm, IU=31.6mm, IV=8.9mm, IW=6mm, IX=55.8mm, IY=54.4mm, IZ=210mm, JA=96.5mm, JB=12. 7mm, JC=93.5mm, JD=89mm, JE=124.4mm, JF=144.7mm, JG=133.1mm, JH=164.9mm, JI=169.6mm, JJ=182.7mm, JK=10.7mm, JL=2mm, JM=30°, JN=1.5mm, JO=0.9mm, JP=diameter 266.7mm, JQ=124mm, JR=38.1mm, JS=130.2mm, JT=98.2mm, JU=92.6mm, JV=43.9mm, JW=12.7mm, JX=14mm, JY=60°, JZ=30°, KA=radius 15.1mm, KB=radius 4.8mm, KC=diameter 77.9mm, KD=diameter 59.9mm, KE=1mm, KF=18.6mm, KG=radius 2.9mm, KH=3m m, KI=radius 2.9mm, KJ=2°, KK=28.2°, KL=19.5mm, KM=2°, KN=radius 2mm, KO=14.9mm, KP=4mm, KQ= 3mm. Of course, these dimensions are merely illustrative of one possible construction and other dimensions may be used.

[0219] E. Some alternative seal configurations possible; general description of seals; various alternative constructions 1. Alternative sealing surface definitions, Figures 66 to 70 A variety of seal configurations can be used with the principles of the present disclosure. Some examples are shown in Figures 66-70. These figures are schematic and are only intended to illustrate possible seal and support definitions.

[0220] In Figure 66, a somewhat "peanut-shaped" shape is shown at 700 having two radially outwardly projecting portions or lobes 701 separated by two inwardly projecting protruding portions 702. Of course, this particular lobe 701 and portion 702 configuration can be modified differently than that shown.

[0221] FIG. 67 shows a three lobe configuration generally designated 730 having three radially outwardly projecting portions or lobes 731 and three radially inwardly projecting portions 732 .

[0222] FIG. 68 shows a “four lobe” configuration at 750 which includes multiple (four) radially outwardly projecting portions or lobes 751 separated by radially inwardly directed projections or portions 752 .

[0223] In Figure 69, a seal structure having radially outwardly projecting portions is shown at 770. In this case, seal structure 770 has six radially outwardly projecting portions 771 separated by portions 772. In this case, portions 772 are straight in the direction between projections 771 and do not project radially inwardly. However, advantages could be gained if portions 772 were configured to project inwardly.

[0224] 70 shows a seal structure generally at 780 having five outwardly projecting portions 781 separated by five inwardly projecting portions 782. In this case, the inwardly projecting portions 782 are not generally straight, but each portion 782 includes straight portions 783, 784 on either side of a radially innermost apex 785.

[0225] Other shapes are possible for the lobes and segments in any of the embodiments of Figures 66-70. Additionally, the configurations of Figures 66-70 demonstrate that a variety of configurations having a different number of segments or lobes than those illustrated can be used.

[0226] 2. Overview of the selected seals and sealing surfaces described above It should be noted that the seals of the structures of Figures 35 and 66-70 are sometimes characterized as "radial". However, because of the non-circular geometry, some of the sealing forces act in directions other than specifically toward or away from the central axis X of the cartridge. Nevertheless, the seals are characterized herein as "radial" because, in general, the seal surfaces of the cartridge and housing are generally radially oriented and the sealing forces are either radially outward or radially inward about the axis X, depending on whether the associated seal surface is an outer or inner seal surface. In other words, the compressive forces are generally radial, rather than axial (i.e., longitudinal) about the axis X. However, there are applications in which the sealing forces are not directly directed toward or away from the axis X in each of these non-circular seal configurations.

[0227] More generally, a radial seal comprises a sealing surface that is defined as being oriented toward or away from a central axis, which is often the central axis of the filter cartridge around which the media is also disposed, although it will be appreciated that in alternative constructions described below, the radial seal may be a seal that circumscribes an axis that is not the central axis of the cartridge (as opposed to an axial seal that is generally aligned with the central axis around which the seal is disposed, which is typically, but not necessarily in all cases, the cartridge central axis X).

[0228] In terms commonly used herein, the various housing seal configurations shown can be characterized as having generally radially oriented sealing surfaces. This is because the sealing direction of the various housing seals shown in the drawings is determined by a surface that engages with some portion of the housing (either a part of the outlet tube or an outer portion of the housing, depending on which of the two housing seals is concerned) that can generally be characterized as a "radially oriented surface". In each case, the surface that actually forms the seal is oriented (either toward or away from) the central axis X (which is also typically the central axis of the cartridge) as opposed to an axial seal, which is generally considered to have a sealing force oriented in the longitudinal direction of the central axis X. The illustrated examples are "outer radial sealing surfaces" or "outwardly oriented radial seals" because the actual surface of the cartridge seal member that engages with the housing to form a seal is generally oriented away from the central axis of the cartridge, rather than toward it. However, many of the principles described herein are applicable to other configurations in which the cartridge seal surface that engages with the housing to form a seal is oriented radially toward the central axis.

[0229] The radial housing seals described herein may generally be characterized as "non-clamping", "unclamping" or "clamp-free" designs, or similar terms. This means that the seal design typically does not include the use of clamps, such as hose clamps or other structures that must be tightened to create a reliable seal. The seal is achieved by simple fitting and compression of the seal material against the housing face oriented by the cartridge components.

[0230] With respect to the structures of Figures 33-70, the non-circular primary seal surface may be characterized as having at least two spaced apart radially outwardly projecting seal surface portions. Indeed, with the exception of the structure of Figure 66, each structure has at least three radially spaced apart radially outwardly projecting seal surface portions, and typically more than four and no more than ten radially spaced apart radially outwardly projecting seal surface portions. In this case, the term "radially outwardly projecting" is intended to indicate a shape of lobes, apexes, or protrusions circumferentially about and relative to the central axis, regardless of whether the seal surface is oriented to form an inwardly or outwardly facing seal. That is, a radially outwardly projecting portion is a portion of the seal surface that projects away from the central axis of the seal (and typically the cartridge), regardless of the direction in which the seal surface itself is oriented for sealing. In the case of the structure of Figure 36 having "six outwardly projecting seal portions," those protrusions are designated by reference numeral 533x. In the case of the "two" outwardly projecting portions of Figure 66, the portions are designated by reference numeral 701. In the case of the three outwardly projecting portions of Figure 67, the portions are designated by reference numeral 731. In the case of the four outwardly projecting portions of Figure 68, the portions are designated by reference numeral 751. In the case of the six outwardly projecting portions of Figure 69, the portions are designated by reference numeral 771. In the case of the five outwardly projecting portions of Figure 70, the portions are designated by reference numeral 781.

[0231] Except for the structure of FIG. 69, each of the seal structures of FIGS. 33-36 and 66-70 has one radially inwardly projecting seal portion disposed between two radially outwardly projecting portions defined above. In the structure of FIG. 36, the portion is designated by reference numeral 533y. In the structure of FIG. 66, the portion is designated by reference numeral 702. In the structure of FIG. 67, the portion is designated by reference numeral 732. In the structure of FIG. 68, the portion is designated by reference numeral 752. In the structure of FIG. 70, the portion is designated by reference numeral 782. It should be noted that the structure of FIG. 69 does not include an inwardly projecting seal portion since it has a straight portion extending between the outwardly projecting regions. In connection with this part of the definition of the seal surface of the inwardly projecting seal surface portion, when referring to the geometric direction relative to the central axis X, it refers to the bending or protruding surface portion in the opposite direction to the direction of the sealing surface force for sealing.

[0232] It should be noted that in many of the structures, the inwardly facing seal face portions are not straight. In conjunction with the general terminology used herein, this refers to the condition of the outwardly projecting portions of the seal faces that extend between them. This characterization applies to all of the seal structures shown in Figures 30, 66-68, and 70, except for the seal structure shown in Figure 69.

[0233] In addition, in FIG. 70, portions 783 and 784 are each straight, but each portion 782 is not straight as a whole between protrusions 781, so that even in the seal structure shown in FIG. 70, the extension portion between portions that protrude outward is "not straight" according to the definition of the extension portion.

[0234] Typically, the radially outwardly projecting sealing surface portions are equally radially spaced about the cartridge central axis, and indeed this is the case for any of the configurations shown herein. However, this equally radially spaced arrangement is not specifically required, and many of the principles described herein are applicable to other configurations. The same is true for the radially inwardly projecting sealing surface portions.

[0235] For convenience in molding, manufacturing and use of the seal, the radially outwardly projecting seal surface portions are typically curved with a radius of at least 5 mm, usually no more than 35 mm, and often in the range of 15 mm to 30 mm, although other values ​​are possible. The radially inwardly projecting portions similarly have a radius of curvature of at least 2 mm, often in the range of 2 to 35 mm, for convenience in manufacturing, although again other values ​​are possible.

[0236] Generally, when the principles of the present disclosure are applied in a preferred structure, the sealing surface forming the primary seal, e.g., seal 533, is positioned radially overlying one edge of the media, typically spaced at least 3 mm outward from the media's innermost periphery and at least 5 mm inward from the media's outermost portion, and where the structure includes a perimeter seal or a second radially oriented seal structure as described herein, the maximum cross-sectional dimension of this sealing surface is typically at least 3 mm smaller than the maximum cross-sectional dimension of the perimeter seal, usually at least 5 mm, often at least 8 mm smaller, typically at least 10 mm smaller, and most typically at least 15 mm smaller.

[0237] It is not specifically required that the cartridge include two seal structures, although it is preferred if the preferred embodiment described is applied. It is also not specifically required that the primary seal 533 be the side of a groove, although this is typical and preferred for the applications described herein. Furthermore, if a groove is used, it is not specifically required that the face of the groove that does not constitute the housing seal be circular by definition, although angled faces are typical and preferred.

[0238] When referring to the dimensions, perimeter or cross-sectional dimensions of a radially oriented seal face, unless otherwise indicated, the reference is to the face when not distorted by installation, and therefore the dimensions are sometimes expressed by terms such as "undistorted cross-sectional dimensions" or similar terms.

[0239] 3. Some exemplary alternative structures Attention is now directed to Figure 33C, which is a generally similar view to Figure 33 shown in a different rotational orientation with respect to the general features than Figure 33, but which illustrates some variations of certain features.

[0240] The assembly of FIG. 33C should be understood to have substantially similar construction and features to those previously described with respect to the assembly of FIG. 33 where like parts are indicated.

[0241] Referring to Figure 33C, an assembly 1000 is shown that includes a housing 1001 in which a cartridge 1010 is removably disposed. The cartridge 1010 may be generally similar to those previously described, with the media 1011 extending between a first end member 1012 and a second end member 1013. One example of a difference is the closed end member 1013, which shows an outer bumper projection structure 1015 oriented to axially overlap an end 1016 of a support structure 1017 around which the media 1011 is disposed. This differs from the assembly of Figure 33, in which the bumper structure is disposed radially offset from the end of the support.

[0242] Referring now to Figure 33D, an enlarged partial view of Figure 33 is shown. It should be noted that end member or end cap 1012 is of a different construction to the end caps previously shown in terms of detailed structure, but operates in a similar manner, particularly in the detailed structure of support 1020 embedded in mold-in-place molding material 1021.

[0243] In FIG. 33E, a perspective view of the assembly 1000 and housing 1001 is shown.

[0244] 34B shows a bottom perspective view of the cartridge 1010. In the illustrated example, the bumper structure 1015 is shown as a continuous ring rather than a split ring, although the principle can also be implemented with a split ring.

[0245] 34C shows an open end perspective view of cartridge 1010. Media 1011 extends between 1012 and 1013. End member 1012 shows a recess, receiving portion or groove 1025 whose inner wall 1026 is configured to form a radially facing sealing surface 1026s with a plurality of radially outwardly facing lobes or projections 1026o separated by spaced apart inwardly facing recesses or regions 1026i, similar to the previously described structures. Cartridge 1010 is further shown as having an outwardly facing sealing surface 1028s surrounding surface 1026 which forms a secondary or second radial seal.

[0246] Figure 35A shows a side view of cartridge 1010. Figure 35B shows a cross-sectional view of cartridge 1010. Figure 36A shows a top view of cartridge 1010 looking towards end member 1012. Example dimensions are: XA = 71 mm, XB = 129 mm radius, XC = 16 mm radius, XD = 3 mm radius, and XE = 93 mm.

[0247] In FIG. 37A, an end view of cartridge 1010 looking towards end member 1013 is shown.

[0248] F. Additional Commentary on Effective Seal Features As previously indicated, it is not specifically required that a filter cartridge or cartridge assembly include all of the features characterized herein in order to obtain any of the advantages of the present disclosure, and in fact, some filter cartridges may benefit from implementing a preferred first seal configuration characterized herein with or without the second seal configuration characterized herein.

[0249] In many typical applications, for application of an effective sealing structure, a filter cartridge includes a media having a first end and a second end, the media typically surrounding and defining an open filter interior space. A first open end cap is disposed at the first end of the media. This end cap may be a molded-in-place end cap in which the first end of the media is embedded, as previously described. However, other structures are possible.

[0250] A housing seal arrangement is disposed in the first end cap. In one example of the definition provided herein, the housing seal arrangement comprises a first radially facing seal face having at least two, typically at least three, and preferably at least four, spaced apart radially outwardly projecting seal face projections. In this regard, a "radially outwardly projecting seal face portion" refers to the direction in which the face projects from the central axis, not the direction in which the face faces to form a seal. Thus, the term refers to the shape of the "lobe" or portion itself, not the direction of sealing. Thus, the seal arrangement can have multiple radially outwardly projecting seal face portions and be either an outwardly facing radial seal or an inwardly facing radial seal.

[0251] Typically, the outwardly projecting seal surface portions are separated by non-straight seal portions, such as radially inwardly projecting seal portions, although other configurations are possible.

[0252] Typically, there will be at least 4 and at most 12 (often at least 4 and at most 10) spaced apart radially outwardly projecting seal face portions, although other numbers are possible.

[0253] Although there is no specific requirement that the outwardly projecting surface portions be generally curved, i.e., outwardly convex, this is the typical configuration. Also, the outwardly projecting surface portions are typically shaped to define a circular radius, although other shapes are possible. Similarly, when an inwardly projecting sealing surface portion is disposed between outwardly projecting sealing surface portions, the surfaces are typically curved (i.e., outwardly concave) and the curvature is typically a circular radius, although other shapes are possible.

[0254] There is no specific requirement that the curvature of the outwardly projecting seal surface portions be the same as the curvature of the inwardly projecting seal surface portions, and indeed in the selected configuration shown, the outwardly projecting seal surface portions are curved at a larger radius than the inwardly projecting seal surface portions, although other configurations are possible.

[0255] Typically, the definition of a seal is defined by a material that is molded in place over (on) a support which also has a radially outwardly projecting portion and, in a typical preferred construction, has a radially inwardly projecting portion.

[0256] Typically, the sealing surface having a non-circular shape generally as defined above is a side of a receiving groove disposed in a molded-in-place end cap. One example is shown in which the sealing surface is a radially inner surface of such a groove, configured with a radially outwardly facing sealing surface. Alternative configurations are possible.

[0257] Typically, the seal surface, which is non-circular as defined in this section and includes portions as defined above, is positioned to overlap one end of the media, with the seal surface set back radially inward from the outermost portion of the media pack and spaced radially outward from the innermost portion of the media. If the media is pleated, the seal will typically be positioned such that the radially outermost extension is spaced inward from the outer pleat tip and the radially innermost direction is radially outward from the inner pleat tip. Typically, the entire seal surface is at least 3 mm away from each of the inner and outer pleat tips.

[0258] Many of the principles described in this section with respect to non-circular radial seals are also applicable in connection with a second or outer radially oriented seal, in accordance with the general principles described earlier in this specification. For example, a secondary or outer seal may be provided that has a cross-sectional dimension that is greater than the maximum cross-sectional dimension of the non-circular inner seal.

[0259] VII. Further Embodiments and Selected Variations, Figs. 71-111 A. Overview 71-111 illustrate some alternative principles and features that may be applied to structures according to the present disclosure, which relate in part to optional alternative configurations of the primary seal that may be effectively implemented. While these optional alternative primary seal configurations may be used with a secondary seal, they may also be used to advantage in structures that do not include a secondary seal.

[0260] Selected features of Figures 71-111 also relate to the use of optional alignment features to facilitate alignment of the filter cartridge with a selected effective outlet tube configuration. These features may be used with the seal structures and variations thereof described in connection with Figures 71-89, but may also be used with other seal structures described herein.

[0261] Selected structures of Figures 71-111 also relate to optional secondary seal variations that may be applied to various structures according to the present disclosure.

[0262] Additionally, selected variations relate to additional types of seals and / or supports and alternative sealing and / or support methods, which may be applied as desired to various of the embodiments characterized herein.

[0263] It should be noted that selected embodiments of Figures 71-111 are shown without the use of a resonator or sonic choke. A sonic choke or resonator according to the embodiments described above may be incorporated as part of selected structures of Figures 71-111 as desired.

[0264] Selected embodiments of Figures 71-111 relate to different types of media that may be used in the structures of the present disclosure. Additionally, selected embodiments relate to filtration of crankcase ventilation gases.

[0265] B. Embodiments and Modifications of FIGS. 71 to 89 An air (gas) cleaner (filter) assembly according to another filter (air cleaner) assembly embodiment of the present disclosure is generally designated 800 in Fig. 71. With reference to Fig. 71, filter (e.g., air or gas cleaner) assembly 800 is shown comprising a housing 802 defining a housing body 803 and an access cover 804, the access cover 804 being removably secured to the housing body 803 by, for example, a latch structure 805.

[0266] The housing 802 defines an interior space 802i within which is disposed a removable and replaceable, i.e., serviceable, filter cartridge component or cartridge 810 (not shown in FIG. 71, see FIG. 72), which is described in more detail below.

[0267] 71, air (gas) cleaner assembly 800 includes a housing 802 with an end wall 811 having an outwardly facing air flow (outlet) tube 812. In the illustrated forward flow system, tube 812 is typically a clean air outlet tube used similarly to tubes 15, 512 previously described. Tube 812 includes an optional pressure tap 812x. The illustrated housing 802 further includes an optional debris exhaust tube structure 814 having an optional pressure reducing exhaust valve structure 815 disposed therein.

[0268] Housing 802 may optionally be provided with a mounting pad structure similar to the previously described embodiments. In an alternative configuration, a clamp or additional structure may be releasably attached to housing 802 for mounting air cleaner assembly 800.

[0269] 71, reference numeral 821 denotes a second air flow (inlet) tube that connects to the air (gas) cleaner assembly 800. Typically, tube 821 is used to direct unfiltered air (gas) into the housing 802. Typically, tube 821 is configured as a tangential air (gas) flow inlet tube, although other configurations are possible.

[0270] 72, a cross-sectional view of the filter (air cleaner) assembly 800 is shown. The filter cartridge 810 can be seen disposed within the (air cleaner) housing interior space 802i. The air flow inlet ramp structure is shown at 817. The shield portion of the housing body 803 is shown at 818, and the shield portion of the access cover portion 804 is shown at 819. An opening 820 is located in the access cover 804 for allowing debris and water to enter into the interior space of the exhaust pipe 814, shown at 814i.

[0271] So far, assembly 800 is generally similar to previously described assemblies 1 and 500. The same features can be configured to operate in the same manner as the analogous structures described in connection with those embodiments.

[0272] One selected difference between the embodiment of Figures 71-89 as compared to previously described embodiments is that filter cartridge 810 is not shown in a configuration that includes a "sonic choke" or "resonator." However, the embodiments of Figures 71-89 may use sonic chokes or resonators similar to those previously described.

[0273] 71-89 compared to previously described embodiments relates to the configuration of the (outlet) tube 812 that engages the filter 810 and selected features of the filter cartridge 810 that engage the (outlet) tube 812, as will be described in more detail below.

[0274] Attention is first directed to Fig. 73, which shows the interaction of (outlet) tube 812 and cartridge 810. That is, for ease of understanding, other portions of air cleaner assembly 800 shown in Figs. 71 and 72 are not shown in Fig. 73. It will be appreciated that the components shown in Fig. 73 would typically be used in the context of the overall air cleaner 800 of Fig. 72.

[0275] 73, a cross-sectional view of a cartridge 810 is shown. The cartridge 810 is a service component that can be used with the air cleaner 800. In particular, removal of an access cover 804, FIG. 73, from the remainder of the housing 802 allows the cartridge 810 to be installed in or removed from the housing 802.

[0276] Generally, referring to FIG. 73, cartridge 810 includes media 825, which in this example is disposed about an open filter interior space 826 (and cartridge central axis X) and extends between a first end member (or end cap) 828 and a second end member (or end cap) 829. Note that in FIG. 73, end member 828 is disposed at the open end of cartridge 810 and is therefore an open end member or end cap through which air can flow during operation. In contrast, end member 829 is shown as a closed end cap, i.e., end member 829 does not have a central opening through which air can flow. While this is a typical configuration, other configurations are possible, including selected features described herein.

[0277] Typically, at least a portion 828m of the end member 828 is typically a molded-in-place formed portion in which an end 825x (end portion) of the media 825 is fixed, e.g., embedded, although other configurations are possible. Similarly, typically, at least a portion of the end member 829 is typically a molded-in-place formed portion in which an end 825y of the media 825 is embedded, although other configurations are possible. The media 825 may be a pleated media, although other configurations are possible. The choice of which particular media 825 is a matter of considering the efficiency and useful life of the media. In general, the media and media feature configurations described above can be used.

[0278] As shown, the medium 825 extends around an optional porous inner liner or central support 827, which in the illustrated example comprises a lattice structure including a plurality of longitudinal sections 827s joined together by ribs 827r. Alternative configurations for the optional support 827 may be used. In general, however, if a support 827 is used, the support 827 is configured to have sufficient porosity to achieve the desired (air) gas flow and sufficient structural robustness or rigidity to support the medium 825. As previously discussed, the support 827 may be configured as a resonator / sonic choke if desired. Indeed, as described below, in some applications, the medium may be configured to include no open interior space.

[0279] End member 828 is an open end member having a central opening 830 therethrough. In use, air flows through opening 830. Also in use, inner tube portion 821i of housing flow tube 812 protrudes through opening 832.

[0280] 78, a perspective view of the cartridge 810 is shown looking towards the end member 828, revealing a central opening 830 which forms an air flow passage in conjunction with the open filter interior space 826. The end member 828 includes a first primary seal structure 833 and an optional secondary seal structure 834. The optional secondary seal structure 834 may be constructed and arranged substantially similarly to the seal structures 66, 534 previously described, although different configurations are possible.

[0281] Referring to FIG. 72A, an enlarged fragmentary view of a portion of FIG. 72 is shown. In this example, since no special support is provided, this optional secondary seal structure 834 is provided in the portion that is capable of deflecting radially outward. Thus, the portion of the housing / outlet tube that protrudes into the receiving groove can be configured to press the region 834 against the portion of the housing surrounding the region 834 to deflect the region 834 outward and form a secondary seal. The portion of the (outlet) flow tube / housing that typically causes the deflection can also be configured to not form a seal with the region 834. Note that, depending on the application of the technology described herein, the region 834 can be provided with a rigid seal support if necessary, and the region 834 can operate without such deflection.

[0282] Returning to FIG. 78, as in selected previous embodiments, in the illustrated example, the primary seal structure 833 is configured as a radially facing radial seal surface disposed in axial overlap with one end of the media 825. As illustrated, the seal surface may be generally radially outwardly facing, but may also be configured as a radially inwardly facing surface if desired. The cartridge (and seal) central axis is designated X, and the term "radial" as used herein shall refer to a direction toward (inner) or away from (outer) axis X, just as in the previous description. In fact, even if the cartridge axis X did not exist, the seal 833 would be characterized as a radial seal, since it would be considered to surround the central axis such that the sealing force is generally toward or away from the central axis (the axis corresponding to axis X). This characterization of a radial seal is general, but applicable to any of the embodiments described herein.

[0283] Also, similar to the previously described embodiment, the primary seal arrangement 833 is preferably a "non-clamping" seal, a "non-clamping" seal or a "clamp-less" seal, in the sense that no additional clamping is typically required. Preferably, a seal is achieved without additional clamping (when the cartridge 810 is properly and correctly installed in the appropriate housing 802).

[0284] 78, for the illustrated cartridge 810, the primary seal 833 includes radially oriented sealing surfaces 833s that define a non-circular configuration in this example, although other configurations are possible. The illustrated example seal structure 833 is a configuration having outwardly projecting portions or lobes 833x (outwardly oriented convex portions in this example) 833x that are alternated with and separated by portions 833y (not linear in this example, but typically inwardly projecting, curved or concave in this example). The particular number of outwardly projecting (curved in this example) sealing surface lobes or portions 833x and inwardly projecting (curved in this example) portions 833y is not critical, at least to some advantage. Typically, the number of each portion is at least two, usually at least three, and (in accordance with the previously described embodiment) at least four, for example in the range of four or more and twelve or less, and possibly four or more and ten or less. However, in the particular example shown, the number of portions 833x and portions 833y is 10 each. In a typical application, there will be more than 4 such portions and no more than 10 such portions, but this number may also be varied.

[0285] As with certain embodiments described above, another definition may characterize sealing surface 833 as having a plurality of spaced apart lobes or radially outwardly projecting (outwardly convex) portions 833x spaced apart from one another by (in this example non-linear, inwardly projecting, e.g., outwardly concave) portions 833y of surface 833. Typically, there are at least two such outwardly projecting lobes or portions, usually at least three, and often at least four, and typically in a number in the range of four to twelve, e.g., four to ten, although other numbers are possible.

[0286] 78, in the illustrated example, an optional concave surface or recess 839 surrounds the primary seal member surface 833s. The concave surface or recess 839 in the illustrated example is a recess, receiving portion or receiving groove 840. The recess, receiving portion or receiving groove 840 is a receiving portion that is positioned and defined to receive a protruding portion of the housing end 811 and / or tube 812, similar to the receiving portions 73, 540 previously described, as will be described in more detail below.

[0287] It should be noted that the principles described herein with respect to seal 833 are also applicable when sealing surface 833 is not surrounded by a recess or receiving groove. That is, sealing surface 833 may be a sealing surface on a protrusion of end cap 828. Indeed, this is the structure found in some of the other embodiments described herein. However, in structures incorporating all of the various features described herein, it is convenient and effective to provide a recess, receiving portion or receiving groove 840 surrounding surface 833s.

[0288] For the particular cartridge 810 shown, it can be seen that the recess or receiving groove 840 is configured to have a radially inner wall forming a surface 833 that is not circular by definition about axis X as shown, and a radially outer surface 841 of the groove 540 that is generally circular by definition about central axis X, although alternative configurations are possible.

[0289] In Fig. 72 it can be seen that a portion 811x of housing end 811 and a portion 812x of outlet tube 812 protrude into the recess, receiving portion or receiving groove 840. In this regard, attention is also directed to Fig. 72A, which shows an enlarged fragmentary view of a portion of Fig. 72.

[0290] As previously explained, the particular secondary seal 834 shown is configured such that the housing portion 811x and the outlet tube portion 812x bias the unsupported end regions of the secondary seal structure 834 outwardly into engagement with the seal tubes surrounding the respective housing portions. This optional bias is useful when size considerations make it undesirable to place rigid supports in the end regions of the secondary seal 834. This structure is applicable to many of the variations described herein with respect to the optional secondary seals.

[0291] 75, cartridge 810 is shown in cross-section, where recess, receiving portion or receiving groove 840 (having inner wall 833 and outer wall 841) can be readily seen. Groove 840 can be dimensioned as previously described, if desired, and can have similar characteristics.

[0292] In Fig. 84, a support structure or central support 845 for cartridge 810 is shown. Support 845 can be manufactured as a preform and used as support 827 of Figs. 72 and 73 corresponding to cartridge 810. As with the alternative structures described above, support 845 may be configured to define a resonator / sonic choke in other applications. However, the particular support 845 shown includes a central portion 845s that defines a central cartridge support 827 that is porous but does not act as a resonator / sonic choke. Support 845 comprises a lattice structure of elongated strips 827s interconnected by ribs 827r.

[0293] Similar to the support 545, the support structure 845 includes an end structure 848 with an inner seal support or hub 849 spaced apart from and surrounded by an optional outer rim 850. An optional open lattice structure 851 with struts 851s is provided to span the gap between the hub 849 and the rim 850. Typically, the seal support 849 is embedded in the molded-in-place formed portion of the end member 828 (and the seal structure 833) during use, providing support to control compression during installation. Thus, the hub 849 operates in many respects similarly to the similar portions of the supports 105, 549. The particular hub 849 shown includes a continuous wall having a non-circular shape preferably with a plurality of radially outwardly projecting (curved in this example) support portions 849x alternating with radially inwardly projecting (curved in this example) seal portions 849y. (Alternatively, in the illustrated example, hub 849 can be characterized as having a number of lobes 849x that are non-circular and separated by radially inwardly projecting portions 849y in this example.) The number of radially outwardly projecting (curved in this example) portions 849x and inwardly projecting (curved in this example) portions 849y when shaped as shown is appropriate for the sealing configuration, and thus there are typically at least two of each, usually three of each, and often at least four, e.g., four or more and up to twelve.

[0294] 84, in the example shown, the non-circular seal support portion of hub 849 is solid and continuous, i.e., it has no side openings or slits therethrough as it extends axially beyond post 851 toward tip 849p. As with the examples described above, this is a typical construction, although other constructions are possible.

[0295] Optional outer supports 850 and supports 851 may be generally similar to supports 550 and posts 851s that replace supports 108 and posts 110 described above. However, in the particular embodiment shown, outer hub 850 differs in that it has a shorter extension to tip 849p and is continuous at edge or tip 849p, without any slots or slits. In some cases, hub 850 may be structured to terminate in posts or projections 851s that have an outer shape that terminates in a molded-in-place formed portion of end member 828.

[0296] Still referring to FIG. 84, in the particular construction shown, the support structure 845 is constructed such that the seal support or end structure 848 is integral with the portion of the end structure that is surrounded by the media (with the lattice structure). This is optional and often preferred for manufacturing convenience. However, there is no requirement that the support structure be one integral piece and that the portion that supports the seal be separate from the optional portion that supports the media. Furthermore, the materials of the two portions may be different, one plastic and the other metal, if desired. When two portions are present but not integral with each other, they may be fixed in place by being embedded together in the mold-in-place molding material of the end cap, but may also be attached to each other prior to assembly of the cartridge.

[0297] Also, if the optional outer rim 850 is used to support a seal, it is not necessary that the outer rim 850 be attached by a rigid connection to the rest of the end structure 848, if desired. For example, a ring (or seal support) may be used that is not attached to the rest of the support structure 845, if desired. Furthermore, there is no specific requirement that the support structure within the outer portion of the end member be circular or continuous in configuration.

[0298] In Fig. 85, a cross-sectional side view of the support 845 is shown. The support 845 is surrounded by a portion 849 and includes an end inner ring structure 854. The ring structure 854 defines, in part, an outlet opening 830 through the end cap 828 of Figs. 73 and 75 and, consequently, through the cartridge 810. The support portion 854 (or more generally the cartridge 810) includes a typically radially inwardly facing (or inner) surface 854i having a first member 856 of a cartridge-outlet tube (or outlet tube-cartridge) rotational alignment structure. In the illustrated example, the first member 856 includes one or more (in this example, a plurality of) spaced apart projections 856x on the surface 854i that typically project radially inwardly, i.e., toward the cartridge central axis X of Fig. 75. In the particular example illustrated, the projections 856x are non-circular. In this example, the projection 850x is U-shaped, with the open end of the U pointing generally toward the closed end cap 829 of the cartridge. The arrow-shaped or curved end points toward the outlet 830, i.e., away from the closed end cap 829 and / or the second end of the media. For reasons explained below, this configuration is typical and effective, although alternative shapes and orientations are possible. Non-circular projections 856x are typical and preferred.

[0299] More generally, at least one, and typically each, protrusion 856x has a non-circular shape including a narrow end and a wide portion (typically an end). The narrow end is generally further from the second end of the medium than the wide portion (typically an end). In the illustrated example of a U-shaped protrusion, the narrow end is the center or curved portion of the U, and the wide portion (the end in this example) is a side end of the U. Of course, variations such as "diamond" or "elliptical" shapes could also be used, in which case the narrow end faces away from the second end of the medium, i.e., as in the case of a "U", and the wide portion (the center in this example) is closer to the second end of the medium.

[0300] Attention is now directed to FIG. 87, where a flow (outlet) tube 812 is shown. In this case, the flow tube 82 is characterized as being part of the housing 802. In use, the outlet tube 812 is typically secured at end 811 to the remainder of the housing 802. In general, the outlet tube 812 can be considered to have the following general features: a mounting flange structure 812f, a sealing surface 812s, an inner flow tube portion 812i, and an outer flow tube portion 812z. Generally speaking, the mounting flange structure 812f serves to mount the flow tube 812 to the end 811 of the housing 802, as described below. The sealing surface or member 812s is the surface against which the seal of the cartridge 810 will abut and seal when the cartridge is installed. The inner flow tube portion 812i projects into the housing and defines the portion of the flow tube that projects into the interior space 830 of the cartridge 810 to receive the gas flow after it has been filtered. Additionally, flow tube section 812i includes features for providing rotational indexing with cartridge 810, which will be described in more detail below. Outer flow tube section 812z is a conduit for directing filtered gas flow outwardly from housing 803. The particular outer flow tube section 812z shown is a right angle bend or L-shaped tube, although other configurations are possible, as with the previously described embodiments.

[0301] Attention is now directed to the inner flow tube portion 812i. The inner flow tube portion 812i includes a tip or edge 812t that projects to the innermost portion of the housing 802, and the tip 812t has at least one recess, and typically a plurality of recesses 812r. The recesses 812r are spaced apart from one another by protrusions or tabs 812b. For the particular assembly shown, there are ten spaced apart recesses 812r, although this particular number is not critical to any advantage.

[0302] Each recess 812r is sized to receive a projection 856s, FIG. 35, of the cartridge 810. The recesses 812r are rotationally positioned about the central axis X such that the projections 856x, FIG. 75, can be received therein only when the cartridge 810 is oriented in the proper rotational position about the central axis X. This rotational indexing is configured such that the projections 856x can be received in the recesses 812r only when the cartridge 810 is rotationally aligned about the axis such that the sealing lobes 833x are properly oriented relative to the receiving portion 812o of the sealing surface 812s to provide a convenient and proper seal.

[0303] Generally speaking, the protrusion 856x constitutes a first member of a cartridge-outlet tube (or outlet tube-cartridge) rotational (indexing) alignment structure. The recess 812r constitutes a second member of a cartridge-outlet tube (or outlet tube-cartridge) rotational (indexing) alignment structure. In other words, the assembly 800 includes a protrusion / receiving portion (indexing) structure that acts as a rotational alignment (indexing) structure between the cartridge 810 and the outlet tube 812 such that the cartridge 810 can be fully installed in the housing 802 only when the cartridge 810 is rotated about the central axis X such that the cartridge 810 is in one of one or more selected rotational positions in which the cartridge 810 can be fully inserted with the seals properly aligned. It should be noted that in the particular example shown, the protrusion structure is located on the cartridge and the receiving structure is located on the housing, i.e., on the outlet tube 812. However, other structures are possible.

[0304] It should be noted that in the particular example shown, cartridge 810 includes one member of rotational alignment structure 856 with five (typically two to eight) spaced apart projections 856x, although the number is not critical. What is important is that unless cartridge 810 is properly radially aligned about axis X, interference will occur.

[0305] It should be noted that there are a greater number of receiving portions 812r than there are protrusions 856x. This is a typical configuration, but is not specifically required. The number of recesses 812r is selected such that, if the desired rotational position does not initially snap into place while the inspector is installing the cartridge, only a small relative rotation of the cartridge is required to achieve sufficient alignment for full insertion.

[0306] It should be noted that typically each projection 856x is sized and shaped such that when properly received in receiving portion 812r, it does not actually engage in direct contact with outlet tube portion 812i, which is preferred but not required in all applications.

[0307] It should be noted that the non-circular shape of the projection 856x, e.g., "U-shaped," provides an advantageous structure in that if the projection 856x strikes the tip 812t during installation, it can easily rotate without getting caught, and the U-shape provides a configuration that is not easily damaged. This advantage is further enhanced by the narrow end and wide portion described above. Alternative configurations are possible.

[0308] It should be noted that, generally, projection 856x is positioned to engage tip 812t before insertion begins until the non-circular sealing structure of sealing lobe 833x is nearly engaged with sealing surface 812x. This structure is preferred because the cartridge must be properly rotationally aligned before the end of the cartridge adjacent the sealing surface strikes or is obstructed by the portion of the structure forming surface 812s.

[0309] It should be noted that the features found in other embodiments described herein may also include a protrusion selection receiving subrange that rotates the recess 812i and the protrusion 856x.

[0310] 87, attention is drawn to a recess or groove 812g disposed between tube 812t and sealing surface 812s. Recess or groove 812g is a receiving groove for receiving a portion of cartridge 810 that protrudes into recess or groove 812g during installation of the cartridge. Specifically, groove 812g is sized and configured to receive a portion of end member 828, designated 828p in FIG. 78. That portion 828p of end member 828 is a protrusion having an outer surface that defines sealing surface 833.

[0311] As previously explained, the sealing surface 833 is non-circular and, in the illustrated example, comprises a plurality of radially outwardly projecting portions 833x separated by radially inwardly projecting recesses 833y.

[0312] 87, a groove 812g is defined between an inner wall 812y and an outer wall 812o. One of the walls 812y, 812o is generally configured as a sealing surface of the cartridge 810. For the particular embodiment shown, the cartridge 810 has a radially outwardly facing sealing surface 833, such that the sealing wall of the groove 812g (designated as 812s in the drawings) is the outer radially inwardly facing wall 812o.

[0313] The sealing surface 812s has a shape and definition that is also non-circular, and is shaped to correspond to the shape of the sealing surface 833 such that when engaged with the sealing surface 833, a seal occurs due to some compression of the material and the projections 828p. Thus, when the surface 833 has the particular shape described above, the surface 812s comprises a plurality of radially outwardly projecting regions 812p spaced apart from one another by regions 812q. In the illustrated example, the regions 812q are not linear, but typically project radially inward. Thus, the regions 812p are inwardly concave (or outwardly convex) and the regions 812q are inwardly convex (or outwardly concave).

[0314] Regions 812p and 812q are radially positioned with respect to central axis X such that when rotational indexing occurs between projection 856x and recess 812r, alignment with surface 833 for a perfect seal is achieved.

[0315] When the configuration is substantially as described herein, the number of portions 812p and the number of portions 812q will generally match the corresponding number of similar regions in cartridge 810, although other configurations are possible. Typically, the number of radially outwardly projecting portions 812p will be at least two, usually at least three, and often at least four, typically four or more and no more than twelve, and often four or more and no more than ten, although other numbers are possible. In this example, there are ten portions 812p, but other numbers are possible.

[0316] 87, attention is drawn to mounting flange 812f. Mounting flange 812f includes a radially outwardly facing rim portion 812v and an axial portion 812a. Axial portion 812a forms a rim around region 812f. Note that openings 812c are located at the location where rim 812a aligns with inwardly projecting portion 812q of face 812s. These openings 812c act to provide some resiliency to the material of raised portion 812a at that location and to help ensure even cooling of the plastic.

[0317] The projection 812a is sized and configured for snap-fit ​​engagement with another portion of the housing, and further includes spaced apart interference portions 812e at the end 811 that engage another portion of the housing for rotational stability, as described below.

[0318] 72A, there is shown the portion of housing end 811 which projects axially inwardly, previously designated 811x. Tube 812 is attached by forcing flange 812a into the opening defined by flange 811x and engaging flange 811x. As shown, flange 812a includes end projection 812j to facilitate snap-fit ​​engagement. Additionally, to facilitate rotational alignment, projection 811x may include a groove or rib on its inner surface for rotational engagement with projection 812e of FIG.

[0319] 72A and 72, other features described above can be used. For example, the end cap or end member 828 can include an optional outwardly facing radial peripheral seal 828s that is arranged to engage with the portion of the housing 802 surrounding the seal 828s, if desired. However, this secondary seal is optional as indicated above. If a secondary seal is used, the secondary seal typically has a larger cross-sectional dimension than the primary seal, as described above with respect to other embodiments. As previously mentioned, the peripheral seal 828s can be configured to be radially biased, but it is also possible to provide internal support for the peripheral seal 828s. Also, the tip portion 828st of the outer seal 828s can be provided as a continuous ring, although other configurations (such as a discontinuous ring including a recess) are possible. One example of a recess is shown in FIG. 74 by phantom line P.

[0320] Typically, end cap portion 828m is molded in place, for example from a moldable urethane or similar material, with a portion of frame structure 845 of Fig. 85 embedded within it, as can be seen with reference to Fig. 79. Figs. 82 and 83 show what the molded portion of end cap 828 would look like if it were not embedded with structural material, but the perimeter definition would be the same.

[0321] The remaining views of the embodiment shown in Figures 71-89 are generally as follows: In Figure 74, a side view of cartridge 810 is shown generally. It can be seen that media 85 extends between end members 828-829. A central axis X is indicated.

[0322] 76 shows an end view of cartridge 810 as viewed generally toward end member 828. First or primary seal structure 833 can be seen, along with radially outwardly facing sealing surface 833x. Additionally, protrusion 856x can be seen passing through opening 830. Note that the cross-section of FIG. 75 is shown in FIG. 76.

[0323] 77 shows an end view of cartridge 810 as viewed generally toward end member 829. As shown, end member 829 has molded therein a protruding ring 860, which in the illustrated example has a split ring. Protruding ring 860 may engage an access cover to provide stability to cartridge 810 when installed.

[0324] 79 shows an enlarged partial cross-sectional view of selected portions of cartridge 810. Portions of end member 848, including seal support 849 and outer rim 850, can be seen embedded within molded-in-place end member 828.

[0325] FIG. 80 shows the structure of FIG. 79 without the molded-in-place portion 828m of end member 828. In particular, the media 825 is shown extending around the support 827. The axial alignment of the media 825 with the end portion 848 of the support can be seen. The struts 851 of FIG. 84 can be seen to be angled generally away from the media 825 while extending radially outwardly, similar to the previously described embodiment. In general, the configuration of FIG. 80 can be inserted into a mold with resin to form the overmolded or molded portion 828m of FIG. 79 of the end cap 828.

[0326] When the structure of Figure 80 is positioned in a mold, if the mold is appropriately configured, protrusions 856 can be used for radial orientation relative to the mold, similar to fins or protrusions 626 of Figure 65. Thus, protrusions 856x can be used for two purposes: to control the molding of portion 828m of end cap 828 to obtain the desired configuration, and to provide rotational indexing with respect to the housing, and in particular with respect to inner portion 812i of the outlet tube, as previously described.

[0327] 81 shows an end view of cartridge 810 as viewed towards end member 828. This defines approximately the section line of FIG.

[0328] Fig. 82 shows a schematic plan view of the molded-in-place formed portion 828m of the end member 828. Fig. 83 shows a cross-sectional view of the molded-in-place formed portion 828m. Fig. 83 also shows a schematic perimeter definition of the molded-in-place formed portion 828m. It goes without saying that in an actual cartridge, a structural material would be embedded within the end portion 828m.

[0329] Fig. 86 shows an end view of the support 845 of Fig. 84. The view is generally looking towards the end structure 848.

[0330] In Fig. 88 there is shown a tube 812, more fully described above in connection with the perspective view of Fig. 87. In Fig. 89 there is shown an enlarged portion of Fig. 88.

[0331] It will be apparent from the above that the cartridge may be configured similarly to the cartridges previously described herein. The preform 845 may be configured as a support. The media 825 may be placed around the support, and then the two end members 828, 829 may be placed, typically by mold-in-place molding. A protruding structure 856s may be used to properly rotate the combination of the media and support 845 in the mold to form the sealing surface 833x. This may be similar to the embodiment previously described, particularly with respect to the fin 626 of FIG. 65. It is noted that the protruding structure 856s may be used in place of the previously described embodiment.

[0332] For the embodiment shown in Figures 71-89, example dimensions are given below: In Figure 79, AA = 13 mm; In Figure 80, AB = 22.5 mm, AC = 11.9 mm, AD = 12.5 mm; In Figure 81, AE = 13.5 mm; In Figure 82, AF = 27.5 and AG = 7.1 mm; In Figure 83, AH = 20 mm; In Figure 89, AI = major to minor axis dimension 7.1 mm, AJ = radius 36.8 mm and AK = radius 43.9 mm. Other dimensions of the structure that can be used can be evaluated and considered from scale. Of course, as with all embodiments, other dimensions and other relative dimensions can be used with the principles described herein.

[0333] 71-89, for example, receiving groove 840 as shown in FIG. 79 can have dimensions similar to those previously described receiving grooves with respect to depth and extension from the nearest outer portion of the end member, deepest portion of the groove, outermost open portion of the groove, amount of compression of the seal toward the embedded support, spacing between the inner seal and optional outer seal, etc.

[0334] The embodiments of Figures 71-89 can be implemented in a form that includes various features of the embodiments and alternative embodiments previously described in this specification. The descriptions of the various embodiments shown in the figures are not intended to be mutually exclusive with respect to the application of the features or principles described. Thus, the features of the principles of one embodiment can be applied to other embodiments if they do not conflict with other features present in other embodiments.

[0335] The two-seal configuration as shown is optional, but may be beneficial. In particular, the inner seal, having a non-circular shape, prevents the cartridge from rotating during use, even if the outer seal is circular. This prevents contaminants from entering the clean surface and / or clean air area. Furthermore, by providing two radial seals oriented as shown in a configuration that directs filtered flow from the outside in through the cartridge, only the outer (optional) second seal is directed to the location where dirt particles are present in the housing. Thus, whether the inner seal is non-circular or not, the sealing surface adjacent to the inner seal remains substantially clean during inspection.

[0336] Non-circular shapes have the advantage of reducing vibratory movement of the elements. For a given diameter of the elements, a non-circular seal shape for the primary seal will have a greater perimeter than the simple circumference of a typical circular seal. More specifically, the amount of seal surface area available to contact structures within the housing and resist movement (e.g., resist axial movement) will be greater than the amount of seal surface area of ​​a comparably sized circular seal. Thus, non-circular shapes, especially when using alternating outwardly curving and inwardly curving portions, are effective at supporting the cartridge against seal movement.

[0337] It should be noted that in the embodiments described above, the end member opposite the end of the cartridge having the seal has been described as generally closed. In other applications, that end member could be open. In the example of FIG. 73, this would correspond to end member or end cap 829. It should be noted that the end member of FIG. 29 (which is optional in some embodiments) may also be open, if appropriate to the operation of the cartridge. If the end member needs to be closed for proper operation of the cartridge, it could be closed by structure within the housing or other material.

[0338] Attention is now directed to optional features that can be seen from FIG. 75. Referring to FIG. 75, surface 833s, as previously described, is a sealing surface that forms an optional first seal with the housing. Reference numeral 828q in the figure denotes a sealing surface that forms an optional second seal with the housing. When two radial sealing surfaces 833s, 828q are used, one of which is non-circular as previously described for surface 833s, it may be preferable that the outer peripheral surface 828 (and the portion of the end member on which it is located, which is generally circular in this example) has a maximum axial reach that is different from the maximum axial reach of sealing surface 833s and the portion of the end member on which it is located from the second or distal end of the media, as shown by reference numeral 825y in the figure. More specifically, surface 833s has a predetermined amount of maximum axial reach, i.e., a portion that is spaced a maximum distance from second end 825y. This amount may preferably be different from the portion of surface 828q that engages with the housing to form a radially oriented seal. Preferably the difference is at least 0.5 mm, usually at least 1 mm, and often 2 mm or more in total reach.

[0339] If the two portions have different areas, which is longer will depend on a balance of priorities. For example, in some cases, it may be preferred that surface 833s is part of the inner end member area having the longer reach. The reason why this configuration of maximum axial reach and distance from end 825y is preferred will become clear upon understanding the operation. When installing cartridge 810, the operator must rotate the cartridge slightly to ensure that non-circular sealing surface 833s is properly aligned with the housing portions so that cartridge 810 can be fully inserted and a complete seal can be achieved. During this rotational alignment, it may be preferred that outer periphery radial seal 828q is not yet engaged, as this would prevent rotation of the cartridge. It can be seen that by making the maximum reach of surface 833s greater than the maximum reach of surface 828q, rotation will be easier. This preferred configuration can be effectively implemented in any of the embodiments described herein.

[0340] However, in some cases, insertion of cartridge 810 is limited by projection structure 856x engaging the flow tube before region 828 (and tip 841) reaches the location of the sealing resistance. In that case, it may be desirable to have the outer ring of the end piece longer than the inner portion where seal 833 is located, because when cartridge 810 is stood on end piece 828, the outer ring will prevent the area adjacent seal 833 from contacting contaminants.

[0341] Thus, whether the area forming surface 833s has the same axial reach as the area forming periphery 828q or a different (longer or shorter) one will depend on other features of the system and their implications, but as explained above, advantages can be obtained from variations.

[0342] However, this does not imply that every feature of a particular embodiment must be applied in that embodiment to produce a useful and effective structure, and it is possible to achieve selected advantages without using all of the features shown and described.

[0343] VIII. Some exemplary variations of the structures of FIGS. A. Modifications of Figures 71A, 71B, 72B, 71C, 72B, 72C, 74A, 75A, 75B, 76A, 77A, 78A and 78B 71A, 71B, 71C, 72B, 72C, 74A, 75A, 75B, 76A, 77A, 78A, and 78B show some selected variations of the features previously described in relation to the embodiment of Figures 71 to 89. These variations will now be described. It should be noted that the features of these variations are also applicable to many of the other embodiments described herein, including, for example, Figures 1 to 70.

[0344] 71A, there is shown a filter assembly 1400. The filter assembly 1400 comprises a housing 1401 having features generally in accordance with those previously described, namely, a housing body portion 1402 having an (inlet) flow tube 1403 and an (outlet) flow tube 1404, and a removable access cover 1405. As shown, the removable access cover 1405 has a debris exhaust tube 1406. The debris exhaust tube 1406 is shown without a vent valve arrangement, although typically a vent valve arrangement would be used.

[0345] It should be noted that, unlike the previously described structures, end 1410 of access cover 1405 has multiple axially projecting tabs 1411 as shown. Additionally, latch structure 1415 is shown including a thumb catch, tab or latch portion 1416 positioned to overlap end 1410. Latch tab 1416 is positioned to overlap end 1410 for convenient access during servicing. Tab 1411 helps prevent latch portion 1416 from being damaged if the access cover is placed on a surface with end 1410 projecting downward. Tab 1411 is also useful in preventing the latch from accidentally opening or potentially being damaged if something rubs or bumps against end 1410.

[0346] The tab 1416 overlaps the end 1410, resulting in a relatively long length of the latch 1415 up to the latch end 1415x. Reference numeral 1420 denotes a retaining structure that helps retain the latch 1415 in position adjacent to the exterior surface of the access cover 1405. The retaining structure 1420 also acts as a guide for the latch structure 1415. When the latch structure 1415 is opened, the latch portion 1421 moves toward the outlet 1404. The portion of the latch structure 1421 near the protrusion 1425 is bent so that the end of the latch moves outwardly and overcomes the retaining flange 1422 of the body portion 1402 while moving toward the outlet 1404. The protrusion 1425 prevents the latch retaining structure 1420 from being damaged while the housing 1401 is being operated.

[0347] Reference numeral 1427 denotes a circular recess in the access cover 1405. This recess 1427 mates with a radial sawtooth feature (not visible protruding into the inside of the access cover 1405) on the end of the body 1402. This allows the access cover to be held in a selected angular position and easily locked in that position.

[0348] 71B shows a side view of the assembly 1400. As shown, the outlet 1404 has an optional tap 1430 that can be used according to the principles previously described with respect to other embodiments herein.

[0349] Figure 72B shows a cross-sectional view of assembly 1400 taken along line 72B-72B of Figure 71B. Shown within housing 1401 is a serviceable filter cartridge 1430 generally comprising features as previously described, see Figures 72 and 72A for relevant features previously described.

[0350] 72B, the outlet or flow tube arrangement 1404 includes a flange 1431 that extends radially to approximately the outer periphery of the housing 1401, such as to a portion of the outer periphery as indicated by reference numeral 1401p. This variation is also possible in other embodiments described herein.

[0351] Turning now to Fig. 74A, a side view of cartridge 1430 is shown. Cartridge 1430 generally includes media 1435 extending between first end member 1436 and second end member 1437. A cross-sectional view taken generally along line 75A-75A of Fig. 74A is shown in Fig. 75A. In this view, cartridge 1430 is shown in cross-section.

[0352] With reference to end member 1436, it can be seen that first seal 1440, which may be a non-circular seal as previously described, projects to an outermost maximum reach 1440r in a direction away from the far or second end 1435y of media 1435 as shown, i.e., further than the reach limit indicated by reference numeral 1441r of secondary outer seal 1441. The two seals 1440 and 1441 are shown as being part of end member 1436 located at end 1435x of media 1435. This is advantageous in some constructions, as seal 1441 is provided to be unengaged when seal 1440 is inserted.

[0353] Referring to FIG. 75A, one example of dimension XF would be 273 mm, although other values ​​are possible.

[0354] Still referring to FIG. 75A, the illustrated cartridge 1430 includes a radial projection 1445 that can be used as an indexing member similar to the structures previously described with respect to other embodiments.

[0355] 72B, the portion of end member 1436 that forms outer rim or ring 1450 preferably does not include the majority of the seal support that extends toward tip 1450t. The portion of the housing that is pressed into groove 1460 is sized to bias flexible end 1450 radially outward toward the housing during installation to facilitate sealing. This variation is also applicable to the various other embodiments described herein.

[0356] With further reference to FIG. 72B, the support 1447 provided for support at the end member and near the periphery may be a ring separate from the rest of the support structure within the cartridge 1430.

[0357] Attention is now directed to Fig. 71C, which illustrates yet another embodiment 1470 of a filter assembly in accordance with the present disclosure. This filter assembly 1470 includes many of the general features previously described with respect to structure 1400, but with some modifications and specific features in the details of the structure. Thus, structure 1470 includes a housing 1471 including a body portion 1472 and an access cover 1475. Housing 1471 includes a gas flow inlet 1473 and a gas flow outlet 1474, in this example at access cover 1472. A cross-sectional view of assembly 1470 is illustrated in Fig. 72C. Cartridge 1480 may include media 1481 having a first end 1481x and an opposite second end 1481y and disposed to extend between end members 1484, 1485.

[0358] End member 1484 disposed at first end 1481 of media is an end member having an open central flow opening therethrough and including a seal structure. The seal structure in the illustrated example includes a first radially oriented seal 1486 and a second radially oriented seal 1487 with a receiving groove 1490 disposed between the two seals 1486, 1487. In the illustrated example, each seal 1486, 1487 faces radially outward. First seal 1486 is disposed to have a maximum radially outer cross-sectional dimension that is smaller than the outer periphery cross-sectional size of media 1481. Seal surface 1486 may be circular, but is typically non-circular in accordance with the principles previously described herein.

[0359] 72C, the maximum axial reach of the end cap portion of sealing surface 1486 extends farther away from end 1481y than the maximum extension of the area of ​​the end cap that includes sealing surface 1487. This may be a convenient configuration if the space within area 1495 is too narrow to accommodate a protrusion that projects into the space.

[0360] In Fig. 75B, an outlet end perspective view of cartridge 1480 is shown. As shown, a protrusion 1492 is disposed on one end of end member 1436. Protrusion 1492 can be configured to engage an end wall and facilitate stabilizing cartridge 1480 in place during use. In Fig. 76A, an end view of cartridge 1480 is shown without optional protrusion 1492. Example dimensions are provided as follows: XG=80mm, XH=radius 20mm, XI=radius 27mm, and XJ=90mm.

[0361] In Fig. 77A an end view of the closed end 1437 of the cartridge 1480 is shown. Example dimensions provided are: XK = 106mm. In Fig. 78A a perspective view of the cartridge 1480 is shown and in Fig. 78B a further perspective view of the cartridge 1480 is shown.

[0362] From the above, it may be appreciated that in some applications it may be desirable for the end member having the primary seal to include an outer rim portion that is relatively short relative to the maximum extension length of the portion of the end member having the primary seal, or that is relatively long relative to that portion of the end member. Additionally, in various constructions it may be desirable for the outer portion of the end cap to be made of a relatively flexible material so that it can flex relative to the housing as needed, or for the outer portion to be supported by an internal structural support. A variety of such constructions may be advantageously adapted to the principles described herein, and variations thereof are applicable to the various embodiments described herein.

[0363] B. Additional Variations, Figs. 90-101 FIG. 90 illustrates a variation that may be used in various embodiments of the embodiments described herein. Shown in FIG. 90 is a variation of a support structure 1600 that may be used in various filter cartridges described herein. The illustrated support structure 1600 includes a support portion 1601 that functions as a media support, around which media may be placed during use. This particular support portion 1601 is shown as a media support that does not include a resonator / sonic choke structure, but may be configured to include a resonator / sonic choke portion, for example, as described above, if desired. The support structure 1600 further includes an end support structure that may be embedded in a molded-in-place portion of an end member and act as a seal support.

[0364] 91 shows a partial perspective view of the support structure 1600 as viewed generally toward the end support structure 1602. The end support structure 1602 includes a primary seal support 1604 configured to support a non-circular seal having a plurality of outwardly projecting and inwardly projecting portions as previously described.

[0365] A support structure 1606 including ribs 1607 and an outer flange portion 1608 projects radially outward from the primary seal support 1604 .

[0366] In FIG. 92, a second perspective view is shown for ease of understanding.

[0367] It can be seen from Figures 90-92 that the principles can be applied to constructions where the outermost rim is not a continuous ring, but is a segmented piece, which can be implemented in many of the various cartridges shown and described herein.

[0368] 93, yet another support structure 1650 is shown. Support 1650 is similar to support structure 1600 and includes a support portion 1651 that supports the media and an inlet portion 1652 that would typically be embedded in the end cap material during use. Also, media support portion 1651 is shown as a porous media support, but may include a resonator / sonic choke configuration / feature if desired. End portion 1652 is typically embedded in a molded-in-place portion of the end member during use and includes a primary seal seal support portion 1653, which may be circular, but is shown configured to form a primary seal support with alternating outwardly and inwardly projecting portions.

[0369] In Fig. 94 a perspective view is shown where a support portion 1655 with a radial portion 1656 and an axial projection 1657 projects radially outward from portion 1653. In Fig. 95 another perspective view is shown for further consideration. By examining Figs. 93-95 it will be appreciated that the support for the outer seal can be made up of a portion with outer support areas and segments that are not supported by ribs but are otherwise fixed to other portions of the support structure. An axial support portion 1651 can also be used.

[0370] The principles of Figures 93-95 are applicable to many of the structures described herein.

[0371] 96-101 show variations associated with constructing the seal support separate from the media support.

[0372] Attention is first directed to Fig. 96, in which structure 1700 is shown. Structure 1700 is shown diagrammatically and comprises a media support part 1701 and a seal support part 1702. It can be seen that the two parts 1701, 1702 are separate from each other, i.e. not integral with each other. Support part 1701 is shown diagrammatically. Support part 1701 may be a porous tube with a lattice structure as a media support, but can also be configured as a resonator / sonic choke part if required. The view in Fig. 96 is only intended to show diagrammatically that there are parts that protrude into the interior space surrounded by the media during use.

[0373] The support portion 1702 may be configured according to any of the various supports previously described herein. In the illustrated example, the support portion 1702 comprises a primary seal support 1703 which may be configured to support a variety of different seal shapes. In this particular example, the support 1703 is configured to support a seal structure in which the seal comprises a number of inwardly projecting and outwardly projecting portions. The support 1702 is also provided with an outer rim 1705 secured by ribs 1706. The variations previously described may be used.

[0374] The support 1702 further includes a central portion 1708 having air flow openings 1709 therethrough and has an optional radial indexing feature 1710. FIG. 97 shows the joined together parts 1701 and 1702 as would normally be found during a typical assembly. FIG. 98 shows the structure 1700 of FIG. 97 in schematic form with parts 1701 and 1702 as previously described. FIG. 99 shows an end view looking towards part 1702 with the features previously described. FIG. 100 shows a cross-sectional view of the support structure 1700 with parts 1701 and 1702 as previously described. FIG. 101 shows an enlarged fragmentary view of a portion of FIG. 100 with the same portions previously described.

[0375] During preparation of the cartridge, the support 1700 can be assembled from non-integral parts that will then be joined together during molding of the end members to secure them together and form the appropriate features in the cartridge. The non-integral parts may be made from the same material, but can also be made from different materials.

[0376] IX. EXEMPLARY EMBODIMENTS WITH DIRECT-FLOW ARCHITECTURE, FIG. 102-FIG. 107 The above described examples generally relate to configurations in which the cartridge media surrounds an open filter interior space and flow during filtration passes through the media into the open filter interior space and then through an open end member of the media pack before exiting. The principles described herein are also applicable to "through-flow" configurations, i.e. other configurations in which the media is configured such that flow during filtration enters at one end of the media and exits at the opposite end. Examples can be seen by reference to Figures 102-107. It will be appreciated that the housing may be modified for use with a through-flow cartridge.

[0377] Referring to FIG. 102, a cartridge 900 is shown with a media pack 901 configured for straight through flow during filtration. As an example, unfiltered air (gas) can enter end 902 and exit through the opposite end 903 as filtered air (gas). The media 905 can be configured in a variety of ways. For example, the media 905 can be configured as a grooved configuration with grooves extending between the flow faces 902, 903 at either or both ends, with an inlet groove that is open at end 902 and closed at end 903, and an outlet groove that is closed at end 902 and open at end 903, with the media 903 configured such that air entering end 902 cannot exit through outlet 903 without passing through the media. Such media can be provided in the forms described, for example, in U.S. Patent Nos. 6,190,432 and 7,396,376, which are incorporated herein by reference. According to those US patents, the media pack includes a grooved material secured to a backing material to form an operative groove seal in the media pack.

[0378] A typical example includes a fluted sheet secured to a backing sheet (for example) and wound into a coil, as shown in FIG. 103 at 910. The construction of such media is described, for example, in U.S. Patents 6,190,432 and 7,396,736, which are incorporated herein by reference. The media can be manufactured from a variety of materials and may optionally have a surface treatment such as microfiber. Referring to FIG. 103, as the media is coiled as shown, there is shown a coil 911 having a seal 912 formed at one end of a groove 913, with a second groove 914 already formed between the fluted sheet 916 and the backing sheet 917. Such a coil 911 may be used in the media pack of the cartridge 900.

[0379] Returning to FIG. 102, cartridge 900 is shown having an end member 920 at a first end of media 905. The end member 920 shown generally includes a molded-in-place formed portion 921 configured to have a first seal member 923 as previously described in the form of a radial seal 923s (in this example a radially outwardly facing seal) with a plurality of outwardly curved (convex) lobes 923l preferably spaced apart by non-linear inwardly facing, preferably outwardly facing (concave) regions 931c. The shape and number of lobes 923l may be as previously described with respect to other embodiments. Additionally, the seal material forming surface 923s may be molded onto a structural support as desired.

[0380] The particular end member 920 shown includes an optional receiving groove 940 surrounding the sealing surface 923s, which groove is generally as described above. Additionally, the end member 920 includes a perimeter portion 920p that can be formed from a sealing material to form a secondary perimeter seal, as described above. Additionally, the end member 920 may include an optional support structure embedded within the perimeter portion 920p to provide support for the seal 920p.

[0381] As previously indicated, a support structure may be included that is embedded within the molded-in-place portion of end member 920 and therefore would not be visible in the embodiment shown in FIG. 90. The support structure may include supports 923l and supports for seal 920p, if desired. If supports are used, they could be configured not to extend to the center of media 905, if desired, since in this example media 905 is not coiled around the open filter interior space. A central portion 905c of the coiled media may simply be inserted into end 903.

[0382] 102, the illustrated cartridge 900 includes a second end member 930 adjacent end 902 to facilitate gripping the cartridge. End member 930 is optional. End 902 of end member 930 will typically be open to allow for flow into the media pack.

[0383] The media pack of the cartridge 900 of FIG. 102 may include an impermeable covering or shield surrounding the media, if desired. However, such shielding is optional, and the media pack may simply be a coiled configuration of backing media secured to grooved media, if desired. In general, the features of the end members 920 may be in accordance with the descriptions presented herein above with respect to other embodiments, except for modifications made as necessary to accommodate media types.

[0384] The diagram in Fig. 102 is schematic and is not intended to precisely depict any selected embodiment, but rather to show how the principles described herein can be applied in a structure using the type of media previously described with respect to direct flow, again with a housing that would be configured for a direct flow cartridge as required.

[0385] It should be noted that in the illustrated example, some portions of the end member 920 would be positioned over one end of the media 905 and would therefore block flow through the periphery of the media, i.e., some of the radially outermost grooves. Optionally, the end member 920 may include supports such that the mold-in-place molding portion of the end member 920 and the support portion of the preform are supported at the media surface away from the ends of the grooves, thereby blocking the radially outermost grooves, or at least a few of the grooves, from draining flow. To achieve this result, the principles described in connection with U.S. Patents 6,190,432 and 7,396,376 can be applied to the supports and their seal members.

[0386] It should be noted that the embodiments of Figures 102 and 103 may be implemented with the variations discussed herein above in relation to other embodiments, particularly with respect to details such as seal dimensions, receiving groove dimensions, seal position and orientation, etc.

[0387] The principles described are applicable to straight-through configurations that do not include circular configurations, see for example the configurations in Figures 104 and 105. Figure 104 shows a cartridge 1800 with a media pack 1801 that uses a media substantially as described above in connection with Figure 103, except that it is wrapped in a non-circular pattern. Such elliptical configurations are described, for example, in International Publication Nos. WO 00 / 50149 and WO 2005 / 063361, which are incorporated herein by reference.

[0388] An end 1802 of the media is shown having a support 1803 as a seal structure 1804 around it. The seal structure 1804 shown comprises a number of outwardly projecting portions 1805 separated by inwardly projecting portions 1806 to form a non-circular radially (outwardly in this example) directed seal. In this case, thirteen or more such portions are shown, although other numbers are possible. It will be appreciated that the principles are also applicable to radially inwardly directed seals. It is noted that although the particular embodiment of FIG. 104 is shown as a single primary seal, the principles could also be applied to embodiments having an optional secondary outer seal, if desired. In FIG. 105, an end view of a cartridge 1800 is shown having features as previously described.

[0389] It should be noted that various straight-through configurations are known that use media with fluted sheets secured to a backing sheet, where the media pack is not comprised of a coiled structure, but rather a stack of sheets of media. The sheets comprise fluted media secured to a backing media. An example is described in U.S. Pat. No. 8,216,334, which is incorporated herein by reference. The principles described herein are applicable to such configurations. An example is shown in FIG. 106 and FIG. 107, which show a variation of the configuration shown in U.S. Pat. No. 8,216,334, which is incorporated herein by reference.

[0390] 106, a filter cartridge 1850 is shown. The filter cartridge 1850 includes a media pack 1851 configured for direct flow. A face of the media pack 1851, designated 1852, is generally an inlet face. Provided within the cartridge 1850 is an outlet face, designated 1853. The media pack 1851 may be, for example, a stack of media pieces, with various strips forming a grooved media secured to a backing media, with the inlet and outlet grooves extending between the faces 1852 and 1853.

[0391] 106, cartridge 1850 includes end members 1855, 1856 attached to cartridge 1850. It is noted that end members 1855, 1856 are shown molded in place on media pack 1851, although alternative constructions are possible. Additionally, cartridge 1850 includes a covering 1860 that extends around selected portions of media pack 1851, although variations in configuration are possible.

[0392] 106, end piece 1856 is an open end piece having flow openings 1870 therethrough for the flow of gas. Opening 1890 is typically an exit opening that allows filtered gas, typically air, to exit the interior of cartridge 1850.

[0393] In the illustrated configuration, an opening 1870 is shown having a radially facing seal 1871. The seal 1871 includes multiple lobes 1872 separated by recesses 1873. In the illustrated example, the seal 1871 is a radially inward facing seal, with the lobes 1872 projecting radially inward (convex) and the recesses 1873 projecting radially outward (concave). This illustrates that the principles of the present disclosure can be applied to radially facing seals. However, the cartridge 1850 could be configured with an outward facing seal if desired.

[0394] FIG. 107 shows an end view of a cartridge 1850 having features as previously described.

[0395] X. Application of the principle to crankcase ventilation cartridges, Figs. 108 to 111 As previously indicated, the principles described herein are applicable in connection with the filtration of a wide variety of substances, including various gases and in some cases liquids. Most of these applications are preferably related to the filtration of air, e.g., the engine intake air of an internal combustion engine. However, the principles of the present disclosure may also be applied to the filtration of other gases, such as crankcase ventilation gases. Examples of which are shown in Figures 108-111.

[0396] A first example is shown in Figures 108-109. A crankcase ventilation filter assembly in which the principles of the present disclosure are illustrated may otherwise be a filter generally in accordance with the description of U.S. Patent Application Nos. 61 / 503,008 and 61 / 665,501, which are incorporated herein by reference.

[0397] 108, there is shown a cartridge 1900 with media 1901 arranged to extend between opposite ends 1902, 1903. The particular media 1901 shown is configured to surround an open filter interior space 1905. The selection of media for a crankcase ventilation gas filter may be made according to well known general principles, for example in accordance with International Publication No. WO 2008 / 157251, which is incorporated herein by reference.

[0398] As shown, the cartridge 1900 has end members 1910, 1911 with media 1901 extending between them. In a typical application of a crankcase ventilation filter cartridge, the media 1901 will not be embedded in the end members 1910, 1911, but will simply extend between the end members 1910, 1911, although other configurations are possible. Typically, the end members 1910, 1911 will comprise part of the structure that includes the media support structure, although other configurations are possible.

[0399] End member 1910 is shown as having a periphery 1911 with a radially oriented seal configured with a plurality of outwardly facing lobes 1915 spaced apart by recesses or inwardly protruding regions 1916.

[0400] A top view of a cartridge 1900 having features as shown above is shown in Figure 109. Example dimensions are: XL = 5mm radius, XM = 18.7mm radius, XN = 106.34mm and XO = 100.5mm.

[0401] Still referring to Figs. 108 and 109, the crankcase ventilation filter cartridge is configured to filter crankcase ventilation gases that typically include a liquid (fine droplet or aerosol) phase as well as a solid particulate phase. The media is typically selected as a coalescing media for liquid particles, and a drain path is typically provided to drain liquid collected by the cartridge. The cartridge can be configured to generate an outside-in flow during filtration or an inside-out filtering. Depending on the flow direction, a through opening may be provided in the second end cap to facilitate drainage flow of liquid. Principles related thereto are described in International Publication Nos. WO2007 / 53411 and WO2008 / 157251, which are incorporated herein by reference.

[0402] 110 and 111 show a further example of a crankcase ventilation filter cartridge configured similarly to cartridges that may be used in systems having features such as those described in International Publication Nos. WO 2007 / 53411 and WO 2008 / 157251, both of which are incorporated herein by reference.

[0403] 111, there is shown a cartridge 1950 comprising media 1951 extending between opposed end members 1952, 1953. In this case, end member 1952 comprises a first seal portion and a second seal portion, where first portion 1955 comprises a radially oriented seal (in this example a radially outwardly oriented seal) comprising a plurality of outwardly projecting portions 1956 separated by radially inwardly projecting portions 1957. Primary seal 1955 is shown surrounding an open central opening 1958.

[0404] End member 1958 is shown as having a peripheral portion 1960 radially spaced from seal structure 1955 by a receiving groove 1961. Peripheral rim 1960 can define an outwardly facing seal 1965, which optionally has a secondary seal.

[0405] FIG. 11 shows an end view of a cartridge 1950 having the features previously described and indicated.

[0406] In FIG. 111, example dimensions are: XP=diameter 129 mm, XQ=radius 16 mm, XR=radius 3 mm, XS=93 mm and XT=71 mm.

[0407] XI. Selected General Comments and Observations In accordance with the present disclosure, a filter assembly, its components, and features are described. It is not specifically required that an assembly, component, or feature include all of the specific details characterized herein in order to obtain any benefit of the present disclosure.

[0408] According to one aspect of the disclosure, a filter cartridge for use in a filter assembly is described. The air filter cartridge generally comprises a media having a first end and a second end. In certain embodiments, the media surrounds and defines an open filter interior space. The media may be pleated, although other configurations are possible. The media may have a generally cylindrical perimeter shape or an alternative shape.

[0409] For example, a first end member, typically an end cap, is disposed at one end of the media. The first end member is generally an open end member having a central opening therethrough. In selected embodiments, the first end member is preferably an end cap that extends along the entire first end of the media, thereby completely enclosing the first end of the media. However, other constructions are possible. Typically, a portion of the first open end member is molded in place, although other constructions are possible.

[0410] In many constructions, the second end of the media is engaged with an optional second end member. In selected embodiments, the second end member is a closed end cap that typically does not have a central opening therethrough, although other constructions are possible. The second end member may be molded-in-place or include a molded-in-place portion, although other constructions are possible.

[0411] In one example of the illustrated filter cartridge, a housing seal arrangement is disposed on the first end member. In one example, the housing seal arrangement includes a (first) radially oriented seal surface. In selected examples illustrated, the (first) radially oriented seal surface is not circular in the circumferential direction, e.g., has at least two spaced apart radially outwardly projecting seal surface portions, typically at least three spaced apart radially outwardly projecting seal surface portions, preferably at least four spaced apart radially outwardly projecting seal surface portions (typically more than four, not more than twelve, usually outwardly convex seal surface portions). In many embodiments described herein, the radially outwardly projecting seal surface portions are spaced apart from each other by non-linear, e.g., radially inwardly projecting seal surface portions, usually outwardly convex seal surface portions, although other configurations are possible. Typically, the seal surface is oriented to overlap the media in the axial direction.

[0412] Typically, the seal surface portions face radially outwardly and are configured to define a first radially facing seal surface. An example is shown in which the first radially facing seal surface comprises six outwardly curved surface portions and six inwardly curved surface portions. In another example, ten outwardly curved surface portions and alternating inwardly curved portions are used.

[0413] Examples of housing seal arrangements are described that include a first radially oriented seal arrangement having a first seal surface and an optional second radially oriented seal arrangement having a second seal surface. Typically, when both seal arrangements are provided, the first seal surface is positioned radially at least 5 mm, often at least 10 mm, and typically at least 15 mm, away from the second seal surface, although other arrangements are possible.

[0414] When an optional second seal is provided, typically the first radially directed seal surface has a seal perimeter maximum cross-sectional dimension (when the cartridge is not installed) that is at least 5 mm smaller, usually at least 10 mm smaller, often at least 20 mm smaller, and sometimes at least 30 mm smaller than the maximum cross-sectional dimension of the second radially directed seal surface. When both seal surfaces define a circular pattern, the perimeter cross-sectional dimension is approximately the seal diameter (undistorted by installation) of the seal surface.

[0415] One example is provided in which the first end member comprises a molded-in-place part in which the first end (or portion) of the medium is embedded. The first sealing surface and the optional second sealing surface are typically each surfaces of the molded-in-place part.

[0416] In some example constructions shown, the first radially facing seal surface is a radially outward facing radial seal surface, although other constructions are possible. In some example constructions shown, the optional second radially facing seal surface is a radially outward facing radial seal surface, for example, about the outer periphery of the first end cap. Other constructions are possible.

[0417] In some example constructions shown, the first end member includes a receiving groove and the first sealing surface is a sidewall or face portion of the receiving groove. Typically, the receiving groove is at least 5 mm deep, usually at least 8 mm deep, from the nearest axial end face of the first end member, and typically within a range of 10-25 mm deep from the nearest outer axial end face of the first end member.

[0418] Typically, the receiving groove has opposing inner and outer sidewall portions spaced apart by at least 3 mm, usually at least 4 mm. In the embodiment of Figures 1-32, the sidewall portions are typically spaced apart by no more than 15 mm at 30% of the depth of the receiving groove, usually at 35% of the depth of the receiving groove. However, the deepest portion of the receiving groove may include a tapered portion where the sidewalls meet. In other applications, the seal groove may vary in width around a non-circular sealing face.

[0419] For the illustrated embodiments of Figures 1-32, the receiving groove typically has opposing inner and outer sidewall portions spaced apart by no more than 15 mm at any location within the deepest 30% of the groove, and typically spaced apart by no more than 15 mm at any location within the deepest 35% of the groove.

[0420] Typically, the receiving groove has a cross-section adjacent the outer end face of the first end member that includes an outwardly opening or outwardly opening outer end portion having a maximum opening width of at least 5 mm, typically at least 7 mm, and often substantially greater.

[0421] In the illustrated example structure, the first end member has embedded therein a first seal support that supports a first radial seal. Typically, the first seal support is a relatively rigid structure and is located at a position not more than 20 mm from the first seal surface when the cartridge is unstrained. Typically, the first seal support is not more than 15 mm from the first seal surface when the cartridge is unstrained due to installation. Also, typically, the material between the first seal surface and the first seal support distorts (compresses) toward the first seal support during installation by at least 10%, usually at least 15%, typically in the range of 15% to 35%, and most often in the range of 20% to 30%.

[0422] The first end cap member optionally includes a second seal support embedded no more than 10 mm, typically no more than 8 mm, from the optional second seal surface of the second seal structure. If a second seal structure is used, the second seal structure is typically configured to distort (compress) a face portion of the second seal structure by an amount up to at least 3%, typically at least 5%, and often in the range of 5% or more and 20% or less when compressed against the optional second seal support during installation.

[0423] In one example, the second sealing surface includes a surface portion that extends axially toward the second end of the media in use at least 2 mm further, typically at least 4 mm further, than the deepest portion of the receiving groove and / or any portion of the first sealing surface.

[0424] Thus, a structure has been described having two radial seals, an inner seal and a radially outer peripheral seal, one of which is in a portion of the end member having a greater maximum axial reach away from the second, or far, end of the media than the other seal, which can provide different advantages as previously described, depending on which is longer.

[0425] An exemplary structure is shown in which an optional resonator / sonic choke structure (or sonic choke / resonator) is provided. The resonator / sonic choke includes a first end embedded in a first end member, a central throat, an intermediate region, and a perforated end region adjacent the end of the resonator / sonic choke opposite the first end cap. The intermediate region preferably includes a sidewall portion extending between the central throat and the perforated end region and having an outwardly facing concave region and an outwardly facing convex region. The outwardly facing concave region or portion is typically adjacent the central throat, and the outwardly facing convex region or portion is typically adjacent the liner portion. The outwardly facing convex portion is typically at least 40% open, usually at least 50% open, and in some cases 60% open or more. In this case, openness refers to the open area of ​​the opening as a percentage of the surrounding area.

[0426] The outwardly facing concave region typically has a surface radius of at least 25 mm, and often in the range of 26 mm or more and 35 mm or less.

[0427] The central throat typically has an inside diameter of at least 25 mm, and usually has an inside diameter in the range of 27 mm or more and 35 mm or less.

[0428] The resonator / sonic choke (or sonic choke / resonator) includes a funnel section that expands in width while extending between the throat and the first end member. Typically, the funnel section has a funnel angle of at least 5°, typically in the range of 6° to 8°.

[0429] An exemplary filter cartridge is shown in which the seal support structure is a preform embedded in the first end member, the seal support structure including a central hub and struts fixed to the central hub and extending radially outward. To form an open lattice structure, the strut structure may extend to an optional outer ring. In the illustrated example, the struts extend at an axial angle of at least 0.5°, typically at least 1°, and often in an amount ranging from 1° or more to 3° or less, in a direction away from the hub, e.g., in a direction away from the media (or a plane perpendicular to the second end cap or cartridge central axis) while the struts extend toward the outer ring used. The hub may include a circular seal support or a non-circular seal support, and examples of each are shown.

[0430] When an outer support is used, it typically includes a seal support region extending over an axial length of at least 5 mm and not more than 15 mm, although alternative configurations are possible.

[0431] In one illustrated example, the central hub includes a base region adjacent the media and through which the resin flow opening structure extends. In one illustrated example, the support structure includes a central ring surrounded by and spaced apart from the central base region, the central region forming a trough with the central hub, and the opening structure in the base region of the central hub providing communication to the trough.

[0432] The principles of the present invention may be applied to a variety of filter cartridges using selected or alternative features of those characterized above. As an example of characterization, the present disclosure provides an air filter cartridge including a media, such as those characterized above, and a molded-in-place first end member, the first end member having an outer circumferential surface defining a housing seal feature. The first end member preferably includes a groove having a depth of at least 5 mm, and may include one or more features such as those described above with respect to the receiving groove. For example, a portion of a sidewall portion of the groove may be a housing seal surface.

[0433] Another aspect of an effective filter cartridge according to the present disclosure may be characterized as follows: The filter cartridge may include a media having, for example, a first end and a second end and surrounding and defining, for example, an open filter interior space. The first end member may be molded in place and the first end of the media may be secured, for example embedded, to the first end member. The first end cap may have a first radially facing sealing surface and a second radially facing sealing surface. The seal support structure is embedded in the first end member. The seal support structure includes a first seal support ring embedded in the first end cap at a location adjacent the first end cap and spaced from the first seal surface for operatively supporting material forming the first seal surface to adjust compression. An optional second seal support ring may be positioned to surround and spaced from the first seal support ring. A second seal support ring is embedded in the first end cap at a location adjacent the first end cap and spaced from the second seal surface by an amount sufficient to control compression of the seal material forming the second seal surface.

[0434] One example of such a configuration is shown in which the first seal surface is a radially outwardly facing seal surface, although other configurations are possible, and in the example shown, the second seal surface may be both a radially outwardly facing seal surface and a peripheral surface.

[0435] In one illustrated example, the first sealing surface is a sidewall surface of a groove disposed in the first end cap.

[0436] Various of the features characterized above may be used with this aspect of the disclosure.

[0437] In another aspect of the present disclosure, a filter cartridge is provided having an optional support surrounded by the media. The support includes an optional resonator and / or sonic choke arrangement as generally defined and described above. This aspect may be optionally used with various features of the first end cap and seal arrangement as described above or with various features of the first end cap and seal arrangement of other air filter arrangements.

[0438] Described herein are embodiments in which the principles of the present disclosure can be applied to cartridges having a straight-through configuration, i.e., cartridges in which the media is configured to filter air as it passes from an inlet end to an opposite outlet end of the media pack. An exemplary media pack is described in which the media comprises a number of channels extending between opposite ends of the media pack, with one set of inlet channels being open adjacent the inlet end but closed adjacent the outlet end, and one set of outlet channels being closed adjacent the inlet end and open adjacent the outlet end.

[0439] Also described in accordance with the present disclosure is a filter (e.g., (air or gas) cleaner assembly. The filter (e.g., air cleaner or gas) assembly generally comprises a housing having an (air or gas) flow inlet and an (air or gas) flow outlet. A filter cartridge having selected features as characterized above is operably and removably disposed within the housing.

[0440] In one example shown and described, the housing includes a body portion to which the flow tube is secured, with a connection between the housing body portion and the flow tube. A first end cap of a (air or gas) filter cartridge mounted in the housing includes an end groove into which a portion of the connection between the flow tube and the housing body portion (between the housing body portion and the flow tube) protrudes. In one example shown, the filter cartridge is removably sealed to the flow tube by a radial seal disposed along a sidewall of the groove. Particular examples are described in which the radial seal is an outwardly facing radial seal. In one example, the seal is circular. In other examples, the seal is not circular.

[0441] In one illustrated example, the air flow cartridge is not sealed to the body portion other than the flow tube by any portion of the first end cap that is disposed in the groove. The first end cap includes a peripheral radial seal removably secured to a portion surrounding the body portion.

[0442] Such a configuration can effectively isolate the housing connection between the cartridge seal against the flow tube and the cartridge seal against the housing sidewall.

[0443] The principles described herein are applicable to a variety of filter assemblies. The examples described are examples of the principles being applied to (air) gas filter assemblies. Examples include the air filters and crankcase ventilation filter assemblies described. The principles are also applicable to a variety of other gas filtration structures, and possibly even liquid filter assemblies.

[0444] The principles, techniques, and features described herein are applicable in a wide variety of systems, and it is not required that all of the advantageous features identified must be incorporated into an assembly, system, or component to obtain any benefit of the present disclosure.

Claims

1. 1. A filter cartridge comprising: (a) a filter media having a first end and a second end; (b) a housing seal arrangement disposed on the first end or the second end of the filter media, (i) a radially oriented housing seal surface defining a non-circular configuration having at least two radially outwardly projecting portions and at least one radially inwardly projecting portion between said at least two radially outwardly projecting portions, said radially oriented housing seal surface defining said at least two radially outwardly projecting portions and said at least one radially inwardly projecting portion in a circumferential direction of said filter cartridge and in a radial direction of said filter cartridge, said radially oriented housing seal surface being a surface that engages a housing to provide a seal during use; (ii) a housing seal structure, wherein the radially outwardly protruding portion has a curvature different from a curvature of the radially inwardly protruding portion, the curvature of the radially outwardly protruding portion being the curvature of a most protruding portion of the radially outwardly protruding portion, and the curvature of the radially inwardly protruding portion being the curvature of a least protruding portion of the radially inwardly protruding portion; A filter cartridge having

2. The filter cartridge of claim 1 , wherein: (a) said curvature of said radially outwardly projecting portion is greater than said curvature of said radially inwardly projecting portion.

3. 2. The filter cartridge of claim 1, wherein: (a) the filter media comprises pleated media surrounding an open filter interior.

4. The filter cartridge of claim 1 , wherein: (a) the filter media has a cylindrical or conical outer shape.

5. (a) a first end cap disposed over a first end of the filter media, the first end cap having an opening therethrough, and a second end cap disposed over a second end of the filter media; 2. The filter cartridge of claim 1, wherein: (b) said housing seal arrangement is disposed on said first end cap.

6. 10. The filter cartridge of claim 1, wherein: (a) the filter media comprises a coiled or stacked configuration of alternating fluted media and faced media.

7. 1. A filter cartridge comprising: (a) a filter media having a first end and a second end; (b) a housing seal arrangement disposed on the first end or the second end of the filter media, (i) a radially oriented housing seal surface defining a non-circular configuration having at least two radially outwardly projecting portions and at least one radially inwardly projecting portion between said at least two radially outwardly projecting portions, said radially oriented housing seal surface defining said at least two radially outwardly projecting portions and said at least one radially inwardly projecting portion in a circumferential direction of said filter cartridge and in a radial direction of said filter cartridge, said radially oriented housing seal surface being a surface that engages a housing to provide a seal during use; (ii) the radially outwardly projecting portions are not equally radially spaced on the radially facing housing seal surface; and A filter cartridge having

8. 8. The filter cartridge of claim 7, wherein: (a) the filter media includes pleated media surrounding an open filter interior, the filter media having a cylindrical or conical outer shape.

9. (a) a first end cap disposed over a first end of the filter media, the first end cap having an opening therethrough, and a second end cap disposed over a second end of the filter media; 8. The filter cartridge of claim 7, wherein: (b) said housing seal arrangement is disposed on said first end cap.

10. 8. The filter cartridge of claim 7, wherein: (a) the filter media comprises an alternating coiled or stacked configuration of fluted media and faced media.

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