Multi-functional inlet frame for air filter

Abstract

An air filter comprises a filter media pack having an outer periphery, a first flow face and a second flow face. A first seal assembly comprises a frame and a first annular seal, with the frame secured to the outer periphery, and with the first annular seal supported by the frame, which may be for example an axial seal. A handle portion integrally connected with this frame is provided in a permanent position over the first flow face. A second annular seal may be secured to the filter media pack and positioned proximate the second flow face, which may be for example a radial seal.

Description

MULTI-FUNCTIONAL INLET FRAME FOR AIR FILTERFIELD OF THE INVENTION

[0001] This invention generally relates to air filters, and more particularly to handle and / or sealing systems of such air filters.BACKGROUND OF THE INVENTION

[0002] Air filters with handles and sealing systems are shown for example in U.S. Patent No. 6,610.126 to Xu et al. and US Publication No. 2021 / 0308613 to Krull.

[0003] The '126 patent to Xu discloses a filter with two sealing systems and a handle in the form of a grip / knob that is mounted centrally into the inlet face. This grip / knob attaches to the center winding core of a wound fluted filter element. Because the element is for larger filtration capacity, it is relatively heavy and its sealing engagement with an air cleaner housing is also substantial. These factors can create substantial removal forces, for which this type of handle is inadequate structurally and may be prone to breakage or reliability.

[0004] The ‘613 publication to Krull is entitled “Air Filter With Improved Handle’" and provides a substantial improvement by placing the handle at the outer periphery in connection with an axial dust seal support frame assembly. This dust seal support frame assembly is adhesively attached around a large outer periphery of the filter media pack and thereby has substantial bonding force spread out amongst a larger surface area. This arrangement allows removal force to be applied to the radial seal at the outlet end.However, in doing so, some filtration capacity may be lost in that a smaller diameter filter media pack is necessitated to make room for the handles on the periphery.

[0005] Current products as may be demonstrated by patent publications in the background ty pically have integrated features to assist in installation and removal of an air filter. Current versions as demonstrated by Krull have incorporated handles on the side of the media pack. However, this can limit the media pack diameter that can be used, leading to a reduced media volume. Alternatively, other products provide a small plastic projection 154663241that has a snap-fit connection into the center winding core as in Xu. This connection between the projection and winding core can be broken and become unusable. The location and shape of the projection is also less than ideal resulting in less leverage and poor ergonomics.

[0006] Accordingly, further improvements that may resolve problems in the art discussed above and / or that realizes other advantages or features is provided herein.BRIEF SUMMARY OF THE INVENTION

[0007] At least one embodiment of the invention provides an air filter frame that incorporates a protrusion positioned above the inlet face which provides a handle or grasping structure for improved filter manipulability.

[0008] The air filter frame can also incorporate a dust seal support to retain a seal member, preferably an extruded rubber dust seal gasket and preferably incorporates alignment tabs to position the frame.

[0009] In accordance with an inventive aspect, an air filter, comprise: (a) a filter media pack having an outer periphery', a first flow face and a second flow face, with the outer periphery extending between the first flow face and the second flow face; (b) a first seal assembly comprising a frame and a first annular seal, with the frame secured to the outer periphery and with the first annular seal supported by the frame and having first external housing sealing surface; (c) a handle portion integrally connected the frame in a permanent position over the first flow face; and (c) a second annular seal secured to the filter media pack and positioned proximate the second flow face, with the second annular seal having a second external housing sealing surface.

[0010] In the above aspect, various features below may be employed either alone and / or various multiple features in combination with each other as in any of the below paragraphs.

[0011] It is a feature that the handle is unitarily formed with the frame as a single component part, preferably as an injection molded plastic part.254663241

[0012] It is a feature that the handle portion is rigid, preferably formed of glass filled nylon.

[0013] It is a feature that the handle portion comprises at least one handle strap or at least one handle ledge that is spaced from the first flow face by at least 1 centimeter from the first flow face and more preferably between 2 and 6 centimeters to provide a finger insertion gap therebetween so as to be configured to enable insertion of a finger of a service mechanic into the finger insertion gap.

[0014] It is a feature that the frame comprises an annular side wall merging into a comer portion extending over a comer of the first flow face and the outer periphery. The comer portion includes a locating abutment extending radially inward relative to the side wall that is adapted to abut the first flow face to position the first annular seal relative to the first flow face.

[0015] According to an embodiment, it is a feature that the handle portion comprises a ring overlap structure connected to an annular side wall of the frame and projecting radially inward therefrom over the first flow face. This may also leave an open center region over a central portion of the first flow face. The ring overlap structure has a radially inward handle ledge spaced from the first flow face.

[0016] In the above feature, the ring overlap structure may further define a plurality of apertures between the radially inward handle ledge and the annular side wall that are sized to receive one or more fingers of a service mechanic. For example, portions bridging over / extending above apertures can provide one or more handle straps.

[0017] According to another embodiment, it is a feature that the handle portion comprises a truss arrangement comprising at least two beam members and at least one handle strap. The at least two beam members span across the first flow face to connect different spaced apart locations of the frame. The at least one handle strap connects transversely between at a gap location between the at least two beam members and in spaced relation above the first flow face.354663241

[0018] In the above feature, the beam members are preferably elongated thin webs that are wider in an axial width direction as compared to a thickness perpendicular to the axial width direction.

[0019] In the above truss arrangement embodiment, it is a feature that at least two connection ledge plates are connected to an annular side wall of the frame in angularly spaced relation and overlapping the first flow face. The at least two connection ledge plates can support the at least two beam members, with the at least two beam members spanning between the at least two connection ledge plates. The connection ledge plates preferably include a flow aperture to avoid blinding / blockage of incoming flow. The at least two support beam members preferably pass through a central axis of the filter media pack.

[0020] It is a feature that the frame comprises an axially extending side wall around the outer periphery and a seal support flange extending radially outward from the side wall. The seal support flange supports the first annular seal to provide the first external housing sealing surface as an axial seal.

[0021] In the above feature, it may be a further feature that axially extending side wall comprises a band entirely circumscribing the outer periphery defining a cavity receiving and a first end portion of the filter media pack therein with a ring of adhesive therebetween securing and providing an internal seal between the frame and the filter media pack.

[0022] It is a feature that the filter media pack is a coiled fluted filter media pack comprising filter media provided by a fluted sheet and a facing sheet. The fluted sheet and the facing sheet are wound to define a plurality of flutes providing for airflow between the first flow face and the second flow face. Each flute includes a flute seal sealing between the fluted sheet and the facing sheet configured to cause air to pass through the filter media as air flows between the first and second flow faces when in use.

[0023] It is a feature that the second annular seal can be provided in a second seal assembly. The second seal assembly comprises a support member in combination the second annular seal, with the support member secured to the outer periphery' and supporting454663241the second annular seal over the second flow face to preferably provide the second external housing sealing surface as a radial seal.

[0024] In the above feature, it may be a further feature that filter media pack is a coiled filter media pack wound about a winding core and wherein each of the support member and the frame are in contact engagement with the winding core in a manner that coaxially aligns the first annular seal and the second annular seal.

[0025] In the either of the two above features, it may be a further feature that the support member comprising an outer band and a seal support connected thereto by a step, with the outer band extending over the outer periphery and adhesively connected thereto, and the seal support positioned radially inward of the band to a position radially inward of the outer periphery and over the second flow face.

[0026] It is another aspect according to a truss arrangement embodiment, that an air filter comprises: (a) a wound filter media having an outer periphery and inlet and outlet flow faces; (b) an annular frame fixed to the wound filter media and including i) a seal support portion surrounding the outer periphery of the wound filter media, and ii) a handle portion projecting over at least a portion of one of the inlet or outlet flow faces, in which the handle portion comprises a truss arrangement comprising at least two beam members and at least one handle strap, with the at least two beam members spanning across the first flow face to connect different spaced apart locations of the frame; and (c) an annular sealing member supported on the seal support portion and surrounding the wound filter media.

[0027] In the above aspect, various features below may be employed either alone and / or various multiple features in combination with each other as in any of the above or below paragraphs.

[0028] It is a feature that the at least one handle strap connects transversely between a gap location between the at least two beam members and in spaced relation spaced from the first flow face.554663241

[0029] It is a feature that the beam members are elongated thin webs that are wider in an axial width direction as compared to a thickness perpendicular to the axial width direction.

[0030] It is a feature that at least two connection ledge plates are connected to an annular side wall of the frame in angularly spaced relation and overlapping the first flow face. The at least two connection ledge plates can support the at least two beam members (e.g., by being integrally connected and preferably molded therewith).

[0031] It is a feature that the at least two beam members span between the at least two connection ledge plates.

[0032] In the above feature, the connection ledge plates preferably include a flow aperture and / or the at least two support beam members preferably pass through a central axis of the filter media pack.

[0033] It is a feature that the wound filter media is wound about a winding core.Further, at least one of the truss members can engage a first end of the winding core to coaxially align the seal support with the core.

[0034] While the above aspects / features may be employed in a filter with a single sealing system, it is particular advantageous in filters having multiple sealing systems.

[0035] As such, it is a feature that the air filter may further comprise a second annular seal member. For example, a further feature may be a seal assembly with such second annular sealing member. Preferably, the seal assembly engages a second end of the winding core to coaxially align the second annular sealing member with said annular seal member.

[0036] It is a feature that frame comprises an axially extending side wall around the outer periphery and a seal support flange extending radially outward from the side wall. The seal support flange supports the first annular seal to provide the first external housing sealing surface as an axial seal.

[0037] In the above feature, it may be a further feature that the axially extending side wall comprises a band entirely circumscribing the outer periphery defining a cavity654663241receiving and a first end portion of the filter media pack therein with a ring of adhesive therebetween securing and providing an internal seal between the frame and the filter media pack.

[0038] Another inventive aspect is directed toward an air filter comprising: (a) a wound media core having an outer pen phen- and inlet and outlet flow faces; (b) an annular frame fixed to the media core in which the annular frame includes i) a seal support portion surrounding the outer periphery of the media core, and ii) a handle portion projecting over at least a portion of one of the inlet or outlet flow faces, and with the handle portion including at least one of i) an annular lip and ii) at least one opening for enabling grasping by a user; and (c) an annular sealing member supported on the seal support portion and surrounding the media core.

[0039] In the above aspect, various features below may be employed either alone and / or various multiple features in combination with each other as in any of the above or below paragraphs.

[0040] It is a feature that the seal support portion of the annular frame includes a side wall in adjacent surface-to-surface relation with the outer periphery of the media core.

[0041] It is a feature that the handle portion of the annular frame includes a series of openings located in overlaying relation to the one of the inlet or outlet flow faces, spaced around the handle portion, radially inwardly of an inner diameter of the handle portion.

[0042] It is a feature that the handle portion further includes a series of projecting alignment tabs on an inside surface of the handle portion engaging the one of the inlet or outlet flow faces, for positionally locating the annular frame during assembly with the media core.

[0043] It is a feature that the seal support portion is unitary with the handle portion.

[0044] Another inventive aspect is directed toward an air filter, comprising: (a) a wound media core having an outer periphery and inlet and outlet flow faces; (b) an annular frame754663241fixed to the media core in which the annular frame includes i) a seal support portion surrounding the outer periphery of the media core, and ii) a handle portion projecting over at least a portion of one of the inlet or outlet flow faces; with the handle portion further including at least one projecting alignment tab on an inside surface of the handle portion engaging the one of the inlet or outlet flow faces, for positionally locating the annular frame during assembly with the media core; and (c) an annular sealing member supported on the seal support portion and surrounding the media core.

[0045] In the above aspect, various features below may be employed either alone and / or various multiple features in combination with each other as in any of the above or below paragraphs.

[0046] Although the principles, embodiments and operation of the present invention have been described in detail herein, this is not to be construed as being limited to the particular illustrative forms disclosed. They will thus become apparent to those skilled in the art that various modifications of the embodiments herein can be made without departing from the spirit or scope of the invention.

[0047] Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

[0049] FIG. 1 is an isometric view of an air filter in accordance with a first embodiment of the present invention;

[0050] FIG. 2 is a cross section through the air filter of FIG. 1, coincident and parallel to the central axis of the air filter;854663241

[0051] FIG. 3 is an isometric view of the inlet frame used in FIGS. 1-2. which frame provides a handle and seal support frame,

[0052] FIG. 4 is an isometric view of an air fdter in accordance with a second embodiment of the present invention;

[0053] FIG. 5 is a cross section through the air fdter of FIG. 4, coincident and parallel to the central axis of the air fdter; and

[0054] FIG. 6 is an isometric view of the inlet frame used in FIGS. 4-5, which frame provides a handle and seal support frame.

[0055] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.DETAILED DESCRIPTION OF THE INVENTION

[0056] Referring to FIGS. 1-3, a first embodiment has been illustrated as an air fdter 10 comprising a fdter media pack 12, a seal assembly 14 comprising a frame 16 and an annular seal 18, and a handle portion 20.

[0057] The fdter media pack 12 has an outer periphery 22, a first flow face 24 which may be an inlet flow face and a second flow face 26 which may be an outlet flow face. The outer periphery 22 extends between the first flow face 24 and the second flow face 26. The frame 16 is secured to the outer periphery 22 of the fdter media pack 12. The annular seal 18 is supported by the frame 16 to provide a first external housing sealing surface 28.

[0058] This housing sealing surface 28 may an axial seal and for example this axial seal may be an axial pinch seal surface as shown. The annular seal 18 thereby is provided for axially sealing between two housing portions such as the housing shown in Xu, U.S. Patent No. 6,610,126, which is incorporated by reference to show' the housing and housing sealing954663241for which the air filter 10 can be employed. Alternatively, the annular seal 18 could be a radial seal, or other form of axial seal.

[0059] In accordance with such design, another second annular seal 30 may be secured to the filter media pack 12 (optionally by another seal support frame as later discussed). The second annular seal 30 for example is positioned proximate the second flow face 26. The second annular seal 30 has a second external housing sealing surface 32. This housing seal surface 32 for example may be a radial seal with a radially outward face surface but could also be an axial seal. In the case of a radial seal, the second annular seal 30 may be provided by a soft compressible material that can compress radially such as polyurethane or other similar foam material, for example.

[0060] The handle portion 20 is integrally connected to the frame 16 of the seal assembly 14 in a permanent position over the first flow face 24, and for example the inlet flow face as shown. Preferably, this is accomplished as shown by the handle portion being an integral part of the frame 16.

[0061] Various advantages can be realized with this handle portion 20 arrangement and connection with the frame 1 . This can allow for one single filter frame component to be used at the inlet face end as shown, which may be a single unitarily molded component. For example, the frame 16 and / or handle portion 20 are preferably molded of rigid material such as nylon and more preferably glass reinforced nylon and / or other similar polymer material. Preferably, the handle portion 20 is rigid and not movable but retains a fixed position over the inlet How face and may always be deployed in a readily graspable position without the need to move into a graspable position. This single component in the illustrated frame 16 embodiment can perform multiple functions and reduce the number of components required, and also may provide a thinner profile at the outer periphery allowing for more wrapping of filter media and thereby potentially more filtration capacity.

[0062] Further, the handle portion 20 can transmit force to a large connection area of the filter media pack 12 by being connected to the frame 16, as the frame 16 can in turn be adhesively attached by an annular band of adhesive 34 to the outer periphery 22 along a large force transfer area. This is advantageous in that compression forces for the radial seal 1054663241provided by the second annular seal 30 can provide substantial resistance to removal of the air filter once installed in a housing. By having a large force transmission area for the handle portion 20 via the large adhesive connection area of the frame 16 (e.g., as a unitary part of the frame 16), the design is robust and substantial removal force transmission can be realized without compromise of part and handle connection integrity.

[0063] In the different illustrated embodiments, and as exemplified in FIGS. 1-3 (and also FIGS. 4-6 discussed later below), the handle portion 20 can comprise at least one handle strap and preferably multiple handle straps 36; or if apertures are not formed in the frame 16 of FIGS. 1-3, then at least one handle ledge 38 that provides a graspable handle lip. The strap(s) 36 and / or ledge 38 are elevated above the first flow face 24 in an immediate position to readily be grasped. For example, the handle straps 36 and / or ledge 38 can be elevated from the first flow face 24 (e.g., in a fixed position) by at least 1 centimeter and more preferably between 2 and 6 centimeters so as to provide a finger insertion gap therebetween. In this matter, the handle portion 20 is configured to enable insertion of at least one finger and preferably multiple fingers of a service mechanic into the finger insertion gap.

[0064] This arrangement can allow service mechanic to more easily handle and provide removal force to pull the air filter 10 from the air cleaner housing (the air cleaner housing not illustrated in the figures here, but can be according to the two part air cleaner housing in Xu, US Patent No. 6,610,126). By pulling the air filter 10, the service mechanic can release the radial seal and compression forces of the second annular seal 30 to facilitate removal of a spent air filter for replacement.

[0065] As shown, the frame 16 can comprise an annular side wall 40 merging into a comer portion 42 over at filter media pack comer 44 (of the first flow face 24 and the outer periphery 22). The comer portion 42 includes a locating abutment 46 (e.g., axial ring stop surface and / or one or more alignment stop tabs 47 as shown). This alignment / locating abutment 46 extends radially inw ard relative to the side wall 40 and is adapted to abut the first flow face 24 to position the first annular seal 18 relative to the first flow face 24.1154663241

[0066] The frame 16 may also comprise a seal support portion such as may be provided by a solid or perforated seal support flange 48. The axial, annular seal 18 can be attached and supported by the seal support flange 48, such as via mechanical attachment (e.g, snap fit), glue and / or directly via mold-in-place integrally upon the flange 48.

[0067] In this manner, the frame 16 can comprise the axially extending side wall 40 around and preferably completely surrounding the outer periphery 22 of the filter media pack 12 with the seal support flange 48 extending radially outward from the side wall 40. The seal support flange 48 supports the first annular seal 18 to provide the first external housing sealing surface 28 as an axial seal preferably as shown (or in an alternative embodiment as a radial seal).

[0068] More specifically, the axially extending side wall 40 comprises an annular band entirely circumscribing the outer periphery 22 of the filter media pack 12 as shown and defines a cavity receiving a first end portion (e.g., inlet end portion) of the filter media pack 12 therein. The ring of adhesive 34 is between the side wall 40 and the media pack 12 thereby securing these components together. The ring of adhesive 34 also extends entirely around the filter media pack 12 thereby providing an internal seal between the frame 16 and the filter media pack 12 preventing bypass of unfiltered air between the frame 16 and the filter media pack 12.

[0069] In FIGS. 1-3, the handle portion 20 is preferably an integral portion of the frame 16 and comprises a ring overlap structure 50 connected to an annular side wall 40 of the frame 16. The ring overlap structure 50 projects radially inward from the annular side w all 40 and over the first flow face 24, leaving an open center region 52 over a central portion of the first flow face 24 as shown. The ring overlap structure 50 has the radially inward handle ledge 38 spaced from the first flow face.

[0070] Optionally and as shown, the ring overlap structure 50 defines a plurality of apertures 54 (may also referred to as openings) betw een the radially inward handle ledge 38 providing a graspable handle lip. The apertures 54 are sized to receive one or more fingers of a service mechanic This can advantageously create the one or more handled straps 361254663241that are even more easily grasped and manipulated by a serve mechanic to pull an air filter from the air cleaner housing and overcome frictional / sealing forces.

[0071] To provide for high filtration capacity a substantial amount of filter media is utilized which can provide a significant amount of weight as far an engine air filters are concerned, especially for larger commercial vehicles and generator sets that require larger air intake requirements. To provide such large filtration capacity, the filter media pack 12 preferably is a wound filter media (also may be referred to as wound media core). Also preferably, the filter media pack 12 is a fluted filter media pack comprising separate fluted and facing sheets 56, 58, and preferably such sheets are wound into a coiled fluted filter media pack. Such a coiled fluted filter media pack can contain tightly packed filter media arranged in a manner with organized flow passages to provide low pressure drop.

[0072] For example, here, the filter media pack 12 comprises filter media provided by a fluted sheet 56 and a facing sheet 58, which leading end may be wound about a winding core 59 thereby provide a wound filter media. The trailing end of such wound filter media may be secured and sealed such as via a hot melt flap 61 or such similar trailing end seal member.

[0073] Suitable wound fluted filter media packs and methods of manufacture useable for the media pack 12 herein are shown / discussed in the aforementioned Xu and Krull patent publications, and / or in U.S. Pat. No. 8,083,825 to Mosset et al, and / or U.S. Pat. No.7,255,300 to Johnston et al. entitled "Method and apparatus for winding a filter media pack,"; and / or US Patent No. 8,551,375 to Brown et al. entitled '‘Filter Element”, which are all also incorporated by reference in their entirety to show exemplary wound filter media packs and winding methods. The fluted sheet 56 and the facing sheet 58 can be wound such as shown better in the referenced patents and may be seen with reference to FIG. 2 herein to define a plurality of flutes 60 providing for airflow betw een the first flow face 24 and the second flow' face 26. Each flute 60 (e.g., either at inlet or outlet flow face) is provided with a flute seal 62 (e.g., a bead of sealant) sealing betw een the fluted sheet 56 and the facing sheet 58 and configured to cause air to pass through the filter media as air flows between the first and second flow faces 24, 26 when in use.1354663241

[0074] The second annular seal 30 that provides the radial seal and the external housing sealing surface 32 may be configured as in US Publication No. 2021 / 0308613 to Krull. However, more advantageously, it is realized by the present inventors that substantial radial space for such radial seal is needed to facilitate sufficient material for radial compression. As such, more preferably, the second annular seal 32 is over the second flow face 26. which may be provided by a second seal assembly 64.

[0075] The second seal assembly 64 may be the same or similar to that of the aforementioned ‘375 patent to Brown et al and / or that of the ‘126 patent to Xu, or other device comprising a support and a seal.

[0076] For example, as shown herein, the second seal assembly 64 comprises support member 66 in combination the second annular seal 30. The support member 66 is secured to the outer periphery 22 (e.g., via an annular bead of adhesive 68 similar to that of adhesive 34). The support member 66 supports the second annular seal 30 over the second flow face 26 to provide the second external housing sealing surface 32 as a radial seal.

[0077] More specifically, the support member 66 preferably can comprise an outer band 70 and a seal support projection 72 connected thereto by a step 74 that reduces circumference. The outer band 70 extends over the outer periphery 22 is and adhesively connected thereto by the annular bead of adhesive 68. The seal support member 66 is positioned radially inward of the band to a position radially inward of the outer periphery and over the second flow face 26.

[0078] From the foregoing, it is seen in FIGS. 1-3 that the frame 16 incorporates a protrusion positioned above the inlet face which functions as a handle to aid in installation and removal, primarily when pulling the filter out of sealing engagement with an air cleaner housing. This handle protrusion can be revolved around the entire perimeter of the frame as shown. This helps to limit the warpage of the part when manufactured with standard injection molding. The handle symmetry’ is also beneficial when handling as it doesn’t need to be oriented relative to the housing. Disadvantages of background designs can be addressed in this embodiment by providing more leverage with positioning the handle1454663241farther from the center, better ergonomics with a larger handle that fits an entire hand, and more strength with being formed from a singular injection molded component.

[0079] In an embodiment, the filter frame 16 also incorporates the seal support flange 48 for an extruded rubber dust seal gasket that provides the annular seal 18. This flange protrudes out from the side of the frame. The dust seal is stretched over and nests to the flange. The dust seal is held in tension both axially and radially keeping it from moving in any direction without the use of any adhesives. This has advantages over current designs as there is no processing step required for gluing the dust seal. The rubber dust seal's position is set by the dust seal flange which prevents the dust seal from being installed incorrectly and eliminates the need for fixturing to locate the seal's position. Additionally, the introduction of the dust seal flange allows for the more expensive rubber gasket to be smaller leading to material cost savings.

[0080] In an embodiment, alignment tabs providing abutments 46 are added to the top of the filter frame just under the handle protrusion. These alignment tabs provide a stop for the frame 16 ensuring that the dust seal is at the desired height relative to the media. The alignment tabs are positioned evenly across the perimeter of the frame and touch off on the inlet face of the media pack. The tabs are made small and thin enough to support the frame while covering up the smallest media surface area having minimal effect on the dirt holding capacity. This avoids having to rely upon fixturing to set the height of the frame and / or seal location leading to increased manufacturing costs compared to embodiments with the alignment tabs.

[0081] Turning to FIGS. 4-6, a second illustrated embodiment provides for an air filter 110, that is the same as the first embodiment, other than the difference of a different frame 116 and different handle portion 120 as compared to frame 16 and handle portion 20 of FIGS. 1-3. As such, other than as indicated, the disclosure and discussion above as applied to FIGS. 1-3 is applicable to the embodiment of FIGS. 4-6 and vice versa. As frame 116 and handle portion 120 provide additional / altemative features, discussion will be focused thereon, but like reference numbers for common components used in the earlier FIG. 1 -3 will be carried over for the discussion of FIGS. 4-6.1554663241

[0082] Referring to FIGS. 4-6. the air filter 110 can comprise the filter media pack 12 as the earlier embodiment, with a seal assembly comprising the differently configured frame 116 that can use the same annular seal 18 as in the first illustrated embodiment (and the various different options / embodiments for such annular seal 18 as previously described).

[0083] Also, here the same second annular seal 30 is secured to the filter media pack 12 which can use the same second seal assembly 64 as discussed above for the first embodiment.

[0084] In this embodiment, the handle portion 120 is also integrally connected to the frame 116 of the seal assembly 114 in a permanent position over the first flow face 24, and for example the inlet flow face as shown. Preferably, this is also accomplished as shown by the handle portion 120 being an integral part of the frame 116.

[0085] Various advantages can be realized with this handle portion 120 arrangement and connection with the frame 116. This can allow for one single filter frame component to be used at the inlet face end as shown, which may be a single unitarily molded component. For example, like the earlier embodiment, the frame 116 and / or handle portion 120 are preferably molded of rigid material such as nylon and more preferably glass reinforced nylon and / or other similar polymer material. Preferably, the handle portion 120 is rigid and not movable but retains a fixed position over the inlet flow face and thereby always deployed in a readily graspable position without the need to move into a graspable position. This single component in the illustrated frame 116 embodiment can perform multiple functions and reduce the number of components required, and also may provide a thinner profile at the outer periphery allowing for more wrapping of filter media and thereby more filtration capacity with addition media at the outer periphery .

[0086] The handle portion 120 can transmit force to a large connection area of the filter media pack 12 by being connected to the frame 116, in that the frame 116 can in turn be adhesively attached by an annular band of adhesive 34 to the outer periphery 22 along a large force transfer area. This is advantageous in that compression forces for the radial seal provided by the second annular seal 30 can provide substantial resistance to removal of the air filter once installed in a housing. By having a large force transmission area for the 1654663241handle portion 120 via the large adhesive connection area of the frame 116 (e.g., as a unitary part of the frame 11 ), the design is robust and substantial removal force transmission can be realized without compromise of part integrity.

[0087] In this embodiment of FIGS. 4-6, the handle portion 120 can comprise at least one handle strap and preferably multiple handle straps 136 with at least one handle ledge 138, but as apparent from the illustrations these are differently oriented than that of FIGS. 1-3. The strap(s) 136 and ledge 138 are elevated above the first flow face 24 in an immediate position to readily be grasped.

[0088] For example, the handle straps 136 and ledge 138 can be elevated from the first flow face 24 (e.g., in a fixed position) by at least 1 centimeter and more preferably between 2 and 6 centimeters so as to provide a finger insertion gap therebetween. In this matter, the handle portion 120 is configured to enable insertion of at least one finger and preferably multiple fingers of a service mechanic into the finger insertion gap.

[0089] In this embodiment, the handle portion comprises a truss arrangement 180 comprising at least two beam members 182 and the at least one handle strap 136. The beam members 1 2 span across the first flow face 24 to connect different spaced apart locations of the frame 116, which may provide a robust structure by interconnecting portions thereby limiting flexure. The at least one handle strap 136 connects transversely between a gap location 184 bridging between the beam members 182 and in spaced relation above the first flow face 24. This interconnection of beam members also increases rigidity’ and support.

[0090] As shown, the beam members 182 are elongated thin webs that are wider in an axial w idth direction 186 as compared to a thickness that spans perpendicular to the axial width direction and perpendicular to the extending length of the beam members 182 (e.g., the circumferential direction). Stated another way, the beam members 182 are wider axially as compared to a thickness 188 that extends perpendicular thereto.

[0091] To provide for abutment stops 146 and alignment tabs, at least two connection ledge plates 190 are connected to an annular side wall 140 of the frame 116 in angularly spaced relation and overlapping the first flow face 24. The connection ledge plates 190 may 1754663241also support and be connected directly with the beam members 182. The beam members 182 span between the at least two connection ledge plates 190.

[0092] The connection ledge plates 190 can perform the same alignment functions and benefits as described above with respect to locating the frame 116 and the annular seal 18 without fixturing.

[0093] The connection ledge plates 190 preferably include a flow aperture 192 to allow flow therethrough and to minimize blinding / blocking of filter media.

[0094] Also preferably, the support beam members 182 preferably intersect and intersection connection 194 and pass through a central axis 76 of the filter media pack 12.

[0095] A further benefit can be realized with attachment to the winding core 59 to the frame 116, and also to the second seal assembly 64, in that this aligns the space apart different seals 18, 30 coaxial, so that the sealing seating location match those of the filter housing in use and one is not offset or prone to have a gap due to some misalignment. As such, as shown, each of the support member 66 and the frame 116 are in contact engagement with the winding core 59 in a manner that coaxially aligns the first annular seal 18 and the second annular seal 30.

[0096] For example, a projection / receiver arrangement may be used between the winding core 59 and the support member 66 and the frame 116, for example with open receivers 195, 196 defined at opposite ends of the core 59 that receive projection stubs 197, 198 of the respective support member 66 and frame 116, thereby to accomplish coaxial alignment components. Stub 197 of the support member 66 can be connected to the outer band 70 via spokes 71 so that openings at the outlet second flow face 22 are provided between spokes to allow air to pass centrally through the support member 66 at the outlet face.

[0097] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were1854663241individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0098] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including.” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary' language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any nonclaimed element as essential to the practice of the invention.

[0099] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.1954663241

Claims

WHAT IS CLAIMED IS:

1. An air filter, comprising:a filter media pack having an outer periphery, a first flow face and a second flow face, the outer periphery extending between the first flow face and the second flow face; a first seal assembly comprising a frame and a first annular seal, the frame secured to the outer periphery, the first annular seal supported by the frame and having first external housing sealing surface;a handle portion integrally connected the frame in a permanent position over the first flow face;a second annular seal secured to the filter media pack and positioned proximate the second flow face, the second annular seal having a second external housing sealing surface.

2. The air filter of claim 1, wherein the handle is unitarily formed with the frame as a single component part, preferably as an injection molded plastic part.

3. The air filter of any of claims 1 or 2, wherein the handle portion is rigid, preferably formed of glass filled nylon.

4. The air filter of any of claims 1-3, wherein the handle portion comprises at least one handle strap and / or at least one handle ledge that is spaced from the first flow face by at least 1 centimeter from the first flow face and more preferably between 2 and 6 centimeters to provide a finger insertion gap therebetween so as to be configured to enable insertion of a finger of a service mechanic into the finger insertion gap.

5. The air filter of any of claims 1-4, wherein the frame comprises an annular side wall merging into a comer portion extending over a comer of the first flow face and the outer peri phery, the comer portion including a locating abutment extending radially inward2054663241relative to the side wall and adapted to abut the first flow face to position the first annular seal relative to the first flow face.

6. The air filter of any of claim 1-5, wherein the handle portion comprises a ring overlap structure connected to an annular side wall of the frame and projecting radially inward therefrom over the first flow face leaving an open center region over a central portion of the first flow face, the ring overlap structure having a radially inward handle ledge spaced from the first flow face.

7. The air filter of claim 6, wherein the ring overlap structure defines a plurality of apertures between the radially inward handle ledge and the annular side wall that are sized to receive one or more fingers of a service mechanic.

8. The air filter of any of claims 1-5, wherein the handle portion comprises a truss arrangement comprising at least two beam members and at least one handle strap, the at least two beam members spanning across the first flow face to connect different spaced apart locations of the frame, the at least one handle strap connecting transversely between at a gap location between the at least two beam members and in spaced relation above the first flow face.

9. The air filter of claim 8, wherein the beam members are elongated thin webs that are wider in an axial width direction as compared to a thickness perpendicular to the axial width direction.

10. The air filter of any of claims 8-9. wherein at least two connection ledge plates are connected to an annular side wall of the frame in angularly spaced relation and overlapping the first flow face, the at least two connection ledge plates supporting the at least two beam members, the at least two beam members spanning between the at least two connection ledge plates, wherein the connection ledge plates preferably include a flow aperture, and2154663241wherein the at least two support beam members preferably pass through a central axis of the filter media pack.

11. The air filter of any of claims 1-10. wherein the frame comprises an axially extending side wall around the outer periphery and a seal support flange extending radially outward from the side wall, the seal support flange supporting the first annular seal to provide the first external housing sealing surface as an axial seal.

12. The air filter of claim 11, wherein the axially extending side wall comprises a band entirely circumscribing the outer periphery defining a cavity receiving and a first end portion of the filter media pack therein with a ring of adhesive therebetween securing and providing an internal seal between the frame and the filter media pack.

13. The air filter of any of claims 1-12. wherein the filter media pack is a coiled fluted filter media pack comprising filter media provided by a fluted sheet and a facing sheet, the fluted sheet and the facing sheet wound to define a plurality of flutes providing for airflow between the first flow face and the second flow face, each flute including a flute seal sealing between the fluted sheet and the facing sheet configured to cause air to pass through the filter media as air flows between the first and second flow faces when in use.

14. The air filter of any of claims 1-13, further comprising a second seal assembly, the second seal assembly comprising a support member in combination the second annular seal, the support member secured to the outer periphery and supporting the second annular seal over the second flow face to provide the second external housing sealing surface as a radial seal.

15. The air filter of claim 14, wherein the filter media pack is a coiled filter media pack wound about a winding core, wherein each of the support member and the frame are in contact engagement with the winding core in a manner that coaxially aligns the first annular seal and the second annular seal.225466324116. The air filter of claim 15. wherein the support member comprising an outer band and a seal support connected thereto by a step, the outer band extending over the outer periphery and adhesively connected thereto, and the seal support positioned radially inward of the band to a position radially inward of the outer periphery' and over the second flow face.

17. An air filter, comprising:(a) a wound filter media having an outer periphery' and inlet and outlet flow faces; (b) an annular frame fixed to the wound filter media and including i) a seal support portion surrounding the outer periphery' of the wound filter media, and ii) a handle portion projecting over at least a portion of one of the inlet or outlet flow faces, the handle portion comprises a truss arrangement comprising at least two beam members and at least one handle strap, the at least two beam members spanning across the first flow face to connect different spaced apart locations of the frame; and(c) an annular sealing member supported on the seal support portion and surrounding the wound filter media.

18. The air filter of claim 17, the at least one handle strap connects transversely between a gap location between the at least two beam members and in spaced relation spaced from the first flow face.

19. The air filter of any of claims 17-18, wherein the beam members are elongated thin webs that are wider in an axial width direction as compared to a thickness perpendicular to the axial width direction.

20. The air filter of any of claim 17-19,. wherein at least two connection ledge plates are connected to an annular side wall of the frame in angularly spaced relation and overlapping the first flow face, the at least two connection ledge plates supporting the at least two beam members.235466324121. The air filter of claim 20, wherein the at least two beam members span between the at least two connection ledge plates, wherein the connection ledge plates preferably include a flow aperture, and wherein the at least two support beam members preferably pass through a central axis of the filter media pack.

22. The air filter of any of claims 18-21, wherein the wound filter media is wound about a winding core, and wherein at least one of the truss members is engaging a first end of the winding core to coaxially align the seal support with the core.

23. The air filter of claim 22, further comprising a seal assembly with a second annular sealing member, the seal assembly engaging a second end of the winding core to coaxially align the second annular sealing member with said annular seal member.

24. The air filter of any of claims 17-23, wherein the frame comprises an axially extending side wall around the outer periphery and a seal support flange extending radially outward from the side wall, the seal support flange supporting the first annular seal to provide the first external housing sealing surface as an axial seal.

25. The air filter of claim 25, wherein the axially extending side wall comprises a band entirely circumscribing the outer periphery defining a cavity receiving and a first end portion of the filter media pack therein with a ring of adhesive therebetween securing and providing an internal seal between the frame and the filter media pack.

26. An air filter, comprising:(a) a wound media core having an outer periphery and inlet and outlet flow faces; (b) an annular frame fixed to the media core and including i) a seal support portion surrounding the outer periphery of the media core, and ii) a handle portion proj ecting over2454663241at least a portion of one of the inlet or outlet flow faces, the handle portion including at least one of i) an annular lip and ii) at least one opening for enabling grasping by a user; and (c) an annular sealing member supported on the seal support portion and surrounding the media core.

27. The air filter as in claim 26, wherein the seal support portion of the annular frame includes a side wall in adjacent surface-to-surface relation with the outer periphery of the media core.

28. The air filter as in claim 26, wherein the handle portion of the annular frame includes a series of openings located in overlaying relation to the one of the inlet or outlet flow faces, spaced around the handle portion, radially inwardly of an inner diameter of the handle portion.

29. The air filter as in claim 26, wherein the handle portion further includes a series of projecting alignment tabs on an inside surface of the handle portion engaging the one of the inlet or outlet flow faces, for positionally locating the annular frame during assembly with the media core.

30. The air filter as in claim 26, wherein the seal support portion is unitary with the handle portion.

31. An air filter, comprising:(a) a wound media core having an outer periphery and inlet and outlet flow faces; (b) an annular frame fixed to the media core and including i) a seal support portion surrounding the outer periphery of the media core, and ii) a handle portion projecting over at least a portion of one of the inlet or outlet flow faces; the handle portion further including at least one projecting alignment tab on an inside surface of the handle portion engaging the2554663241one of the inlet or outlet flow faces, for positionally locating the annular frame during assembly with the media core; and(c) an annular sealing member supported on the seal support portion and surrounding the media core.54663241

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