U.S. patent application number 09/771779 was filed with the patent office on 2001-06-21 for air cleaner, filter element, and methods.
This patent application is currently assigned to Donaldson Company, Inc.. Invention is credited to Bishop, Wayne R.W., Finnerty, Carolyn J., Gieseke, Steven Scott, Ramos, Timothy M., Steinbrueck, Edward A..
Application Number | 20010003893 09/771779 |
Document ID | / |
Family ID | 22980440 |
Filed Date | 2001-06-21 |
United States Patent
Application |
20010003893 |
Kind Code |
A1 |
Ramos, Timothy M. ; et
al. |
June 21, 2001 |
Air cleaner, filter element, and methods
Abstract
An air cleaner includes a housing having first and second
opposite ends. A media pack is preferably oriented within the
interior volume of the housing. In preferred embodiments, the media
pack will have a first and second opposite flow face and be
constructed and arranged for air to flow into the media pack
through the first flow face, and for air to exit the media pack
through the second flow face. The air cleaner will include a seal
member forming a seal between the media pack and the housing. In
preferred constructions, a secondary filter element is oriented
within the interior volume of the housing. In some preferred
embodiments, the housing is constructed and arranged as a
resonator. Certain embodiments include a seal construction that
engages the secondary filter element. Methods of filtering systems,
servicing filtration systems, and constructing filter arrangements
and housings will use filter elements and constructions as
characterized above.
Inventors: |
Ramos, Timothy M.;
(Burnsville, MN) ; Steinbrueck, Edward A.; (Eden
Prairie, MN) ; Gieseke, Steven Scott; (Richfield,
MN) ; Finnerty, Carolyn J.; (Bloomington, MN)
; Bishop, Wayne R.W.; (St. Louis Park, MN) |
Correspondence
Address: |
MERCHANT & GOULD
P O BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Donaldson Company, Inc.
Minneapolis
MN
|
Family ID: |
22980440 |
Appl. No.: |
09/771779 |
Filed: |
January 29, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09771779 |
Jan 29, 2001 |
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09258412 |
Feb 26, 1999 |
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6179890 |
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Current U.S.
Class: |
55/482 ; 55/486;
55/502; 55/503; 55/521 |
Current CPC
Class: |
B01D 46/527 20130101;
B01D 2267/40 20130101; F02M 35/024 20130101; B01D 46/62 20220101;
B01D 46/0086 20130101; B01D 46/88 20220101; B01D 46/0004 20130101;
B01D 46/446 20130101; F02M 35/0203 20130101 |
Class at
Publication: |
55/482 ; 55/486;
55/502; 55/503; 55/521 |
International
Class: |
B01D 035/30; B01D
029/56 |
Claims
We claim:
1. An air cleaner arrangement comprising: (a) a housing having
first and second opposite ends and defining an interior volume;
said housing defining an inlet adjacent to said first end and an
outlet adjacent to said second end; (b) a media pack oriented
within said interior volume of said housing; (i) said media pack
having a first flow face and an opposite second flow face; said
first flow face being adjacent to said first end, and said second
flow face being adjacent to said second end; (A) said media pack
being constructed and arranged for air to flow into said media pack
through said first flow face, and for air to exit said media pack
through said second flow face; (c) a seal member forming a seal
between said media pack and said housing; and (d) a secondary
filter element oriented within said interior volume of said
housing.
2. An air cleaner arrangement according to claim 1 wherein: (a)
said secondary filter element is oriented between said seal member
and said outlet.
3. An air cleaner according to claim 1 wherein: (a) said housing
includes a cup and a body member; one of said cup and said body
member having an alignment protrusion, and one of said cup and said
body member having a channel in receipt of said protrusion.
4. An air cleaner according to claim 3 further including: (a) at
least one latch member for selectively securing together said cup
and said body member.
5. An air cleaner according to claim 1 wherein: (a) said media pack
comprises a plurality of flutes; each of said flutes having an
upstream portion adjacent to said first flow face and a downstream
portion adjacent to said second flow face; (i) selected ones of
said flutes being open at said upstream portion and closed at said
downstream portion; and selected ones of said flutes being closed
at said upstream portion and open at said downstream portion.
6. An air cleaner according to claim 1 wherein: (a) said seal
member is supported by an extension of a frame arrangement; (i)
said extension projecting axially from one of said first and second
flow faces; (ii) said seal member forming a radial seal between and
against said extension and said housing.
7. An air cleaner according to claim 6 wherein: (a) said housing
includes an internal annular sealing surface; (b) said seal member
is circumscribed by said sealing surface; said radial seal being
formed by compression of said seal member between and against said
sealing surface and said extension of said frame arrangement.
8. An air cleaner according to claim 7 wherein: (a) said housing
includes a first seat for engaging said seal member; (i) said first
seat being angled relative to said annular sealing surface.
9. An air cleaner according to claim 8 wherein: (a) said extension
includes an end tip; an outer radial surface, and an opposite inner
radial surface; and (b) said seal member includes a first portion
being oriented against at least said outer radial surface of said
extension.
10. An air cleaner according to claim 9 wherein: (a) said seal
member includes a second portion oriented against said end tip; and
a third portion oriented against said inner radial surface.
11. An air cleaner according to claim 10 wherein: (a) said second
portion of said seal member is oriented between said end tip and
said first seat.
12. An air cleaner according to claim 11 wherein: (a) said third
portion of said seal member includes a plurality of projections
extending therefrom; (i) said projections engaging said secondary
filter element.
13. An air cleaner according to claim 12 wherein: (a) said housing
includes a second seat for engaging said secondary filter element;
(i) said secondary filter element being between and against said
second seat and said projections.
14. An air cleaner comprising: (a) a housing having an inlet, an
outlet, and a wall extending between said inlet and said outlet;
said inlet and outlet being at opposite ends of said housing; said
wall defining a housing interior portion; (i) said housing having
an annular seat constructed and arranged to support a filter
element; (ii) said inlet comprising a first open area defined by
said housing; (iii) said outlet comprising a second open area
defined by said housing; (A) said first open area being about 5-10
percent smaller than said second open area; (iv) said wall being
cylindrical and having a diameter about 100-250 percent larger than
a largest cross-sectional dimension of said outlet; (v) said wall
having a length extending between said inlet and said annular seat;
a ratio of said wall length to said diameter of said wall being at
least about 1.5; (b) a filter element oriented within said housing
interior portion against said annular seat; (c) a seal member
forming a seal between said filter element and said housing; and
(d) a non-internal tube construction within said housing interior
portion between said filter element and said outlet.
15. An air cleaner according to claim 14 wherein: (a) said filter
element comprises a cylindrical construction with a first flow
face, and an opposite second flow face; said filter element being
constructed and arranged to permit the flow of air into the filter
element through the first flow face and exit the filter element
through the second flow face; (i) said filter element having a
plurality of flutes; each of said flutes having an upstream portion
adjacent to said first flow face and a downstream portion adjacent
to said second flow face; (ii) selected ones of said flutes being
open at said upstream portion and closed at said downstream
portion; and selected ones of said flutes being closed at said
upstream portion and open at said downstream portion; and (b) said
seal member is supported by an extension of a frame arrangement;
(i) said extension projecting axially from one of said first and
second flow faces; (ii) said seal member forming a radial seal
between and against said extension and said wall.
16. An air cleaner according to claim 15 further including: (a) a
secondary filter element oriented in said housing interior between
said seal member and said outlet; (i) said secondary filter element
including a region of filter media and a frame construction holding
said region of filter media; (A) said region of filter media having
a skirted portion; said skirted portion being positioned between
said wall and said frame construction.
17. An air cleaner according to claim 16 wherein: (a) said housing
includes a cover and a body member; said cover defining said
housing inlet; (i) said inlet comprises a plurality of slots
defined by said cover; (A) each of said slots having first and
second ends; each of said first ends being adjacent to an outer
periphery of said cover; each of said second ends being adjacent to
a center of said cover; (B) each of said slots being tapered in
width from said first end to said second end.
18. An air cleaner arrangement comprising: (a) a housing having
first and second opposite ends and defining an interior volume;
said housing defining an inlet adjacent to said first end and an
outlet adjacent to said second end; (b) a primary filter element
oriented within said interior volume of said housing; (c) a seal
member forming a seal between said primary filter element and said
housing; (d) a secondary filter element oriented within said
interior volume of said housing; (i) said secondary filter element
being oriented between said seal member and said outlet; and (ii)
said seal member engaging a portion of said secondary filter
element.
19. An air cleaner arrangement according to claim 18 wherein: (a)
said secondary filter element includes a frame construction; (b)
said seal member comprises a circular gasket having opposite outer
and inner radial sides; (i) said seal member having a plurality of
projections extending from said inner radial side; (ii) said
projections axially abutting said frame construction.
20. An air cleaner arrangement according to claim 19 wherein: (a)
said housing defines a first seat constructed and arranged to
support said seal member; and a second seat constructed and
arranged to support said secondary filter element; (i) said
secondary filter element being between and against said second seat
and said projections.
Description
FIELD OF THE INVENTION
[0001] This disclosure describes air cleaners for engines and
methods. In particular, this disclosure describes an air cleaner
having a straight-through flow, sealing system, resonator, and
methods for servicing and use.
BACKGROUND OF THE INVENTION
[0002] Gas streams often carry particulate material therein. In
many instances, it is desirable to remove some or all of the
particulate material from a gas flow stream. For example, air
intake streams to engines for motorized vehicles or other motorized
equipment often include particulate material therein. The
particulate material, should it reach the internal workings of the
various mechanisms involved, can cause substantial damage thereto.
It is therefore preferred, for such systems, to remove the
particulate material from the gas flow upstream of the engine or
other equipment involved. A variety of air filter or gas filter
arrangements have been developed for particulate removal. In
general, however, continued improvements are sought.
SUMMARY OF THE DISCLOSURE
[0003] This disclosure concerns, in one embodiment, an air cleaner
including a housing having first and second opposite ends.
Preferably, the housing defines an inlet adjacent to the first end
and an outlet adjacent to the second end. A media pack is
preferably oriented within the interior volume of the housing. In
preferred embodiments, the media pack will have a first and second
opposite flow face and be constructed and arranged for air to flow
into the media pack through the first flow face, and for air to
exit the media pack through the second flow face. The air cleaner
will include a seal member forming a seal between the media pack
and the housing. In preferred constructions, a secondary filter
element is oriented within the interior volume of the housing.
[0004] In some preferred embodiments, the housing is constructed
and arranged as a resonator.
[0005] Certain preferred embodiments will include seal
constructions that engage the secondary filter element to help hold
the secondary filter element axially within the housing.
[0006] Methods of filtering systems, servicing filtration systems,
and constructing filter arrangements and housings are described
herein. Preferred methods will use filter elements and
constructions as characterized above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of one embodiment of an air
cleaner, according to principles of this disclosure;
[0008] FIG. 2 is an exploded, perspective view of the air cleaner
of FIG. 1 and its internal components;
[0009] FIG. 3 is a cross-sectional view of the air cleaner housing
taken along the line 3-3 of FIG. 1;
[0010] FIG. 4 is a schematic view of one embodiment of a system in
which air cleaners according to the present disclosure are
used;
[0011] FIG. 5 is an enlarged, fragmented, schematic cross-sectional
view of one embodiment a compressible seal member utilized to form
a seal between a media pack and the air cleaner housing of FIG.
1;
[0012] FIG. 6 is an end elevational view of one embodiment of a cup
of the air cleaner housing shown in FIG. 1;
[0013] FIG. 7 is a cross-sectional view of the cup depicted in FIG.
6 taken along the line 7-7 of FIG. 8;
[0014] FIG. 8 is an opposite end elevational view of the cup
depicted in FIG. 6;
[0015] FIG. 9 is a cross-sectional view of one embodiment of a body
member of the air cleaner housing depicted in FIG. 1 taken along
the line 9-9 of FIG. 2;
[0016] FIG. 10 is an exploded, perspective view of one embodiment
of a secondary filter element usable in the air cleaner depicted in
FIG. 1, according to the principles of the present disclosure;
[0017] FIG. 11 is a schematic, perspective view of a portion of
filter media usable in the media pack shown in FIGS. 2 and 3;
and
[0018] FIG. 12 is a schematic, end view of the media pack depicted
in FIGS. 2 and 3, according to principles of the present
disclosure.
DETAILED DESCRIPTION
[0019] A. Systems of Use, FIG. 4
[0020] The filter constructions and arrangements described herein
are usable in a variety of systems. One particular type of system
is depicted schematically in FIG. 4 generally at 700. In FIG. 4,
equipment 702, such as a vehicle, having an engine 703 with some
defined rated air flow demand, for example at least 35 cfm, and
typically 45-65 cfm is shown schematically. The equipment 702 may
comprise a lawn tractor, golf cart, power boat, or other powered
equipment. The engine 703 powers the equipment 702, through use of
an air and fuel mixture. In FIG. 4, air flow is shown drawn into
the engine 703 at an intake region 705. An air cleaner 710 having a
filter construction 712 and a secondary element 713 is upstream of
the engine 703. The air cleaner 710 can be constructed to have a
resonator 706 integral therewith to reduce the sound pressure level
exiting the system 700 upon which the air cleaner 710 is
installed.
[0021] In general, in operation air is drawn in at arrow 714 into
the air cleaner 710 and through the primary element 712 and the
secondary element 713. There, particles and contaminants are
removed from the air. The cleaned air flows downstream at arrow 716
into the intake 705. From there, the air flows into the engine 703
for use in powering the equipment 702.
[0022] B. Overview of the Air Cleaner
[0023] Attention is directed to FIGS. 1-3. These Figs. illustrate
an embodiment of an air cleaner, generally designated as reference
no. 1. The air cleaner 1 is usable in engine air intake systems,
such as system 700, described above.
[0024] In FIG. 1, an air cleaner housing 2 is depicted. The air
cleaner housing 2 holds or contains internal components for
filtering or cleaning air that flows through the housing 2.
[0025] FIG. 2 is an exploded, perspective view of an assembly of
the air cleaner 1. In the particular embodiment illustrated, the
air cleaner 1 includes the housing 2 and an indicator system 5. The
housing 2 holds, or contains within it, a media pack 3 and a
secondary element 6. The media pack 3 has a filter construction 100
and a sealing system 4.
[0026] When the particular air cleaner 1 depicted in FIG. 2 is
operably constructed and assembled together, the air cleaner 1 will
have the cross-section as shown in FIG. 3. By the term "operably,"
it is meant that during use in the system 700 (FIG. 4), when the
air cleaner 1 is removing particulate matter from an air stream,
the air cleaner 1 will be configured and arranged as illustrated in
FIG. 3. FIG. 3 demonstrates the general, overall operation of the
air cleaner 1: (a) fluid, such as air, enters the housing 2 at an
inlet or first end 10 in the direction of arrow 306; (b) passes
through the media pack 3, where particulate matter is removed from
the fluid; (c) passes through the secondary element 6; and (d)
exits the housing 2 at an outlet or second end 11 in the direction
of arrow 307. In preferred embodiments, the housing 2 is
constructed and arranged to act as a resonator 14. As such, when
air moves through the housing 2, the resonator 14 will decrease the
sound pressure level exiting the system 700 (FIG. 4). When the
optional indicator system 5, typically a conventional restriction
indicator, is used with the air cleaner 1, the indicator system 5
will provide an indication of when the media pack 3 is occluded and
requires servicing.
[0027] As can be seen in FIG. 3, when media constructions such as
filter constructions 100 of the type shown are used in the housing
2, the sealing system 4 is needed to ensure that air flows through
the filter construction 100, rather than in a path that bypasses
the filter construction 100.
[0028] When constructions of the type shown in FIG. 3 are used, the
media pack 3 will be removable and replaceable from the housing 2.
After a period of use, when the media pack 3 is serviced, debris
and contaminants may be knocked from the media pack 3. The
secondary element 6 operates to catch debris and contaminants and
prevent these contaminants from being sucked into the engine.
[0029] Further details on the construction and methods of the air
cleaner 1 follow.
[0030] C. The Housing 2
[0031] A variety of embodiments of housings for the air cleaner 1
are possible. A preferred housing construction 2 is illustrated in
perspective in FIG. 1. An exploded view of the housing 2 is shown
in FIG. 2.
[0032] In the particular embodiment illustrated in FIG. 2, the
housing 2 preferably includes a body member or portion 12 and a
cover or cup portion 13. Attention is directed to FIG. 9. FIG. 9 is
a cross-sectional view of the body 12. In general, the body 12
includes a first media chamber exterior wall 15, a sealing chamber
exterior wall 16, a secondary element exterior wall 17, and an
outlet exterior wall 18.
[0033] When the housing 2 is constructed according to principles
herein, the first media chamber exterior wall 15 will define a
first media chamber 20. The first media chamber 20 is configured
for receiving, holding, and containing a portion of the media pack
3. This can be seen in the cross-section of FIG. 3. The first media
chamber exterior wall 15 will have a cross-sectional configuration
selected by the system designer, based on space considerations,
manufacturing techniques, and other factors. In the particular
embodiment illustrated, the first media chamber 20 is cylindrical,
or has a slight frusto-conical shape, with a circular
cross-section, having a first diameter D1 and a first axial length
L1. It should be noted that the use of the term "cylindrical"
herein denotes a general shape. After demolding, during
manufacture, a draft angle may cause the housing 2 to have a slight
angle or frusto-conical shape rather than a cylindrical shape.
[0034] In reference again to FIG. 9, the sealing chamber exterior
wall 16 defines a sealing chamber 21. The sealing chamber 21
defines a sealing surface 82. The sealing surface 82 provides a
rigid surface for receiving compression pressure of the sealing
system 4. This will be described in further detail below, in
conjunction with the description of the sealing system 4. In the
embodiment illustrated, the sealing chamber 21 is cylindrical with
a circular cross-section having a second diameter D2 and a second
axial length L2. As such, the sealing surface 82, in the particular
embodiment shown, is an annular, radial sealing surface 82. The
diameter D2 is smaller than the diameter D1 of the first media
chamber 20. As a result, there is a step 83 between the first media
chamber 20 and the sealing chamber 21.
[0035] The body member 12 also defines a first seat 84. The seat 84
is preferably configured for acting as a stop for properly
positioning and orienting the media pack 3 within the body member
12. In the particular arrangement shown in FIG. 9, the seat 84
includes a surface 85 angled relative to the sealing surface 82.
The surface 85 of the seat 84 can be angled between
60.degree.-120.degree., typically 70-110.degree., and in the
particular embodiment illustrated about 90.degree., relative to the
sealing surface 82. The stop surface 85 will axially engage, or
abut, an end axial surface 86 (FIG. 3) of the sealing system 4.
[0036] Adjacent to the stop surface 85 is a secondary element
chamber 22. The secondary element chamber 22 is defined by the
secondary element exterior wall 17. The secondary element chamber
22 has an inner wall 269, which corresponds to an opposite side
from the exterior wall 17. As will be explained further below, the
inner wall 269 acts as an engagement surface such that a portion of
the secondary filter element 6 can be compressed thereagainst. This
will be discussed in further detail below, in connection with the
discussion of the secondary filter element 6. The secondary element
chamber 22 also includes a seat 86 for helping the proper
orientation and positioning of the secondary filter element 6 in
the body member 12. In particular, the secondary filter element
seat 86 has a surface 87 that will axially engage or abut an axial
surface of the secondary filter element 6. The stop surface 87 is
angled relative to the engagement surface 269, in order to provide
the stopping or engagement purposes. The surface 87 can be angled
relative to the engagement surface 269 in a range between about
60.degree.-120.degree., typically 70.degree.-110.degree., and in
the particular embodiment illustrated, about 90.degree..
[0037] Still in reference to FIG. 9, in the particular embodiment
shown, the secondary element chamber 22 is cylindrical with a
circular cross-section, which has a third diameter D3 and a third
axial length L3. As can be seen in FIG. 9, D3 is smaller than the
diameter of D2 (the sealing chamber 21) and D1 (the diameter of
first media chamber 20). This construction allows for insertion and
removal of the secondary filter element 6 through an opening 80
defined by the body member 12, through the first media chamber 20,
through the sealing chamber 21, and into the secondary element
chamber 22.
[0038] Still in reference to FIG. 9, the outlet exterior wall 18 is
depicted as adjacent to the secondary element chamber 22. The
outlet exterior wall 18 defines an outlet 23, through which air
exits the air cleaner assembly 1. The outlet 23, in the embodiment
illustrated, is angled relative to the stop surface 87 by an angle
of between 70-110.degree., and in the one shown in the drawing,
about 90.degree.. Also, in the particular embodiment illustrated,
the outlet 23 is cylindrical with a fourth axial length L4 and a
circular cross-section of a fourth diameter D4.
[0039] In the particular embodiment illustrated in FIGS. 2 and 9,
the first media chamber exterior wall 15 includes integral ridges
or ribs 24. Preferably, the ribs 24 are continuous around the
outside circumference of the first media chamber exterior wall 15.
In general, the ribs 24 provide additional structural integrity or
strength to the overall housing 2. In the particular embodiment
illustrated, the ribs 24 are ornamental, eye-catching, and
distinctive to Donaldson, the assignee.
[0040] Attention is directed to FIG. 7. FIG. 7 is a cross-sectional
view of the cup portion 13 of the housing 2 (FIG. 2). In general,
the cover or cup 13 includes a body chamber exterior wall 25, a
second media pack exterior wall 26, and a top wall, or inlet,
27.
[0041] Preferably, the body chamber exterior wall 25 defines a body
chamber 30 arranged and configured to receive the body portion 12
(FIG. 2) of the housing 2 (FIG. 2). During assembly, the first
media pack exterior wall 15 of the body portion 12 is designed to
fit within the body chamber 30. In the particular embodiment
illustrated, the body chamber 30 is cylindrical and has a fifth
diameter D5 and a fifth axial length L5.
[0042] Preferably, the second media pack exterior wall 26 defines a
second media pack chamber 31 arranged and configured to receive a
portion of the media pack 3 (FIG. 2). In the embodiment depicted,
the second media pack chamber 31 is cylindrical and has a sixth
diameter D6 and a sixth axial length L6.
[0043] Preferably, the top wall 27 secures the media pack 3 (FIG.
2) within the housing 2 (FIG. 2) and allows air to enter the air
cleaner assembly 1 (FIG. 1) while preventing large objects, such as
sticks, leaves, and butterflies, from entering the housing 2.
[0044] In the particular embodiment illustrated in FIG. 7, the cup
portion 13 further includes a support structure 35. The support
structure 35 provides support for holding the media pack 3 (FIG. 2)
placed within the housing 2 (FIG. 2) and prevents axial slippage of
the media pack 3 during use. Referring to FIG. 3, typically, the
support structure 35 is not in touchable engagement with the media
pack 3. Preferably, a gap 106, having an eighth axial length of L8,
exists between the media pack 3 and the support structure 35.
During use, this gap 106 helps distribute the inlet air stream 306
throughout the face 105 of the media pack 3. During use, forces
exerted on the air cleaner assembly 1 may cause the media pack 3 to
vibrate loose. In other words, the media pack 3 may become
dislodged from its sealing engagement, described in detail below,
with the housing 2. In this event, the support structure 35
prevents the media pack 3 from becoming completely dislodged and
thereby ensures a sealing engagement between the media pack 3 and
the housing 2.
[0045] In alternative embodiments, the gap 106 may be partially
filled with a ring or gasket (not shown) to ensure minimal axial
slippage of the media pack 3, thereby ensuring that the media pack
3 remains in sealing engagement with the housing 2.
[0046] The support structure 35 also helps to maintain an air space
37 between the top wall 27 of the cup portion 13 and the media pack
3 when assembled. In addition, the support structure 35 partially
creates an expansion chamber 65 for sound, as will be discussed in
more detail below. This air space 37 improves the air flow through
the media pack 3, as will be described in more detail below.
[0047] The support structure 35 generally extends from the top wall
27 of the cup 13 into the second media pack chamber 31 a first
distance K1. Preferably, the support structure 35 comprises a
plurality of fins or ribs 36 as illustrated in FIGS. 7 and 8. FIG.
8 is an end elevational view of the inside of the cup portion 13.
The fins 36 extend from the top wall 27 of the cup 13 and typically
are integral with the top wall 27.
[0048] Referring back to FIGS. 1 and 2, preferably, the housing 2
includes a securing system 39 for securing the cup 13 to the body
12. In typical applications, the securing system 39 includes first
and second latches 42, 43. Latch connections such as those
described in U.S. Pat. Nos. 5,547,480, 5,545,241, and Des. 399,119,
incorporated herein by reference, can be used. In alternative
embodiments, the securing system 39 may include a twist lock
mechanism as described in co-pending, commonly assigned, U.S.
patent applications Ser. No. 08/928,684, filed Sep. 12, 1997, and
Ser. No. 09/146,291, filed Sep. 3, 1998, entitled "Air Cleaner
Assembly; and Method," hereby incorporated by reference.
[0049] In the particular embodiment illustrated in FIG. 7, the cup
portion 13 includes first and second latch supports 40, 41.
Referring back to FIG. 2, the latches 42, 43 are mounted on the
first and second latch supports 40, 41 (FIG. 7). In the particular
embodiment illustrated in FIG. 9, the body portion 12 also includes
first and second latch extensions 44, 45. Referring back to FIGS. 1
and 2, the latches 42, 43 are designed to hook or latch the first
and second latch extensions 44, 45 to secure the cup 13 to the body
12 of the housing 2.
[0050] Preferably, the body chamber 30 of the cup 13 is arranged
and configured to receive the first and second latch extensions 44,
45. Referring back to FIG. 8, the body chamber exterior wall 25
includes first and second latch extension regions 46, 47, axially
aligned with the latch supports 40, 41, respectively. The first and
second latch extension regions 46, 47 are arranged and configured
to receive the first and second latch extensions 44, 45,
respectively as illustrated in FIG. 1. In this manner, the first
and second latch extension regions 46, 47 and the first and second
latch extensions 44, 45 helps to ensure that the cup 13 is
appropriately aligned with the body 12 prior to securing the cup 13
to the body 12.
[0051] Referring back to FIG. 1, the housing 2 further includes an
optional radial alignment system 46. In the particular embodiment
illustrated in FIGS. 1 and 2, the alignment system includes an
alignment ridge, protrusion, or bump 48 on the body 12 and an
alignment region or channel 47 in the body chamber 30 of the cup
13. The alignment channel 47 is arranged and configured to receive
the alignment ridge 48. During assembly, the alignment ridge 48 and
the alignment channel 47 ensure that the cup can be oriented only
in one direction with respect to the body member 12. This ensures
proper air flow through the air cleaner assembly 1, as will be
described in more detail below. In other embodiments, the ridge 48
may be on the cup 13, while the channel 47 is on the body member
12.
[0052] Attention is directed to FIG. 6. FIG. 6 is an end
elevational view of one embodiment of the cup portion 13 of the air
cleaner assembly 1 shown in FIG. 1. In the particular embodiment
illustrated in FIG. 6, the top wall 27 defines an inlet arrangement
27a for intaking air flow into the housing 2. In preferred
embodiments, the inlet arrangement 27a will include a radial
diffuser 49 for distributing the air flow through the media pack 3
(FIG. 2). In the particular embodiment illustrated in FIG. 6, the
radial diffuser 49 comprises a plurality of slots 50. The slots 50
allow a fluid, such as air, to enter the air cleaner assembly 1
(FIG. 1) while restricting large objects, such as sticks, from
entering the air cleaner assembly 1. Preferably, the slots 50 are
designed for efficient air flow through the air cleaner assembly
1.
[0053] In the particular embodiment illustrated in FIG. 6, the
slots are diverging-converging openings or tear shaped. By the term
"tear shaped," it is meant that the slots 50 have a wider opening
at a first end 51 than at a second end 52. The wider opening at the
first end 51 allows more air to enter the assembly 1 around the
outer circumference of the assembly 1. The narrower opening at the
second end 52 restricts the air entering the assembly 1 near the
center of the assembly 1. Each of the slots 50 is tapered from the
wider opening at the first end 51, down toward the opening at the
second end 52. This particular arrangement improves air flow and
filtration capacity since a larger surface area of media exists at
the outer circumference of the media pack 3 (FIG. 2) than at the
center of the media pack 3. By directing a larger volume of air
around the outer circumference of the media pack 3, greater
filtration capacity is achieved.
[0054] Still in reference to FIG. 6, preferably, the slots 50 are
placed in generally the upper half 90 of the top wall 27 of the cup
13. By the term "upper half," it is meant that when the air cleaner
assembly 1 is installed in the system 700 (FIG. 4), the top wall 27
will be arranged to be within a vertical plane such that the top
wall 27 will have an upper half with a higher vertical elevation
than a lower half 91 of the top wall 27. In typical applications,
the air cleaner assembly 1 is oriented such that the slots 50 align
with an opening (not shown) in a shroud or hood of equipment for
which the air cleaner assembly 1 is designed. For example, on
garden tractors, the hood of the garden tractor contains an opening
for air flow. The air cleaner assembly 1 is mounted within the hood
such that the slots 50 of the cup 13 generally align with the
opening in the hood of the garden tractor. This ensures maximum air
flow through the air cleaner assembly 1.
[0055] In the particular embodiment illustrated, the top wall 27
includes an arrow 55 and the word "top" 56 to ensure proper
orientation by the user of the air cleaner assembly 1 with the
openings in the hood of the garden tractor. In addition,
preferably, the housing 2 includes the alignment system 46
previously discussed to ensure proper orientation. In the
particular embodiment illustrated in FIG. 6, the slots 50 are
arranged in a semi-circular array, with each of the slots extending
radially from a center 77 of the top wall 27 toward the outer
periphery 78 of the top wall 27.
[0056] In the particular embodiment illustrated, the top wall 27
includes a drain hole 60 near the lower half of the top wall 27 of
the cup 13. The drain hole 60 allows any liquid, such as water or
water condensation, that may enter the air cleaner assembly 1, to
drain out of the air cleaner assembly 1 through the drain hole 60.
The alignment system 46 helps to ensure that the drain hole 60 is
oriented at or near the bottom of the air cleaner 1.
[0057] Although the particular body 12 and cup 13 depicted are
preferred for the housing 2, many different embodiments are
possible. The embodiment depicted, however, is particularly
convenient for manufacturing techniques, such as injection molding.
Further, the particular housing 2 depicted is preferred because it
is attractive in appearance, eye-catching, and distinctive to
Donaldson, the assignee. Further views of the housing 2 are
depicted in co-pending and commonly assigned U.S. patent
application Ser. No. ______, filed the same date herewith, and
entitled, "In-line Air Cleaner," which application is incorporated
by reference herein.
[0058] D. The Resonator 14
[0059] In certain preferred systems, the housing 2 is constructed
and arranged to act as a resonator 14. That is, in preferred
constructions, the housing 2 is constructed and arranged to reduce
the sound pressure level exiting the system 700 (FIG. 4). When
constructed according to the following principles, the resonator 14
will reduce the sound pressure level by at least 1 dB(A), typically
between 1.5 and 3 dB(A), when compared to an air cleaner with an
open end; that is, an air cleaner where an end of a media pack is
not covered by a portion of a housing of the air cleaner. This
sound pressure level decrease can be measured with equipment such
as a Larson Davis Real Time Analyzer, with the microphone mounted
about 30 inches above the seat of the equipment, such as a garden
tractor. Alternatively, equipment such as an Aachen Head can be
used, again, with the simulated head mounted about 30 inches above
the seat of the equipment.
[0060] Attention is directed to FIG. 3. FIG. 3 is a cross-sectional
view of the assembled air cleaner assembly 1 of FIG. 1. Preferably,
the length L7 of an expansion chamber 65, which includes both the
first and second media pack chambers 20, 31 (FIGS. 7 and 9) of the
body 12 and the cup 13, respectively, and the inlet 27 are
constructed and arranged to act as the resonator 14. L7 extends
between the inlet wall 27 and the first seat surface 86.
Preferably, the overall length L7 of the expansion chamber 65 is
equal to the speed of sound divided by 4 times the frequency
desired to be removed by the resonator 14. This particular length
L7 of the expansion chamber 65 causes the sounds waves to bounce
back and forth, canceling each other, according to sound pressure
principles commonly known. The frequency desired to be removed by
the resonator 14 is dependent on the particular source impedance of
the downstream equipment. For example, a Yanmar, twin cylinder
diesel engine operating at rated conditions and having a 20
horsepower rating, has a predominate source strength frequency at
500 hertz. Knowing this source strength frequency, the length L7 of
the expansion chamber 65 is determined. A ratio of the length L7 of
the expansion chamber 65 to the open area equivalent diameter of
the inlet 27 is between about 4.5 and 5.0, for example about 4.7. A
ratio of the length L7 of the expansion chamber 65 to the largest
outermost sectional dimension (in the particular illustrated
embodiment, diameter) is at least 1.5, and typically between about
1.75 and 2.00, for example, about 1.8.
[0061] In addition, the inlet arrangement 27a is arranged and
constructed to have an opening that has a smaller cross-sectional
area than the opening of the outlet chamber 23. The smaller
cross-sectional area of the inlet 27a acts to restrict the sound
from exiting the inlet 27a. Preferably, the inlet 27a has a
cross-sectional area that is at least 3 percent smaller than the
cross-sectional area of the outlet 23, and typically between 5 and
10 percent smaller.
[0062] The expansion chamber 65 reduces, within the space
constraints, the radiated sound of the predominate source strength
frequency through the inlet 27 by destructive interference. Sound
waves with frequencies above a few hundred Hertz are further
attenuated by acoustic attenuation within the media pack 3,
according to sound absorption principles commonly known. The
configuration thus provides effective broadband sound absorption
and attenuation.
[0063] In the particular embodiment illustrated, the expansion
chamber 65 is cylindrical and has a diameter about at least 80
percent, and typically 100 to 250 percent larger than the largest
cross-sectional dimension (in this case, diameter) of the outlet
23.
[0064] Still in reference to FIG. 3, there is a non-internal tube
construction 93 within the interior of the housing 2 between the
media pack 3 and the outlet 23. By the term "non-internal tube
construction", it is meant that there are no internal tubular
structures for sound attenuation mounted within the housing 2. In
other words, the housing 2 is constructed and arranged to attenuate
sound with the resonator 14 without any additional tubes located
therewithin. In addition, the entire housing 2 includes a
non-internal tube construction 94, in that there are no acoustic
tubes located anywhere within the housing interior. While there is
a negative cylinder at 95 for supporting the fins 36, the negative
cylinder 95 does not act as a acoustic tube, and is not within the
definition of "non-internal tube construction."
[0065] In the particular embodiment illustrated, the resonator 14
is designed to reduce the sound pressure levels exiting the air
cleaner assembly 1 without the use of baffles, absorptive packing
material, sonic chokes, or other sound attenuating devices. The
sound pressure level reduction is achieved by the housing 2
consisting essentially of only the structure as described
previously herein.
[0066] E. The Media Pack 3
[0067] Referring back to FIG. 2, the filter construction 100
depicted is designed to remove particulates from a fluid, such as
air, passing through the filter construction 100, while the sealing
system 4 is designed to seal the media pack 3 against the sealing
chamber exterior wall 16 of the housing 2, as shown in FIG. 3. By
the term "seal," it is meant that the sealing system 4, under
normal conditions, prevents unintended levels of fluid from passing
through a region between the media pack 3 and the sealing chamber
exterior wall 16 of the housing 2; i.e., the sealing system 4
inhibits fluid flow from avoiding passage through the media pack
3.
[0068] In certain arrangements, the media pack 3 will be configured
for straight-through flow. By "straight-through flow," it is meant
that the media pack 3 is configured in a construction 100 with a
first flow face 105 (corresponding to an inlet end, in the
illustrated embodiment) and an opposite, second flow face 110
(corresponding to an outlet end, in the illustrated embodiment),
with fluid flow entering in one direction 114 through the first
flow face 105 and exiting in the same direction 116 from the second
flow face 110. When used with an inline-flow housing, such as the
housing 2 of FIG. 1, in general, the fluid will enter through the
inlet of the housing in one direction 306, enter the filter
construction 100 through the first flow face 105 in the same
direction, exit the filter construction 100 in the same direction
from the second flow face 110, and exit the housing through the
housing outlet 11 also in the same direction 307.
[0069] Although the first flow face 105 is described above as
corresponding to an inlet end, and the second flow face 110 is
described above as corresponding to an outlet end, the inlet and
outlet ends can be reversed. That is, the first flow face 105
depicted in FIG. 2 can correspond to an outlet end, while the
second flow face 110 depicted in FIG. 2 can correspond to an inlet
end.
[0070] In FIG. 2, the first flow face 105 and the second flow face
110 are depicted as planar and as parallel. In other embodiments,
the first flow face 105 and the second flow face 110 can be
non-planar, for example, frusto-conical. Further, the first flow
face 105 and second flow face 110 need not be parallel to each
other.
[0071] Generally, the filter construction 100 will be a wound
construction. That is, the construction 100 will typically include
a layer of filter media that is turned completely or repeatedly
about a center point. Typically, the wound construction will be a
coil, in that a layer of filter media will be rolled a series of
turns around a center point. In arrangements where a wound, coiled
construction is used, the filter construction 100 will be a roll of
filter media, typically permeable fluted filter media.
[0072] Attention is now directed to FIG. 11. FIG. 11 is schematic,
perspective view demonstrating the principles of operation of
certain media usable in the filter constructions herein. In FIG.
11, a fluted construction is generally designated at 122. The
fluted construction 122 includes: a layer 123 of corrugations
having a plurality of flutes 124 and a face sheet 132. The FIG. 11
embodiment shows two sections of the face sheet 132, at 132A
(depicted on top of the corrugated layer 123) and at 132B (depicted
below the corrugated layer 123). Typically, the media construction
125 used in arrangements described herein will include the
corrugated layer 123 secured to the bottom face sheet 132B. When
using this media construction 125 in a rolled construction, it
typically will be wound around itself, such that the bottom face
sheet 132B will cover the top of the corrugated layer 123. The face
sheet 132 covering the top of the corrugated layer is depicted as
132A. It should be understood that the face sheet 132A and 132B are
the same sheet 132.
[0073] When using this type of media construction 125, the flute
chambers 124 form alternating peaks 126 and troughs 128. The
troughs 128 and peaks 126 divide the flutes into an upper row and
lower row. In the particular configuration shown in FIG. 11, the
upper flutes form flute chambers 136 closed at the downstream end,
while flute chambers 134, having their upstream end closed, form
the lower row of flutes. The fluted chambers 134 are closed by a
first end bead 138 that fills a portion of the upstream end of the
flute between the fluting sheet 130 and the second facing sheet
132B. Similarly, a second end bead 140 closes the downstream end of
alternating flutes 136. In some systems, both the first end bead
138 and second end bead 140 are straight along all portions of the
media construction 125, never deviating from a straight path. In
some systems, the first end bead 138 is both straight and never
deviates from a position at or near one of the ends of the media
construction 125, while the second end bead 140 is both straight
and never deviates from a position at or near one of the ends of
the media construction 125. The flutes 124 and end beads 138, 140
provide the media construction 125 that can be formed into filter
construction 100 and be structurally self-supporting without a
housing.
[0074] When using media constructed in the form of media
construction 125, during use, unfiltered fluid, such as air, enters
the flute chambers 136 as indicated by the shaded arrows 144. The
flute chambers 136 have their upstream ends 146 open. The
unfiltered fluid flow is not permitted to pass through the
downstream ends 148 of the flute chambers 136 because their
downstream ends 148 are closed by the second end bead 140.
Therefore, the fluid is forced to proceed through the fluting sheet
130 or face sheets 132. As the unfiltered fluid passes through the
fluting sheet 130 or face sheets 132, the fluid is cleaned or
filtered. The cleaned fluid is indicated by the unshaded arrow 150.
The fluid then passes through the flute chambers 134 (which have
their upstream ends 151 closed) to flow through the open downstream
end 152 (FIG. 12) out the fluted construction 122. With the
configuration shown, the unfiltered fluid can flow through the
fluted sheet 130, the upper facing sheet 132A, or lower facing
sheet 132B, and into a flute chamber 134.
[0075] Typically, the media construction 125 will be prepared and
then wound to form the rolled filter construction 100 (FIGS. 3 and
12) of filter media. When this type of media is selected for use,
the media construction 125 prepared includes the sheet of
corrugations 123 secured with the end bead 138 to the bottom face
sheet 132B (as shown in FIG. 11, but without the top face sheet
132A). In these types of arrangements, the media construction 125
will include a leading edge at one end and a trailing edge at the
opposite end, with a top lateral edge and a bottom lateral edge
extending between the leading and trailing edges. By the term
"leading edge," it is meant the edge that will be initially turned
or rolled, such that it is at or adjacent to the center or core of
the rolled construction. The "trailing edge" will be the edge on
the outside of the rolled construction, upon completion of the
turning or coiling process.
[0076] The leading edge and the trailing edge should be sealed
between the corrugated sheet 123 and the bottom face sheet 132B,
before winding the sheet into a coil, in these types of media
constructions 125. While a number of ways are possible, in certain
methods, the seal at the leading edge is formed as follows: (a) the
corrugated sheet 123 and the bottom face sheet 132B are cut or
sliced along a line or path extending from the top lateral edge to
the bottom lateral edge (or, from the bottom lateral edge to the
top lateral edge) along a flute 124 forming a peak 126 at the
highest point (or apex) of the peak 126; and (b) sealant is applied
between the bottom face sheet 132B and the sheet of corrugations
123 along the line or path of cut. The seal at the trailing edge
can be formed analogously to the process of forming the seal at the
leading edge. While a number of different types of sealant may be
used for forming these seals, one usable material is a non-foamed
sealant available from H. B. Fuller of St. Paul, Minn., identified
under the designation HL0842.
[0077] When using the media construction 125, it may be desired by
the system designer to wind the construction 125 into a rolled
construction of filter media, such as the filter construction 100
of FIG. 12. FIG. 12 is a schematic, end view of the media pack 3. A
variety of ways can be used to coil or roll the media. The media
construction 125 may be wound about a center mandrel or other
element to provide a mounting member for winding. The center
mandrel may be removed or left to plug to act as a core at the
center of the cylindrical filter construction 100. It can be
appreciated that non-round center winding members may be utilized
for making other filtering construction shapes, such as filter
constructions having an oblong, oval, rectangular, or
racetrack-shaped profile, and can be usable in filtering systems
herein. Various filter constructions with non-circular (as well as
circular) cross-sections are described in co-pending, commonly
assigned, U.S. patent application Ser. No. ______, entitled,
"Filter Arrangement; Sealing System; and Methods," filed the same
date herewith, and herein incorporated by reference. Further view
of various filter constructions that may be usable herein are
depicted in copending and commonly assigned U.S. patent application
Ser. No. ______, filed the same day herewith, and entitled, "Filter
Element Having Sealing System," herein incorporated by
reference.
[0078] Still in reference to FIG. 11, the media construction 125
can also be wound without a mandrel or center core. One method of
forming a coreless rolled construction is as follows: (a) the
troughs 128 of the first few corrugations of the corrugated sheet
123 spaced from the leading edge are scored from the top lateral
edge to the bottom lateral edge (or from the bottom lateral edge to
the top lateral edge); for example, the first four corrugations
from the leading edge will have a score line cut along the troughs
128; (b) the bead 140 of sealant is applied along the top of the
sheet of corrugation 123 along the lateral edge opposite from the
lateral edge having end bead 138; (c) the leading edge is initially
turned or rolled over against itself and then pinched together to
be sealed with the sealant bead 140; and (d) the remaining
corrugated sheet 123 having the bottom face sheet 132B secured
thereto is coiled or rolled or turned around the pinched leading
edge.
[0079] In other methods, coreless constructions can be made from
the media construction 125 by automated processes, as described in
U.S. Pat. Nos. 5,543,007 and 5,435,870, each incorporated by
reference herein. In still other methods, the media construction
can be rolled by hand.
[0080] When using rolled constructions, such as the filter
construction 100, the system designer will want to ensure that the
outside periphery of the construction 100 is closed or locked in
place to prevent the filter construction 100 from unwinding. There
are a variety of ways to accomplish this. In some applications, the
outside periphery is wrapped with a periphery layer. The periphery
layer can be a non-porous, adhesive material, such as plastic with
an adhesive on one side. When this type of layer is utilized, the
periphery layer prevents the filter construction 100 from unwinding
and prevents the fluid from passing through the outside periphery
of the filter construction 100, maintaining straight-through flow
through the filter construction 100.
[0081] In some applications, the filter construction 100 is secured
in its rolled construction by sealing the trailing edge of the
media construction 125 with an adhesive or sealant along a line 179
(FIG. 2) to secure the trailing edge to the outside surface of the
filter construction 100. For example, a bead of hot-melt may be
applied along the line 179.
[0082] Attention is again directed to FIG. 12. In FIG. 12, the
second flow face 110 is shown including the open ends 152 and
closed ends 148. Top and bottom plan views, as well as side
elevational views of the media pack 3 and the sealing system 4
usable in the systems and arrangements described herein are
depicted in copending and commonly assigned U.S. patent application
Ser. No. ______, filed the same day herewith, and entitled, "Filter
Element Having Sealing System," herein incorporated by
reference.
[0083] F. The Sealing System 4
[0084] Turning back to FIG. 3, the media pack 3 is shown installed
in a housing 2. In the arrangement shown, air flows into the
housing 2 at 306, through the media pack 3, and out of the housing
2 at 307. When media constructions such as the media pack 3 of the
type shown are used in a duct or housing 2, sealing system 4 will
be needed to ensure that air flows through the media pack 3, rather
than bypass it.
[0085] The particular sealing system 4 depicted includes a frame
construction 170 and a seal member 250. When this type of sealing
system 4 is used, the frame construction 170 provides a support
structure or backing against which the seal member 250 can be
compressed to form a radial seal 172 with the housing 2.
[0086] Attention is further directed to FIGS. 2, 3 and 12. FIG. 2
is a schematic, perspective view of the sealing system 4; FIG. 3 is
a schematic, cross-sectional view of the media pack 3 installed in
the housing 2; and FIG. 12 is a schematic, end view of the sealing
system 4 and the media pack 3.
[0087] In general, when using frame constructions 170 such as those
described herein, the frame construction 170 will include a frame
205. The frame 205 may be a variety of shapes. In the particular
embodiment illustrated in FIG. 3, the shape of the frame 205 is
generally circular. The frame 205 depicted in FIG. 3 is convenient
in that it is arranged and configured for attachment to the second
flow face 110 (FIG. 2) of the filter construction 100.
[0088] In the particular arrangement depicted, the frame 205 has a
band, skirt, or depending lip 251 that is generally circular and
has an inside diameter. Preferably, the inside diameter is
approximately equal to the outside diameter of the filter
construction 100. The depending lip 251 depends or extends down a
first distance from a bottom 252 surface of cross braces 210 (FIG.
12). The depending lip 251 is arranged and configured to extend
radially around the second flow face 110 the filter construction
100. In the particular embodiment depicted, the depending lip 251
extends radially around the second flow face 110 of the filter
construction 100, such that the depending lip 251 extends inboard
the first distance of the second flow face 110 of the filter
construction 100, defining an overlap region 255.
[0089] The frame 205 is preferably secured to the filter
construction 100. A variety of ways to secure the frame 205 to the
filter construction 100 are possible. One particularly preferred
way to secure the frame 205 to the filter construction 100 is by
use of an adhesive. In the particular embodiment depicted in FIG.
3, the adhesive is oriented in the overlap region 255 between the
depending lip 251 and the filter construction 100.
[0090] Preferably, the adhesive permanently affixes the frame 205
to the filter construction 100 while preventing the fluid from
leaking out through the overlap region 255 between the filter
construction 100 and the frame 205. In alternative embodiments, the
frame 205 may be temporarily attached to the filter construction
100. By the term "temporarily," it is meant that the frame 205 may
be removed from the filter construction 100 without damaging either
the sealing system 4 or the filter construction 100.
[0091] Referring to FIG. 12, during use of frames 205 of the type
depicted herein, inward forces are exerted around the circumference
of the frame 205. Cross braces 210 support the frame 205. By the
term "support," it is meant that the cross braces 210 prevent the
frame 205 from radially collapsing under the forces exerted around
the circumference of the frame 205.
[0092] Referring again to FIG. 3, the particular frame construction
205 depicted preferably includes a tip portion 263, or annular
sealing support. In the one depicted in FIG. 3, the tip portion 263
is generally circular and is arranged and configured for insertion
into the housing 2. When circular, the tip portion 263 defines an
inside diameter. Between the tip portion 263 and the depending lip
251, the frame 205 includes a step 253. The step 253 provides a
transition area between the larger inside diameter of the depending
lip 251 and the smaller inside diameter of the tip portion 263.
[0093] When constructed according to the arrangement shown in FIG.
3, the tip portion 263 provides support for the compressible seal
member 250. The compressible seal member 250 is preferably
constructed and arranged to be sufficiently compressible to be
compressed between the tip portion 263 of the frame 205 and a
sidewall 260 of the housing 2. When sufficiently compressed between
the tip portion 263 and the sidewall 260, a radial seal 172 is
formed between the media pack 3 and the sidewall 260 of the housing
2.
[0094] A variety of ways are possible to secure the seal member 250
to the tip portion 263. One particularly convenient and preferred
way is by molding the seal member 250 to engage, cover, or overlap
both the outer radial side 271 of the tip portion 263 and the inner
radial side 270 of the tip portion 263, including the end tip 180.
One particular embodiment of this configuration is depicted in FIG.
3. The seal member 250 completely covers the tip portion 263.
[0095] The tip portion 263 of the frame 205 defines a wall or
support structure between and against which the radial seal 172 may
be formed by the compressible seal member 250. The compression of
the compressible seal member 250 at the sealing system 4 is
preferably sufficient to form a radial seal under insertion
pressures of no greater than 80 pounds, typically, no greater than
50 pounds, for example, about 20-30 pounds, and light enough to
permit convenient and easy change out by hand. Preferably, the
amount of compression of the compressible seal member 250 is at
least fifteen percent, preferably no greater than forty percent,
and typically between twenty and thirty-three percent. By the term
"amount of compression," it is meant the physical displacement of
an outermost portion of the seal member 250 radially toward the tip
portion 263 as a percentage of the outermost portion of the seal
member 250 in a resting, undisturbed state and not installed within
a duct or subject to other forces.
[0096] Attention is directed to FIG. 5. FIG. 5 is an enlarged
schematic, fragmented view of a particular preferred seal member
250 in an uncompressed state. In the preferred embodiment shown,
the seal member 250 has a stepped cross-sectional configuration of
decreasing outermost dimensions (diameter, when circular) from a
first end 264 to a second end 265, to achieve desirable sealing.
Preferred specifications for the profile of the particular
arrangement shown in FIG. 5 are as follows: a polyurethane foam
material having a plurality of (preferably at least three)
progressively larger steps configured to interface with the
sidewall 260 (FIG. 3) and provide a fluid-tight seal.
[0097] The compressible seal member 250 defines a gradient of
increasing internal diameters of surfaces for interfacing with the
sidewall 260. Specifically, in the example shown in FIG. 5, the
compressible seal member 250 defines three steps 266, 267, 268. The
cross-sectional dimension or width of the steps 266, 267, 268
increases the further the step 266, 267, 268 is from the second end
265 of the compressible seal member 250. The smaller diameter at
the second end 265 allows for easy insertion into a duct or
housing, such as the housing 2 of FIG. 3. The larger diameter at
the first end 264 ensures a tight seal.
[0098] In general, for a properly functioning radially sealing
structure, the compressible seal member 250 needs to be compressed
when the element is mounted in the housing 2 (FIG. 3). In many
preferred constructions, it is compressed between about fifteen
percent and forty percent (often about twenty to thirty-three
percent) of its thickness, in the thickest portion, to provide for
a strong robust seal, yet still be one that can result from hand
installation of the element with forces on the order of 80 pounds
or less, preferably 50 pounds or less, and generally 20-30
pounds.
[0099] Referring back to FIG. 3, in general, the media pack 3 and
sealing system 4 can be arranged and configured to be press-fit
against the sidewall 260 of the housing 2 or duct. In the specific
embodiment shown in FIG. 3, the compressible seal member 250 is
compressed between the sidewall 260 and the tip portion 263 of the
frame 205. After compression, the compressible seal member 250
exerts a force against the sidewall 260 as the compressible seal
member 250 tries to expand outwardly to its natural state, forming
the radial seal 172 between and against the tip portion 263 and the
sidewall 260.
[0100] Referring back to FIG. 12, in the particular embodiment
illustrated, the media pack 3 also includes a retention system 280
for retaining the secondary element 6 (FIG. 3) within the secondary
element chamber 22 (FIG. 3). Stated in other words, the retention
system 280 prevents the secondary element from axially slipping out
of the secondary element chamber 22 within the housing 2 (FIG.
3).
[0101] In the particular embodiment illustrated in FIG. 12, the
retention system 280 includes first, second, and third retention
extensions 281, 282, 283. Preferably, the retention extensions 281,
282, 283 are integral with the compressible seal member 250 of the
sealing system 4. Typically, the retention extensions 281, 282, 283
radially extend toward the center of the media pack 3 as
illustrated. While a variety of configurations are contemplated,
the particular embodiment illustrated shows the retention
extensions 281, 282, 283 as having a semi-oval or quarter-moon
cross-sectional shape.
[0102] Referring to FIG. 3, the retention extensions 281, 282, 283
(FIG. 12) are configured and arranged to touchably engage the
secondary element 6 within the housing 2. Specifically, the second
retention extension 282 is illustrated in FIG. 3 radially extending
toward the center of the media pack 3 overlapping with an outside
edge 285 of a frame construction 402 of the secondary element 6.
The second retention extension 282 extends in overlapping
engagement with the outside edge 285 of the secondary element 6
such that there is axial abutment between the retention extension
282 and a frame of the secondary element 6. This ensures that the
secondary element 6 is locked or secured within the secondary
element chamber 22 and prevented from axially slipping within the
housing 2. The first and third extensions 281, 283, likewise,
touchably engage and axially abut the frame of the secondary
element 6 to retain the secondary element 6 within the secondary
element chamber 22. As such, the secondary element 6 will be
trapped between the stop surface 87 and the first, second, and
third retention extensions 281, 282, and 283.
[0103] In alternative embodiments, the retention extensions may be
of other sizes or shapes, and the retention system 280 may include
other numbers of retention extensions. The particular arrangement
depicted is preferred in that it lends itself to convenient
manufacturing techniques and is ornamental, eye-catching, and
attractive.
[0104] G. The Secondary Element 6
[0105] Attention is directed to FIG. 10. FIG. 10 depicts an
exploded, perspective view of the secondary element 6, shown in the
air cleaner 1 of FIGS. 2 and 3.
[0106] In general, the secondary element 6 includes a frame
construction 402 and a region of media 404. In preferred
constructions, the frame construction 402 is usable for holding and
supporting the region of media 404. Preferably, the media 404 is
for removing at least some particulates from a gas stream (that is,
particulates having a smallest outermost dimension that is larger
than a largest pore size of the media 404). For example, the media
404 can be used to remove particulates from air being taken into an
engine.
[0107] In preferred systems, the media 404 preferably is
constructed and arranged to introduce little restriction into the
air intake duct. For example, the secondary element 6 including the
media 404, in some arrangements, will have a restriction of no more
than two inches of water, preferably no more than one inch of
water.
[0108] The region of media 404 within the periphery of the frame
construction 402, in the embodiment depicted in FIG. 10, is
nonpleated and noncylindrical. Further, in the particular FIG. 10
embodiment, the region of media 404 is nonwoven and comprises not
more than a single layer. The particular type of media 404 depicted
in FIG. 10 includes a region of depth media, such as fibrous
media.
[0109] When media 404 of the type depicted in FIG. 10 is assembled
in the frame construction 402 depicted in FIG. 10, the media 404
will include a filtering portion 406 and a skirted portion 408 as
illustrated in FIG. 2. The filtering portion 406 will operate to
remove contaminants and particulates having a size (i.e., smallest
outermost dimension) greater than the pore size of the media 404
from an air or gas stream passing therethrough. For example, with
certain types of media 404 described herein, the filtering portion
406 will remove about 50% of dust particles having an average
particle size (smallest outermost dimension) of less than 1-10
microns passing therethrough.
[0110] The skirted portion 408 preferably operates to cooperate
with an annular surface of a duct, such as the secondary element
chamber interior wall 269 to occupy or fill a volume between the
wall 269 and the secondary element 6 and create a "sealing effect."
By the term "sealing effect," it is meant that high restriction is
introduced in the volume between the periphery of the frame
construction 402 and an inner wall portion 269 of the housing 2;
while some air or gas may be allowed to pass through the region
between an outer periphery of the frame construction 402 and the
annular surface of the housing 2, the air or gas that does pass
through, for the most part, will pass through the media in the
skirted portion 408. This is described further below.
[0111] Still in reference to FIG. 10, the particular frame
construction 402 depicted in FIG. 10 includes an outer periphery
410. The outer periphery 410 defines a perimeter area 412
therewithin. In other words, in the specific configuration depicted
in FIG. 10, the perimeter area 412 comprises the entire region
within the outer periphery 410. The outer periphery 410 may have a
variety of shapes. In the particular embodiment shown in FIG. 10,
the outer periphery 410 is circular. In the particular embodiment
of FIG. 10, the perimeter area 412 would include everything within
the circular periphery 410 and can be calculated by squaring the
radius of the circular outer periphery 410 and multiplying it by pi
(.pi.).
[0112] When constructed in the way shown in FIG. 2, the filtering
portion 406 occupies or fills the entire perimeter area 412 (FIG.
10). When cleaning a gas stream passing therethrough, by occupying
the entire perimeter area 412, there are no regions of unfiltered
areas that the gas stream may escape through. As can also be seen
in FIG. 2, preferably the skirted portion 408 extends outside of
the outer periphery 412 and is not part of the perimeter area 410.
In the particular arrangement shown in FIG. 2, the skirted portion
408 extends both outside and radially projects from the outer
periphery 412. In FIG. 2, it can be seen that the media 404 (FIG.
10) includes an outermost edge or periphery at 414. This outermost
edge 414 is spaced from the outer periphery 412, when the secondary
element 6 is not installed in a duct or tubular construction.
[0113] In some preferred constructions, the frame construction 402
is a multi-piece construction. In the particular arrangement
depicted in FIG. 10, the frame construction 402 is a two-piece
construction. In the particular FIG. 10 embodiment, the frame
construction 402 includes first and second frame pieces 416, 418.
The first and second frame pieces 416, 418 preferably are
constructed and arranged to hold the media 404 within the housing
2, while providing sufficient structural integrity to prevent
collapse under air pressure.
[0114] When a multi-piece frame construction 402 is used, there
will include structure or a construction holding the multiple
pieces together with the media 404. In the particular illustrated
arrangement, the first and second frame pieces 416, 418 include a
locking arrangement 420, constructed and arranged to permit the
first and second pieces 416, 418 to lock, or fit, or snap, or
matably engage together. In preferred arrangements, the locking
construction or arrangement 420 holds the region of media 404
between the first and second frame pieces 416, 418 to securely hold
the media 404 in place and under sufficient tension to minimize the
restriction through the media 404.
[0115] A variety of locking arrangements 420 may be implemented. In
the particular construction illustrated, the locking arrangement
420 includes a bead and recess system. That is, preferably, at
least one of the first and second frame pieces 416, 418 has a
projection, such as a bead, while the other of the first and second
frame pieces 416, 418 has a cooperating recess or indent for
receiving the bead. In the particular illustrated embodiment
depicted in FIG. 10, the first frame piece 416 defines a recessed
portion 422, while the second frame piece 418 defines a projection
or bead member 424 for projecting or snapping therein.
[0116] In certain preferred arrangements, the frame construction
402 will include a handle system for permitting the convenient
installation and removal of the secondary element 6 from the
housing 2. Many different types of handle systems may be
implemented. One particularly preferred embodiment of a handle
system is illustrated in FIG. 10. In the particular FIG. 10
embodiment, the first frame piece 416 includes a first handle
construction 440. While a variety of constructions are contemplated
herein, in the embodiment shown in FIG. 10, the first handle
construction 440 includes a plurality of ribs 442 radially
extending from the first region 444 of the first frame piece 416.
In the embodiment shown, the ribs 442 intersect at a center frame
member 446. The ribs 442 and center frame member 446 provide
structure for a user to grasp when handling the secondary element
6, for example when changing out the secondary element 6.
[0117] In certain preferred constructions, the first handle
construction 440 including the ribs 442 and center frame member 446
also provide support structure to the frame construction 402.
Again, the frame construction 402 should have sufficient structural
integrity to prevent collapse under air intake pressures, that can
typically range from at least 25 in. of water, and can be up to 100
inches of water. In addition, the first handle construction 440
helps to maintain sufficient tension in the media 404 to minimize
the restriction through the media 404.
[0118] Likewise, the second frame piece 418 includes a second
handle construction 450. While a variety of constructions are
contemplated herein, in the embodiment shown in FIG. 10, the second
handle construction 450 includes a plurality of ribs 452 radially
extending from a second region 454 of the first frame piece 418. In
the embodiment shown, the ribs 452 intersect at a center frame
member 456. The ribs 452 and center frame member 456 provide
structure for a user to grasp when handling the secondary element
6.
[0119] In certain preferred constructions, the second handle
construction 450 including the ribs 452 and center frame member 456
also provide support structure to the frame construction 402.
Again, the frame construction 402 should have sufficient structural
integrity to prevent collapse under air intake pressures, that can
typically range from at least 25 in. of water, and can be up to 100
inches of water. In addition, the second handle construction 450
helps to maintain sufficient tension in the media 404 to minimize
the restriction through the media 404.
[0120] Alternatively, additional structure may be attached to the
frame construction 402 to allow for the convenient installation and
removal of the secondary element 6 from the housing 2. Because both
the first and second frame pieces 416, 418 include handle
constructions 440, 450, the secondary element 6 is reversible. By
the term "reversible," it is meant that the secondary element 6 may
be installed in the housing 2 with either the first frame piece 416
or the second frame piece 418 in the most upstream position
(alternatively stated, the first frame piece 416 or the second
frame piece 418 may be installed in the most downstream position).
The media construction 404 will deflect in the proper orientation
and occupy to fill the space between the periphery of the frame
construction 402 and the wall 269, when the secondary element 6 is
inserted.
[0121] Attention is directed to FIG. 3. In FIG. 3, the secondary
element 6 is depicted installed in the housing 2. The skirt 408
fills the volume between the inner wall 269 of the housing 2 and
the frame construction 402. As can be seen in FIG. 3, the skirted
portion 408 of the media 404 is preferably constructed and arranged
to be sufficiently compressible to be compressed between the frame
construction 402 and the inner wall 269 of the housing 2. When
sufficiently compressed between the frame construction 402 and
inner wall 269, sealing effect 460, or media-stuffed volume or
media-filled region, is formed for the secondary element 6 with the
housing 2. Specifically, the sealing effect 460 is formed between
the secondary element 6 and the inner wall 269. In the particular
embodiment shown in FIG. 3, the sealing effect 460 is formed by
compressing the skirted portion 408 of the media 404 between and
against the frame construction 402 and the inner wall 269.
[0122] The compression of the media 404 at the skirted portion 408,
in preferred systems, will be preferably sufficient to form the
sealing effect 460 under pressures of up to 100 in. of water, and
light enough to permit convenient and easy change out by hand.
Preferably, the compression of the skirted portion 408 to form the
media-occupied volume or region is at least 70%, preferably no
greater than 90%, and typically between 75-85%. In preferred
systems, the sealing effect 460 can be created by applying
typically under 5 pounds of force, and ranging between 1-20
pounds.
[0123] One usable secondary element is described in commonly
assigned and co-pending U.S. patent application Ser. No. ______,
entitled, "Filter Element and Methods," filed on the same date
herewith, and herein incorporated by reference.
[0124] H. Indicator System 5
[0125] Referring back to FIG. 1, in the particular embodiment
illustrated, the air cleaner assembly 1 includes the restriction
indicator 5 for providing an indication to an user of the air
cleaner assembly 1 of the restriction across the media pack 3 of
the air cleaner assembly 1. The restriction indicator 5 is designed
to provide the user with an indication of when the media pack 3
needs to serviced or replaced.
[0126] Referring to FIG. 2, in general, the restriction indicator 5
includes an outlet extension 800, an indicator tube 801, and an
indicator 802. Referring to FIG. 3, the outlet extension 800
extends from the outlet exterior wall 18 of the housing 2 and
defines an indicator chamber 803. Preferably, the indicator chamber
803 is in communication with the outlet chamber 23 such that air
moves through the indicator chamber 803. Typically, the outlet
extension 800 is integral with the outlet exterior wall 18 of the
housing 2.
[0127] In the particular embodiment illustrated, the indicator tube
801 connects the outlet extension 800 with the indicator 802.
Preferably, the indicator tube 801 is in communication with the
outlet extension 800 such that air passes through the indicator
tube 801 therethrough to the indicator 802. Preferably, the
indicator tube 801 is connected to the outlet extension 800 and the
indicator 802 by conventional securing means, such as screwing the
indicator tube 801 onto the outlet extension 800.
[0128] Preferably, the indicator 802 measures the air pressure
across the outlet chamber 23. When the air pressure reaches a
predetermined level, for example 25 inches of water, the indicator
802 provides an indication to the user of the air cleaner assembly
1 that the media pack 3 needs servicing or replacement.
[0129] One such usable restriction indicator device 5 is described
in commonly assigned U.S. Pat. No. 3,443,365, herein incorporated
by reference.
[0130] In alternative embodiments, the air cleaner assembly 1 does
not include a restriction indicator. In these embodiments, the user
services or replaces the media pack 3 after a predetermined number
of hours of use, for example 150 hours, or by visual inspection of
the media pack 3. In other alternative embodiments, the media pack
3 may have color, such as blue, to help the user determine the
level of occlusion in the media pack 3.
[0131] I. Change Out and Replacement
[0132] In certain preferred applications, the media packs described
herein are removable and replaceable from whatever system in which
they are installed. For example, the media pack will be installed
in an air cleaner housing, such as the one shown in FIGS. 1-3.
After a certain number of hours of use, the media in the filter
construction 100 will become occluded, and the restriction in the
media pack 3 will increase. In preferred applications, the media
pack 3 will be periodically replaced to maintain the appropriate
removal of particulates from a fluid, without introducing too high
of a restriction.
[0133] In applications where the restriction indicator 5 is used,
the restriction indicator 5 will provide information to the user
regarding the appropriate time to change out the media pack 3.
[0134] To service the air cleaner arrangements described herein,
the user will need access to the media pack 3. For example, if the
media pack 3 is installed in an air cleaner housing such as the
housing 2 shown in FIGS. 1-3, the user will unlatch the cover 13
from the body member 12, and remove the cover 13 from the body
member 12. This will expose an opening 80 (FIG. 9) defined by the
body member 12. The user will grasp the media pack 3 and break the
radial seal 172 formed by the media pack 3 against the sidewall 16
of the housing 2. In certain systems, the seal member 250 and the
housing 2 will be designed such that the user will need to exert a
force of no more than about 80 pounds, preferably no more than 50
pounds, and in some applications between 20 and 30 pounds to break
the radial seal 172 and remove the media pack 3. The user will then
pull the media pack 3 through the opening 80 formed by the body
member 12. The old media pack 3 may then be disposed of. In certain
preferred systems, the media pack 3 will be constructed of
non-metallic materials, such that it is readily incineratable. For
example, in some preferred constructions, the media pack 3 will
comprise at least 95 percent, and typically at least 98 percent
nonmetallic materials.
[0135] When the media pack 3 is being serviced, sometimes debris
and particulate materials can be knocked or jarred from the media
pack 3 and fall into the housing 2. The secondary element 6
operates to catch this debris and contaminant and prevent these
contaminants from being sucked into the engine.
[0136] After the media pack 3 has been removed, the secondary
element 6 may be serviced. It is contemplated that the secondary
element 6 may not need servicing every time the media pack 3 is
serviced. When it is desired to service the secondary element 6,
the user removes the secondary element 6 from the housing 2 by
breaking the sealing effect 460 formed by the media 404. More
specifically, the user grasps the handle construction 440 of the
frame construction 402 and removes the secondary element 6 from the
housing 2. This may be done by grasping the ribs 442 and center
framework 446 and axially pulling the element 6 from the housing 2
by sliding it along the interior wall 269 of the secondary element
chamber 22 of the housing 2. As the secondary element 6 is being
slid along the wall 269 of the housing 2, the skirted portion 408
of the media 404 wipes the wall 269 to help clean the housing
2.
[0137] After the secondary element 6 is removed from the housing 2,
either the entire secondary element 6 can be disposed of and
replaced with a new one, or alternatively, only the media 404 is
disposed of while the frame construction 402 is reused. Preferably,
the secondary element 6 is constructed of substantially metal free
materials such that it is readily incineratable. For example,
preferably the secondary element 6 comprises at least 95%, and more
preferably 98-100% nonmetallic materials. If the entire secondary
element 6 is disposed of, the old secondary element 6 can be
incinerated.
[0138] Alternatively, the secondary element 6 can be disassembled
and the media 404 removed. The old filter media 404 would be
disposed of, such as by incineration. The frame construction 402
could be recycled, or alternatively, re-used. If re-used, a new
region of filter media 404 would be secured to the frame
construction 402. For example, when disassembling the secondary
element 6, the first and second frame pieces 416, 418 are removed
or unlocked or unsnapped from each other. A screwdriver or other
suitable tool may be used to pry the first frame piece 416 from the
second frame piece 418. By unlocking the first and second frame
pieces 416, 418 from each other, this frees the first, old filter
media 404, which may then be incinerated. The secondary element 6
is then reassembled. This may be done by placing a new region of
media over the end portion 462 of the second frame piece 418. The
skirted portion 408 of the media should be extending outwardly from
the second frame piece 418. The first frame piece 416 can then be
aligned with the second frame piece 418 and snapped or locked to
the second frame piece 418.
[0139] The new secondary element 6 can then be installed in the
housing 2. This may be done by grasping the frame construction,
such as the ribs 442 (FIG. 10) of the handle construction 440 (FIG.
10) and inserting it into the housing 2. The secondary element 6 is
inserted until the frame construction 402 axially engages or abuts
the stop surface 87. The skirted portion 408 (FIG. 2) of the filter
element becomes compressed between and against the frame
construction 402 and the inner wall 269 of the housing 2 to occupy
or fill the volume therebetween and create a media-filled region
460 and a sealing effect.
[0140] After the secondary element 6 is replaced, the media pack 3
may also then be replaced within the housing 2.
[0141] To install a new media pack 3, the user grasps the media
pack 3 and inserts it through an opening in the housing 2. The
media pack 3 is inserted into the opening until the retention
extensions 280, 281, 283 of the retention system 280 touchably
engage the secondary element 6 and until the seal member 250 is
sufficiently compressed against the annular wall 16 of the housing
2 to form radial seal 172 between and against the housing wall 16
and the tip portion 263 of the frame 205. The end tip 86 of the
seal member 250 will usually axially abut the stop surface 85 of
the seat 84, when properly installed. The cover 13 is then oriented
over the exposed end of the media pack 3 to cover the opening 80.
The cover 13 is then latched to the body member 12 by the latches
42, 43.
[0142] J. Example Materials
[0143] In this section, examples are provided of usable materials.
The particular choice for any given material will vary, depending
on the filtering application. In other words, the particular
material selected for the systems usable herein will be decided
upon by the system designer based on the system requirements. A
variety of materials are possible. The following section provides
examples of materials that have been found to be suitable.
[0144] The housing 2 can be constructed of plastic, such as
glass-filled nylon.
[0145] The media 122 can comprise cellulose. One example of media
usable in the system described above is as follows: cellulose media
with the following properties: a basis weight of about 45-55
lbs./3000 ft.sup.2 (84.7 g/m.sup.2), for example, 48-54 lbs./3000
ft.sup.2; a thickness of about 0.005-0.015 in, for example about
0.010 in. (0.25 mm); frazier permeability of about 20-25 ft/min,
for example, about 22 ft/min (6.7 m/min); pore size of about 55-65
microns, for example, about 62 microns; wet tensile strength of at
least about 7 lbs/in, for example, 8.5 lbs./in (3.9 kg/in); burst
strength wet off of the machine of about 15-25 psi, for example,
about 23 psi (159 kPa).
[0146] The cellulose media can be treated with fine fiber, for
example, fibers having a size (fiber diameter) of 5 microns or
less, and in some instances, submicron. A variety of methods can be
utilized for application of the fine fiber to the media. Some such
approaches are characterized, for example, in U.S. Pat. No.
5,423,892, column 32, at lines 48-60. More specifically, such
methods are described in U.S. Pat. Nos. 3,878,014; 3,676,242;
3,841,953; and 3,849,241, incorporated herein by reference. Another
alternative is a trade secret approach comprising a fine polymeric
fiber web positioned over conventional media, practiced under trade
secret by Donaldson Company under the designation ULTRA-WEB.RTM..
With respect to the configurations of the filter element, the
operation of the sealing system, and the construction and operation
of the housing and resonator, there is no particular preference
for: how the fine fibers are made; and, what particular method is
used to apply the fine fibers. Enough fine fiber would be applied
until the resulting media construction would have the following
properties: initial efficiency of 99.5% average, with no individual
test below 90%, tested according to SAE J726C, using SAE fine dust;
and an overall efficiency of 99.98% average, according to SAE
J726C.
[0147] The frame 205 (FIG. 3) of the sealing system 4 will be
constructed of a material that will provide structural integrity
and is not subject to creep. The frame 205 will be constructed of a
non-metallic material such that it is environmentally friendly and
either recyclable or readily incineratable. The frame 205 can be
constructed from most plastics, for example, glass reinforced
plastic. One usable reinforced plastic is propylene or nylon. Of
course, other suitable materials may be used.
[0148] The compressible seal member 250 (FIG. 5) can be made from a
variety of materials. There is no particular preference, provided
that the seal member 250 forms a seal in the proper location under
compression. One usable material will be a soft polymeric material,
such as foamed urethane. One example usable material includes
foamed polyurethane, processed to an end product having an "as
molded" density of fourteen to twenty-two pounds per cubic foot.
Foamed polyurethanes are available from a variety of sources, such
as BASF Corporation of Wyandotte, Mich. One example of a foamed
polyurethane comprises a material made with I35453R resin and
I305OU isocyanate, which is sold exclusively to the assignee
Donaldson by BASF Corporation.
[0149] The materials should be mixed in a mix ratio of 100 parts
I35453 resin to 36.2 parts I305OU isocyanate (by weight). The
specific gravity of the resin is 1.04 (8.7 pounds/gallon), and for
the isocyanate it is 1.20 (10 pounds/gallon). The materials are
typically mixed with a high dynamic shear mixer. The component
temperatures should be seventy to ninety-five degrees Fahrenheit.
The mold temperatures should be 115-135.degree. Fahrenheit.
[0150] The resin material I35453R has the following
description:
[0151] (a) Average molecular weight
[0152] 1) Base polyether polyol=500-15,000
[0153] 2) Diols=60-10,000
[0154] 3) Triols=500-15,000
[0155] (b) Average functionality
[0156] 1) total system=1.5-3.2
[0157] (c) Hydroxyl number
[0158] 1) total systems=100-300
[0159] (d) Catalysts
[0160] 1) amine=Air Products 0.1-3.0 PPH
[0161] 2) tin=Witco 0.01-0.5 PPH
[0162] (e) Surfactants
[0163] 1) total system= 0.1-2.0 PPH
[0164] (f) Water
[0165] 1) total system=0.03-3.0 PPH
[0166] (g) Pigments/dyes
[0167] 1) total system=1-5% carbon black
[0168] (h) Blowing Agent
[0169] 1) 0.1-6.0% HFC 134A.
[0170] The I3050U isocyanate description is as follows:
[0171] (a) NCO content--22.4-23.4 wt %
[0172] (b) Viscosity, cps at 25.degree. C.=600-800
[0173] (c) Density=1.21 g/cm.sup.3 at 25.degree. C.
[0174] (d) Initial boiling pt.--190.degree. C. at 5 mm Hg
[0175] (e) Vapor pressure=0.0002 Hg at 25.degree. C.
[0176] (f) Appearance--colorless liquid
[0177] (g) Flash point (Densky-Martins closed cup)=200.degree.
C.
[0178] The frame construction 402 (FIG. 10) of the secondary
element 6 will be constructed of a material that will provide
structural integrity and is not subject to creep. Further, the
frame construction 402 can be constructed of a non-metallic
material such that it is environmentally friendly and either
recyclable or readily incineratable. The frame construction can be
constructed from most plastics, for example, glass reinforced
plastic. One usable reinforced plastic is propylene or nylon.
[0179] The media 404 (FIG. 10) for the secondary element 6 will be
a media that will introduce little restriction into the duct. The
media can be a nonpleated, noncylindrical, nonwoven media. In
particular, the media can be depth media, such as a fibrous media.
One example of fibrous media usable in the system described above
is as follows:
[0180] 1 layer of 4.0-4.8 oz/yd.sup.2 (136-163 g/m.sup.2) polyester
fiber depth media (mixed fibers); 0.55-0.70" (14-18 mm) thickness
freestate (as measured under 0.002 psi compression); average fiber
diameter about 21.0 micron (mass weighted average) or about 16.3
micron (length weighted average); permeability (minimum) 500 ft/min
(152 m/min.); free state solidity about 0.6-1.0%, typically about
0.7%.
[0181] K. Example Construction
[0182] In this section, examples are provided of a set of operating
specifications. These are intended as an example. A wide variety of
alternate sizes can be used.
[0183] The first diameter D1 of the first media chamber 20 of FIG.
9 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm),
and in one example would be approximately 4.1 inches (about 10 cm).
The first axial length L1 of the first media chamber 20 will be
between 2 inches (about 5 cm) and 5 inches (about 13 cm), and in
one example would be approximate 3.7 inches (about 9 cm).
[0184] The second diameter D2 of the sealing chamber 21 of FIG. 9
will be between 2 inches (about 5 cm) and 5 inches (about 13 cm),
and in one example would be approximately 3.7 inches (about 9 cm).
The second axial length L2 of the sealing chamber 21 will be
between 0.5 inches (about 1 cm) and 2 inches (about 5 cm), and in
one example would be approximately 0.8 inches (2 cm).
[0185] The third diameter D3 of the secondary element chamber 22 of
FIG. 9 will be between 1.5 inches (about 4 cm) and 4.5 inches
(about 11 cm), and in one example would be approximately 2.7 inches
(about 7 cm). The third axial length L3 of the secondary element
chamber 22 will be between 0.4 inches (1 cm) and 1.5 inches (about
4 cm), and in one example would be approximately 0.6 inches (1.5
cm).
[0186] The fourth diameter D4 of the outlet 23 of FIG. 9 will be
between 1 inch and 3 inches, and in one example would be
approximately 1.5 inches (about 4 cm). The fourth axial length L4
of the outlet 23 will be between 1 inch (2.5 cm) and 4 inches
(about 10 cm), and in one example would be approximately 2.1 inches
(about 5 cm).
[0187] The fifth diameter D5 of the body chamber 30 of FIG. 7 will
be between 3 inches (about 8 cm) and 6 inches (about 15 cm), and in
one example would be approximately 4.3 inches (about 11 cm). The
fifth axial length L5 of the body chamber 30 will be between 0.2
inches (0.5 cm) and 1 inch (2.5 cm), and in one example would be
approximately 0.3 inches (about 1 cm).
[0188] The sixth diameter D6 of the second media chamber 31 of FIG.
7 will be between 3 inches (about 8 cm) and 6 inches (about 15 cm),
and in one example would be approximately 4.1 inches (about 10 cm).
The sixth axial length L6 of the second media chamber 31 will be
between 1 inch (2.5 cm) and 4 inches (about 10 cm), and in one
example would be approximately 2.2 inches (about 6 cm).
[0189] The seventh axial length L7 of the overall media pack
chamber 67 of FIG. 3 will be between 5 inches (about 13 cm) and 10
inches (about 25 cm), and in one example would be approximately 7.1
inches (18 cm).
[0190] The eighth axial length L8 of the gap 106 of FIG. 3 will be
between 0.1 inches (about 0.5 cm) and 0.5 inches (about 1 cm), and
in one example would be approximately 0.2 inches (0.5 cm).
[0191] The first distance K1 of the support structure 35 of FIG. 7
will be between 0.5 inches (about 1 cm) and 1.5 inches (about 4
cm), and in one example would be approximately 0.8 inches (2
cm).
[0192] The filter construction 100 of FIG. 3 will provide at least
250 sq. in and typically 400-500 sq. in. for example about 450-460
sq. in. of media surface area. It will occupy a volume of no
greater than about 200 in.sup.3, and typically between 50-100
in.sup.3, and for example about 65-75 in.sup.3.
[0193] The above specification, examples and data provide a
complete description of the manufacture and use of the composition
of the invention. Since many embodiments of the invention can be
made without departing from the spirit and scope of the invention,
the invention resides in the claims hereinafter appended.
* * * * *