Z-filter media pack arrangement; and, methods

Abstract

Z-filter media pack arrangements and methods for providing them are described. The preferred arrangements have a cured-in-place jacket around an outside of a coiled z-filter media combination. The preferred cured-in-place jacket is a mold-in-place overmold which includes, integral therein, a housing seal arrangement. Preferably a cured-in-place center core is used, most preferably one that has opposite concave ends with seal arrangements configured to seal a lead end portion of the coiled z-filter media combination.

What is claimed is: 
     
       1. An air filter cartridge comprising:
 (a) a coiled media combination comprising a fluted sheet secured to a facing sheet and defining a set of inlet flutes and a set of outlet flutes extending between first and second, opposite, media combination flow ends; the coiled media combination defining:
 (i) a coil having a center extending between the first and second, opposite, media combination flow ends and an outer sidewall extending between the first and second, opposite, media combination flow ends; and, 
 (ii) a media combination lead end positioned inside of the coil center; and, 
   (b) a mold-in-place center resulting from putting a sealant material into an open end of the center of the coil and allowing the sealant to seal at least a portion of the lead end and to close the center against air flow therethrough.   
     
     
       2. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center has opposite ends at least one of which has an axially, outwardly, projecting end skirt to seal a portion of the lead end. 
 
     
     
       3. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center is formed from a resin that increases in volume by at least 20% during cure. 
 
     
     
       4. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center is formed from a resin that increases in volume by at least 40% during cure. 
 
     
     
       5. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center is formed from a resin that increases in volume by at least 50% during cure. 
 
     
     
       6. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center comprises a foamed polyurethane core formed from a resin that increases in volume by at least 20% during core. 
 
     
     
       7. An air filter cartridge according to  claim 1  wherein:
 (a) the center has a density of no greater than 0.24 g/cc. 
 
     
     
       8. An air filter cartridge according to  claim 1  wherein:
 (a) the coiled media combination has a circular perimeter shape. 
 
     
     
       9. An air filter cartridge according to  claim 1  wherein:
 (a) a housing seal arrangement is positioned secured to the media pack. 
 
     
     
       10. An air filter cartridge according to  claim 9  wherein:
 (a) the housing seal arrangement extends around the media pack. 
 
     
     
       11. An air filter cartridge according to  claim 10  wherein:
 (a) the housing seal arrangement comprises a mold-in-place seal positioned on an outside of the media pack. 
 
     
     
       12. An air filter cartridge according to  claim 11  wherein:
 (a) the housing seal arrangement comprises an axial pinch seal. 
 
     
     
       13. An air filter cartridge according to  claim 9  wherein:
 (a) the housing seal arrangement includes a mold-in-place seal member. 
 
     
     
       14. An air filter cartridge according to  claim 9  wherein:
 (a) the housing seal arrangement comprises an axial pinch seal. 
 
     
     
       15. An air filter cartridge according to  claim 14  wherein:
 (a) the axial pinch seal has opposite housing engagement surfaces spaced at least 4 mm apart. 
 
     
     
       16. A method of forming an air filter cartridge; the method comprising:
 (a) coiling a strip of fluted media secured to facing media to define a media combination comprising:
 (i) inlet and outlet flutes; 
 (ii) a coil center; and, 
 (iii) a media combination lead end positioned in the coil center; and, 
   (b) molding a molded-in-place center within an end of the coil center;
 (i) the step of molding comprising putting a sealant material in an end of the coil center, after the step of coiling, and molding the sealant material to seal at least a portion of a lead end and to seal the center against air flow therethrough. 
   
     
     
       17. A method according to  claim 16  wherein:
 (a) the step of molding comprises using a resin that increases in volume by at least 40% during cure. 
 
     
     
       18. A method according to  claim 16  wherein:
 (a) the step of molding comprises using a resin that increases in volume by at least 50% during cure. 
 
     
     
       19. A method according to  claim 16  wherein:
 (a) the step of molding comprises curing a polyurethane resin. 
 
     
     
       20. An air filter cartridge according to  claim 16  wherein:
 (a) the fluted sheet is connected to the facing sheet with sonic welding. 
 
     
     
       21. An air filter cartridge according to  claim 1  wherein:
 (a) the coiled media includes sonically welded media therein. 
 
     
     
       22. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center comprises a mold-in-place center core is configured to extend along at least 80% of a lead end seal length. 
 
     
     
       23. An air filter cartridge according to  claim 1  wherein:
 (a) the mold-in-place center is formed from a resin that will rise during cure. 
 
     
     
       24. A method according to  claim 16  wherein:
 (a) the step of molding includes projecting a projection on a mold into the coil center. 
 
     
     
       25. A method according to  claim 16  wherein:
 (a) the mold-in-place center is formed from a resin that will rise during cure. 
 
     
     
       26. A method according to  claim 16  wherein:
 (a) the mold-in-place center is formed from a resin that will increase in volume by at least 40% during cure. 
 
     
     
       27. An air filter cartridge comprising:
 (a) a coiled media combination comprising a fluted sheet secured to a facing sheet and defining a set of inlet flutes and a set of outlet flutes and defining first and second, opposite, media combination flow ends; the coiled media combination defining a coil having a center extending between the first and second, opposite, media combination flow ends and an outer sidewall extending between the first and second, opposite, media combination flow ends; and,   (b) a mold-in-place center resulting from putting at least a portion of sealant material through an open end of the center of the coil and allowing the sealant to seal and close the center against air flow therethrough.   
     
     
       28. An air filter cartridge according to  claim 27  wherein:
 (a) the mold-in-place center is formed from a resin that increases in volume by at least 20% during cure. 
 
     
     
       29. A method of forming an air filter cartridge; the method comprising:
 (a) coiling a strip of fluted media secured to facing media to define a media combination comprising:
 (i) inlet and outlet flutes; and 
 (ii) a coil center; and 
   (b) molding a molded-in-place center within an end of the coil center;
 (i) the step of molding being conducted after the step of coiling and comprising putting at least a portion of sealant material through an open end of the coil center and molding the sealant material to seal the center against air flow therethrough. 
   
     
     
       30. A method according to  claim 29  wherein:
 (a) the step of molding comprises using a resin that increases in volume by at least 40% during cure. 
 
     
     
       31. An air filter cartridge comprising:
 (a) a coiled media combination comprising fluted media secured to facing media and defining a media combination inlet flow end and an opposite media combination outlet flow end; the media combination defining:
 (i) a coil having a center extending between the opposite flow ends; 
 (ii) a media combination lead end positioned inside of the coil center; and, 
   (b) a mold-in-place center resulting from putting a sealant material into an open end of the center of the coil and allowing the sealant to seal at least a portion of the lead end and to close the center against air flow therethrough.   
     
     
       32. An air filter cartridge according to  claim 31  wherein:
 (a) the mold-in-place center is formed from a resin that increases in volume by at least 20% during cure. 
 
     
     
       33. An air filter cartridge according to  claim 32  wherein:
 (a) a housing seal arrangement is positioned secured to the media pack. 
 
     
     
       34. A method of manufacturing an air filter cartridge constructed for use in an air cleaner comprising steps of:
 (a) applying a curable resin circumscribing a filter media pack and extending at least 80% of a length of the filter media pack between an inlet flow face of the filter media pack and an outlet flow face of the filter media pack, wherein:
 (i) the filter media pack comprises a combination of a fluted sheet and a facing sheet arranged in a coiled arrangement and having the inlet flow face and the outlet flow face, and defining a plurality of flutes extending from the inlet flow face to the outlet flow face; 
 (ii) the combination of the fluted sheet and the facing sheet includes a lead end at a center of the coiled arrangement and a tail end at an outside of the coiled arrangement, and the curable resin is applied to the tail end; and 
 (iii) the curable resin is applied directly to the filter media pack; 
   (b) curing the curable resin to form a cured-in-place coating circumscribing the filter media pack and extending at least 80% of the length between the inlet flow face and the outlet flow face; and   (c) molding a housing seal around the media pack at a location between the inlet flow face and the outlet flow face, wherein the housing seal is constructed to form a radially directed seal with an air cleaner housing when the air filter cartridge is operably installed in the air cleaner housing.    
     
     
       35. A method according to claim 34 wherein:
 (a) the steps of applying and curing results in the cured-in-place coating extending at least 90% of the length between the filter media pack inlet flow face and the filter media pack outlet flow face.    
     
     
       36. A method according to claim 34 wherein:
 (a) the steps of applying and curing results in the cured-in-place coating extending at least 95% of the length between the filter media pack inlet flow face and the filter media pack outlet flow face.    
     
     
       37. A method according to claim 34 wherein:
 (a) the steps of applying and curing results in the cured-in-place coating extending at least 98% up to 100% of the length between the filter media pack inlet flow face and the filter media pack outlet flow face.    
     
     
       38. A method according to claim 34 wherein:
 (a) the step of applying a curable resin comprises applying the curable resin directly to the facing sheet.    
     
     
       39. A method according to claim 34 wherein:
 (a) the step of applying a curable resin comprises spraying the curable resin to the filter media pack.    
     
     
       40. A method according to claim 34 wherein:
 (a) the step of applying the curable resin comprises molding the curable resin in place.    
     
     
       41. A method according to claim 34 wherein:
 (a) the step of molding the housing seal around the media pack comprises molding the housing seal directly to the cured-in-place coating.    
     
     
       42. method according to claim 34 wherein:
 (a) the tail end is sealed by the cured-in-place coating.    
     
     
       43. A method according to claim 34 wherein:
 (a) the facing sheet comprises a flat sheet.    
     
     
       44. A method according to claim 34 wherein:
 (a) the facing sheet comprises a sheet having corrugations and wherein the corrugations extend perpendicularly to the flutes.    
     
     
       45. A method according to claim 34 wherein:
 (a) the inlet flow face and the outlet flow face have generally flat surfaces.    
     
     
       46. A method according to claim 45 wherein:
 (a) the inlet flow face and the outlet flow face are parallel.    
     
     
       47. A method according to claim 34 wherein:
 (a) the housing seal includes opposite axially directed surfaces separated by a peripheral surface.    
     
     
       48. A method according to claim 47 wherein:
 (a) the opposite axially directed surfaces of the housing seal are flat surfaces.    
     
     
       49. A method according to claim 47 wherein:
 (a) the opposite axially directed surfaces of the housing seal are parallel.    
     
     
       50. A method according to claim 34 wherein:
 (a) the coiled arrangement is provided around a core.    
     
     
       51. A method according to claim 34 wherein:
 (a) the coiled arrangement has a circular perimeter shape.    
     
     
       52. A method according to claim 34 wherein:
 (a) the coiled arrangement has a perimeter shape with opposite curved ends and opposite sides.    
     
     
       53. A method according to claim 52 wherein:
 (a) the opposite sides are straight and parallel.    
     
     
       54. An air filter cartridge for use in an air cleaner comprising:
 (a) a filter media pack comprising a fluted sheet and a facing sheet, wherein:
 (i) the fluted sheet and the facing sheet are adhered together and provided in a coiled arrangement having the facing sheet as outwardly directed; 
 (ii) the filter media pack having an inlet flow face and an outlet flow face; 
 (iii) the fluted sheet and the facing sheet defining a plurality of flutes extending from the inlet flow face to the outlet flow face; and 
 (iv) the fluted sheet and the facing sheet forming a lead end at a center of the coiled arrangement and a tail end at an outside of the coiled arrangement; 
   (b) a resin jacket provided around a periphery of the filter media pack and adhered to the outwardly directed facing sheet, wherein the resin jacket extends at least 80% of a length between the filter media pack inlet flow face and the filter media pack outlet flow face; wherein the resin jacket is cured-in-place and seals the tail end of the fluted sheet and the facing sheet; and   (c) a housing seal arrangement molded-in-place to the cured-in-place resin jacket around the periphery of the filter media pack and located between the inlet flow face and the outlet flow face, wherein the housing seal is constructed to form a radially directed seal with an air cleaner housing when the air filter cartridge is operably installed in the air cleaner housing.    
     
     
       55. An air filter cartridge according to claim 54 wherein:
 (a) the resin jacket extends at least 90% of the length between the filter media pack inlet flow face and the filter media pack outlet flow face.    
     
     
       56. An air filter cartridge according to claim 54 wherein:
 (a) the resin jacket extends at least 95% of the length between the filter media pack inlet flow face and the filter media pack outlet flow face.    
     
     
       57. An air filter cartridge according to claim 54 wherein:
 (a) the resin jacket extends at least 98% up to 100% of the length between the filter media pack inlet flow face and the filter media pack outlet flow face.    
     
     
       58. An air filter cartridge according to claim 54 wherein:
 (a) the cured-in-place resin jacket comprises a spray coated cured-in-place resin jacket.    
     
     
       59. An air filter cartridge according to claim 54 wherein:
 (a) the cured-in-place resin jacket comprises a molded cured-in-place resin jacket.    
     
     
       60. An air filter cartridge according to claim 54 wherein:
 (a) the housing seal is molded-in-place adjacent to one of the filter media pack inlet flow face or the filter media pack outlet flow face.    
     
     
       61. An air filter cartridge according to claim 54 wherein:
 (a) the housing seal is molded-in-place spaced from the filter media pack inlet flow face and spaced from the filter media pack outlet flow face.    
     
     
       62. An air filter cartridge according to claim 54 wherein:
 (a) the inlet flow face and the outlet flow face have generally flat surfaces.    
     
     
       63. An air filter cartridge according to claim 62 wherein:
 (a) the inlet flow face and the outlet flow face are parallel.    
     
     
       64. An air filter cartridge according to claim 54 further comprising:
 (a) a core within the coiled arrangement.    
     
     
       65. An air filter cartridge according to claim 54 wherein:
 (a) the coiled arrangement has a circular perimeter shape.    
     
     
       66. An air filter cartridge according to claim 54 wherein:
 (a) the coiled arrangement has a perimeter shape with opposite curved ends and opposite sides.    
     
     
       67. An air filter cartridge according to claim 66 wherein:
 (a) the filter media pack opposite sides are straight and parallel.    
     
     
       68. An air filter cartridge according to claim 54 wherein:
 (a) the housing seal includes opposite axially facing surfaces separated by a peripheral surface.