Air filter arrangement; air cleaner assembly; and, methods

Abstract

A media pack for including in a filter cartridge of an air filter arrangement, is provided. A variety of configurations for the media pack are described and shown, an example shown being trapezoidal. Filter cartridges including such media packs, air cleaner assemblies and equipment systems are described. Also methods of use assembly are described.

What is claimed is: 
     
       1. An air cleaner assembly comprising:
 (a) a housing base;
 (i) the housing base including a perimeter wall and an end; the housing base defining an access opening opposite the housing end; 
 (ii) the housing base including an aperture arrangement through the perimeter wall; and, 
 (iii) the housing base having an air flow outlet therein; 
 
 (b) an access cover removably mounted on the housing base and over the access opening;
 (i) the access cover including: an outer cover; a pressure flange; and, a side arrangement extending between the outer cover and the pressure flange; the access cover being positioned on the housing base with the pressure flange projecting into the housing base to a location between the aperture arrangement, through the perimeter wall, and the air flow outlet; and, 
 
 (c) an air filter cartridge operably positioned in the housing; the air filter cartridge comprising;
 (i) a media pack having first and second, opposite, inlet and outlet flow faces;
 (A) the media pack comprising media including fluted media secured to facing media to define inlet and outlet flutes extending in a direction between the first and second, opposite, inlet and outlet flow faces; 
 (B) the media pack being closed to flow of unfiltered air completely therethrough from the first flow through second flow face; and, 
 
 (ii) a housing seal arrangement positioned around the media pack;
 (A) the housing seal arrangement including a portion molded-in-place in contact with a portion of the media; 
 (B) the housing seal arrangement including a pinch flange and defining a receiving gap between a portion of the pinch flange and the media pack; and, 
 (C) the pinch flange defining a non-rectangular perimeter shape; 
 
 
 (c) the housing base including a flange projecting into the receiving gap between the pinch flange of the housing seal arrangement, and the media pack; and, 
 (d) the housing base including a housing base pressure flange portion against which the pinch flange of the housing seal arrangement is pressed by the pressure flange on the access cover;
 (i) the housing base pressure flange portion being positioned such that the aperture arrangement through in perimeter wall of the housing base is located between the access opening and the housing base pressure flange portion. 
 
 
     
     
       2. An air cleaner assembly according to  claim 1  wherein:
 (a) the housing base pressure flange portion includes a bead projection thereon pressed into the pinch flange of the housing seal arrangement. 
 
     
     
       3. An air cleaner assembly according to  claim 1  wherein:
 (a) the pinch flange includes a flat surface directed toward, and pressed against, the housing base pressure flange. 
 
     
     
       4. An air cleaner assembly according to  claim 2  wherein:
 (a) the cartridge includes a protective covering on at least one side of the media pack; and, 
 (b) at least a portion of the flange projecting into the receiving gap projects into a location between a portion of the protective covering and a portion of the pinch flange. 
 
     
     
       5. An air cleaner assembly according to  claim 1  wherein:
 (a) each of the inlet and outlet flow faces of the media pack has a non-circular perimeter definition; and, 
 (b) the pinch flange defines a non-rectangular perimeter shape comprising a plurality of straight sections. 
 
     
     
       6. An air cleaner assembly according to  claim 5  wherein:
 (a) the perimeter definition of each one of the inlet flow face and the outlet flow face is trapezoidal. 
 
     
     
       7. An air cleaner assembly according to  claim 1  wherein:
 (a) the non-rectangular perimeter shape of the pinch flange includes at least 3 straight sections of different lengths. 
 
     
     
       8. An air cleaner assembly according to  claim 7  wherein:
 (a) the non-rectangular perimeter shape of the pinch flange includes 4 straight sections of different lengths. 
 
     
     
       9. An air cleaner assembly according to  claim 1  wherein:
 (a) the first flow face is planar; and, 
 (b) the second flow face is planar. 
 
     
     
       10. An air cleaner assembly according to  claim 1  wherein:
 (a) the housing seal arrangement is recessed from the inlet flow face. 
 
     
     
       11. An air cleaner assembly according to  claim 1  wherein:
 (a) the housing seal arrangement has a constant cross-section in extension around the media pack. 
 
     
     
       12. An air filter cartridge comprising:
 (a) a media pack having first and second, opposite, flow faces;
 (i) the media pack comprising a stack of alternating corrugated filter media and facing filter media, wherein the corrugated filter media includes a plurality of ridges extending in an axial direction of extension between the first and second, opposite, flow faces; 
 (ii) the first flow face comprising a planar flow face with a non-rectangular perimeter shape; 
 (iii) the media pack having a first pair of first and second opposite sides, wherein the first side extends along a direction of the plurality of ridges between the first and second opposite flow faces and having a plane non-parallel to the second opposite side of the media pack; and, 
 (iv) the media pack having a second pair of third and fourth opposite sides, wherein the second pair of third and fourth opposite sides are parallel; and, 
   (b) sealant applied to, and covering, the first side of the first pair of first and second opposite sides.    
     
     
       13. An air filter cartridge according to claim 12 including:
 (a) a housing seal arrangement.    
     
     
       14. An air filter cartridge according to claim 13 wherein:
 (a) the housing seal arrangement includes a pinch flange.    
     
     
       15. An air filter cartridge according to claim 12 wherein:
 (a) the first pair of first and second opposite sides extending between the first flow face and the second flow face engage the first flow face along first and second edges; the first edge having a different length than the second edge; and,   (b) the second pair of third and fourth opposite sides extend between the first and second flow faces and also between the first and second sides; the second pair of third and fourth opposite sides engaging the first flow face along third and fourth edges, wherein the third and fourth edges have a same length.    
     
     
       16. An air filter cartridge according to claim 12 wherein:
 (a) the third side comprises an exposed corrugated filter media surface; and   (b) the fourth side comprises an exposed facing filter media surface.    
     
     
       17. An air filter cartridge according to claim 12 wherein:
 (a) the corrugated filter media comprises a folded sheet.    
     
     
       18. An air filter cartridge according to claim 12 wherein:
 (a) the corrugated filter media comprises the plurality of ridges having radiused curves.    
     
     
       19. An air filter cartridge according to claim 12 wherein:
 (a) the facing filter media comprises a non-corrugated sheet.    
     
     
       20. An air filter cartridge according to claim 12 wherein:
 (a) the facing filter media comprises corrugations, wherein the corrugations of the facing filter media run in a direction perpendicular to the axial direction.    
     
     
       21. An air filter cartridge according to claim 12 including:
 (a) a first side panel having at least 70% of a length of the first side between the first and second flow faces sealed thereto, and,   (b) a second side panel having at least 70% of a length of the second side between the first and second flow faces sealed thereto.    
     
     
       22. An air filter cartridge according to claim 21 wherein:
 (a) the first side panel is a molded-in-place side panel; and,   (b) the second side panel is a molded-in-place side panel.    
     
     
       23. An air filter cartridge according to claim 21 including:
 (a) a molded-in-place perimeter housing seal arrangement extending around the media pack and across the first and second side panels.    
     
     
       24. An air filter cartridge according to claim 22 wherein:
 (a) an entire portion of the first side between the housing seal arrangement and the outlet flow face is embedded in the first side panel; and,   (b) an entire portion of the second side between the housing seal arrangement and the outlet flow face is embedded in the second side panel.    
     
     
       25. An air filter cartridge according to claim 21 wherein:
 (a) the first and second side panels are each recessed from the inlet flow face by a distance within the range of 5 mm to 10 mm.    
     
     
       26. An air filter cartridge according to claim 12 wherein:
 (a) the first side is embedded in a molded-in-place side panel.    
     
     
       27. An air filter cartridge according to claim 12 wherein:
 (a) the filter media pack comprises rows of the plurality of ridges, wherein the rows of the plurality of ridges are separated by the facing media.    
     
     
       28. An air filter cartridge according to claim 27 wherein:
 (a) the rows of the plurality of ridges separated by the facing media form flutes.    
     
     
       29. An air filter cartridge according to claim 28 wherein:
 (a) the flutes comprise inlet flutes open to flow at the first flow face and closed to flow at the second flow face, and outlet flutes closed to flow at the first flow face and open to flow at the second flow face.    
     
     
       30. An air filter cartridge according to claim 38 wherein:
 (a) at least a portion of the flutes comprise tapered flutes.    
     
     
       31. An air filter cartridge according to claim 23 wherein:
 (a) the alternating corrugated filter media and facing filter media are secured to each other at one of the first flow face and the second flow face.    
     
     
       32. An air filter cartridge according to claim 31 wherein:
 (a) the alternating fluted filter media and facing filter media are secured to each other at the one of the first flow face and the second flow face by adhesive.    
     
     
       33. An air filter cartridge according to claim 28 wherein:
 (a) at least a portion of the flutes do not extend a complete distance between the first flow face and the second flow face.    
     
     
       34. An air filter cartridge according to claim 28 wherein:
 (a) at least a portion of the flutes are closed prior to one of the first flow face and the second flow face.    
     
     
       35. An air filter cartridge according to claim 34 wherein:
 (a) the flutes closed prior to one of the first flow face and the second flow face are closed by folding the flutes closed.    
     
     
       36. An air filter cartridge according to claim 27 wherein:
 (a) the rows the plurality of parallel ridges comprises alternating concave ridge and convex ridge.    
     
     
       37. An air filter cartridge according to claim 12 wherein:
 (a) the plane of the first side is generally perpendicular to the first flow face.    
     
     
       38. An air cleaner assembly comprising:
 (a) a housing having an access cover removably mounted thereon; and,   (b) an air filter cartridge operably positioned within the air cleaner housing; the air filter cartridge comprising;
 (i) a media pack having first and second, opposite, flow faces;
 (A) the media pack comprising a stack of alternating corrugated filter media and facing filter media, wherein the corrugated filter media includes a plurality of ridges extending in an axial direction of extension between the first and second, opposite, flow faces; 
 (B) the first flow face comprising a planar flow face with a non-rectangular perimeter shape; 
 (C) the media pack having a first pair of first and second opposite sides, wherein the first side extends along a direction of the plurality of ridges between the first and second opposite flow faces and having a plane non-parallel to the second opposite side of the media pack; and, 
 (D) the media pack having a second pair of third and fourth opposite sides, wherein the second pair of third and fourth opposite sides are parallel; and, 
 
 (ii) sealant applied to, and covering, the first side of the first pair of first and second opposite sides.  
   
     
     
       39. An air cleaner assembly according to claim 38 wherein:
 (a) the media pack has a first pair of opposite sides; and a second pair of opposite sides;
 (i) the first pair of opposite sides comprising first and second sides extending between the first flow face and the second flow face and engaging the first flow face along first and second edges; the first edge having a different length than the second edge; 
 (ii) the second pair of opposite sides comprising third and fourth sides extending between the first and second, opposite, flow faces and also between the first and second sides; the second pair of opposite sides engaging the first flow face along third and fourth edges; 
   (b) the third side comprising an exposed corrugated media sheet surface;   (c) the fourth side comprising an exposed facing media sheet surface; and,   (d) a housing seal arrangement.    
     
     
       40. An air filter cartridge comprising:
 (a) a media pack having first and second, opposite, flow faces;
 (i) the media pack comprises corrugated filter media forming rows of a plurality of ridges extending in an axial direction between the first and second, opposite, flow faces; 
 (ii) the media pack comprising facing filter media located between the corrugated filter media; 
 (iii) the media pack having a first pair of first and second opposite sides, and a second pair of third and fourth opposite sides, wherein the first side extends in the axial direction between the first and second opposite flow faces and having a plane non-parallel to the second opposite side of the media pack, and the second pair of third and fourth opposite sides are parallel; and, 
   (b) sealant applied to, and covering, the first side of the first pair of first and second opposite sides.    
     
     
       41. An air filter cartridge according to claim 40 wherein:
 (a) the plane of the first side is generally perpendicular to the first flow face.    
     
     
       42. An air filter cartridge according to claim 40 wherein:
 (a) the corrugated filter media forming rows of a plurality of ridges and the facing filter media located between the corrugated filter media forming rows of a plurality of ridges form a plurality of flutes extending in a direction from the first flow face to the second flow face.    
     
     
       43. An air filter cartridge according to claim 42 wherein:
 (a) the plurality of flutes comprise inlet flutes open to flow at the first flow face and closed to flow at the second flow face, and outlet flutes closed to flow at the first flow face and open to flow at the second flow face.    
     
     
       44. An air filter cartridge according to claim 40 wherein:
 (a) the first flow face comprising a planar flow face with a non-rectangular perimeter shape.    
     
     
       45. An air filter cartridge according to claim 40 wherein:
 (a) the corrugated filter media comprises a folded sheet.    
     
     
       46. An air filter cartridge according to claim 40 wherein:
 (a) the corrugated filter media forming rows of ridges have radiused curves.    
     
     
       47. An air filter cartridge according to claim 40 wherein:
 (a) the facing filter media comprises a non-corrugated sheet.    
     
     
       48. An air filter cartridge according to claim 40 wherein:
 (a) the facing filter media comprises corrugations, wherein the corrugations of the facing filter media run in a direction perpendicular to the axial direction.    
     
     
       49. An air filter cartridge according to claim 40 wherein:
 (a) the corrugated filter media and the facing filter media are alternating and are secured to each other at the first flow face and the second flow face.    
     
     
       50. An air filter cartridge according to claim 42 wherein:
 (a) at least a portion of the plurality of flutes do not extend a complete distance between the first flow face and the second flow face.    
     
     
       51. An air filter cartridge according to claim 42 wherein:
 (a) at least a portion of the plurality of flutes are closed prior to one of the first flow face and the second flow face.    
     
     
       52. An air filter cartridge according to claim 51 wherein:
 (a) the flutes closed prior to one of the first flow face and the second flow face are closed by folding the flutes closed.    
     
     
       53. An air filter cartridge according to claim 42 wherein:
 (a) at least a portion of the plurality of flutes comprise tapered flutes.    
     
     
       54. An air filter cartridge according to claim 40 wherein:
 (a) the plurality of parallel ridges comprises alternating concave ridge and convex ridge.