WO2025240907A1 - Filter elements and assemblies - Google Patents

Abstract

A filter cartridge can include a media pack including media extending between a first end and a second end along a longitudinal axis; an end cap including: a seal member presenting a radially inward or outward facing seal surface, the seal member being formed from a first material and being secured to the media pack; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions at least partially embedded within the first material, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by the first material, the plurality of flexible extensions including an exposed portion that is uncovered by the first material; wherein the seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through the exposed portion of the plurality of flexible extensions.

Description

FILTER ELEMENTS AND ASSEMBLIES

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63/649144. filed May 17, 2024, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to the field of gas filtration, such as for instance air filtration. It relates to the field of filter assemblies comprising a filter element which is arranged in a filter housing in a sealing manner, such that air passing from an inlet of the housing to an outlet of the housing is filtered by the filter element. Preferably the assemblies are used for filtering air that is afterwards directed to an engine of for instance a vehicle.

BACKGROUND

[0003] Filter elements, also named filter cartridges, are used for a wide variety of filtering applications and the fluid to be filtered can be a liquid or a gas, e.g., air.

[0004] Indeed, in many instances, it is desired to filter contaminant material from a fluid stream. For example, airflow streams to engines for motorized vehicles or for power generation equipment, construction equipment or other equipment, gas streams to gas turbine systems and air streams to various combustion furnaces, carry particulate contaminant therein. It is preferred for such systems that contaminant materials be removed from the fluid or at least be reduced.

[0005] Filter elements comprise filter media for removing contaminant materials when the fluid flows through the filter media. Commonly used and commercially available filter media are for example pleated media or fluted media. When the filter media is loaded with dust and/or particles above a certain threshold load, a filter element needs to be replaced. Filter elements are typically installed in the housing in a replaceable manner.

[0006] There is a need in industry for new solutions which allow an easy installation of a correct filter element in a filter housing, especially complex filter housing designs, and which would not allow the installation of a wrong filter element. Complex filter housing designs can for instance be a result of boundary conditions imposed by the geometry and positioning of other vehicle/engine components. SUMMARY

[0007] A filter cartridge can include a media pack including media extending between a first end and a second end along a longitudinal axis; and an end cap operably secured to the media pack first end and including: a seal member presenting a radially inward or outward facing seal surface and an undercut portion radially recessed from the seal surface and located axially closer to the media pack second end in comparison to the seal surface, the seal member being formed from a first material; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material: wherein the seal surface and an exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through a portion of the plurality of flexible extensions. [0008] In some examples, the plurality of flexible extensions define a distal end of the filter cartridge.

[0009] In some examples, each of the plurality of flexible extensions have a distal end that is rounded or chamfered.

[0010] In some examples, each of the plurality of flexible extensions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

[0011] In some examples, the first material is a polyurethane material.

[0012] In some examples, the support structure has a lower coefficient of friction in comparison to the seal member.

[0013] In some examples, the flexible extensions include a first portion extending from the base part and an adjoining second portion extending to a distal end.

[0014] In some examples, the first portions are flexible in a radial direction such that a radial force applied to the second portions will cause the reinforcement members to deflect radially in the direction of the applied force.

[0015] In some examples, the second portions have a greater width or thickness in comparison to the first portions.

[0016] In some examples, each of the second portions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension. [0017] In some examples, the seal surface is located proximate a distal end of the seal member.

[0018] In some examples, the seal surface and the undercut together form an L-shaped surface.

[0019] In some examples, the media is pleated media arranged in a tubular manner to define a central opening around the longitudinal axis.

[0020] In some examples, the seal member is overmolded onto the support structure and media pack.

[0021] In some examples, the seal surface faces in a radially inward direction.

[0022] In some examples, the seal surface faces in a radially outward direction.

[0023] In some examples, the flexible extensions protrude radially from a circumferential surface of the seal member.

[0024] A filter cartridge can include a media pack including media extending between a first end and a second end along a longitudinal axis; and an end cap secured to the media pack and including: a seal member presenting a radially inward or outward facing seal surface, the seal member being formed from a first material; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions at least partially embedded within the first material, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material, the plurality of flexible extensions including an exposed portion that is uncovered by the first material; wherein the seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through the exposed portion of the plurality of flexible extensions.

[0025] In some examples, the plurality of flexible extensions define a distal end of the filter cartridge.

[0026] In some examples, each of the plurality of flexible extensions have a distal end that is rounded or chamfered.

[0027] In some examples, each of the plurality of flexible extensions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

[0028] In some examples, the first material is a polyurethane material.

[0029] In some examples, the support structure has a lower coefficient of friction in comparison to the seal member. [0030] In some examples, the flexible extensions include a first portion extending from the base part and an adjoining second portion extending to a distal end.

[0031] In some examples, the first portions are flexible in a radial direction such that a radial force applied to the second portions will cause the reinforcement members to deflect radially in the direction of the applied force.

[0032] In some examples, the second portions have a greater width or thickness in comparison to the first portions.

[0033] In some examples, each of the second portions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

[0034] In some examples, the seal surface is located proximate a distal end of the seal member.

[0035] In some examples, the seal surface is a portion of an L-shaped surface of the seal member.

[0036] In some examples, the media is pleated media arranged in a tubular manner to define a central opening around the longitudinal axis.

[0037] In some examples, the seal member is overmolded onto the support structure and media pack.

[0038] In some examples, the seal surface faces in a radially inward direction.

[0039] In some examples, the seal surface faces in a radially outward direction.

[0040] In some examples, the flexible extensions protrude radially from a circumferential surface of the seal member.

[0041] A filter cartridge can include a media pack including media extending between a first end and a second end along a longitudinal axis; an end cap secured to the media pack and including: a seal member presenting a radially inward or outward facing seal surface, the seal member being formed from a first material; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material, the plurality of flexible extensions including an exposed portion that is uncovered by the first material and that defines an axial end of the cartridge; wherein the seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through the exposed portion of the plurality of flexible extensions. [0042] An air cleaner can include a housing assembly defining an internal volume and defining an air outlet and air inlet in fluid communication with the internal volume, the housing assembly including an outlet structure defining a first seal surface proximate the air outlet; and a filter cartridge disposed within the internal volume, the filter cartridge including: a media pack including media extending between a first end and a second end along a longitudinal axis; and an end cap operably secured to the media pack first end and including: a seal member presenting a radially inward or outward facing second seal surface and an undercut portion radially recessed from the seal surface and located axially closer to the media pack second end in comparison to the seal surface, the second seal surface being sealed against the first seal surface; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material; wherein the seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through a portion of the plurality of flexible extensions.

[0043] In some examples, the housing assembly defines a plurality of circumferentially aligned, spaced apart pocket structures receiving the support structure flexible extensions.

[0044] In some examples, the second seal surface faces in a radially inward direction and the flexible extensions and plurality of pocket structures are located radially outward from the second seal surface.

[0045] In some examples, the housing assembly includes a plurality of circumferentially spaced rib structures located between the plurality of pockets and arranged to rotationally guide the flexible extensions into the pocket structures.

[0046] In some examples, the outlet structure includes a distal circumferential protrusion that is axially aligned with the seal member undercut portion.

[0047] In some examples, the distal circumferential protrusion includes a ramped surface.

[0048] In some examples, the outlet structure is rotatable with respect to a main body of the housing assembly.

[0049] In some examples, the plurality of pocket structures and the seal surface are provided on the outlet structure.

[0050] The present invention is defined, at least in part, in the appended independent claims. The dependent claims define advantageous embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] These and further aspects of the present disclosure will be explained in greater detail by way of example and with reference to the accompanying drawings in which:

[0052] Figure 1 is a schematic view of a first example of an air cleaner assembly having features in accordance with the present disclosure.

[0053] Figure 2 is a partial cross-sectional side view of the air cleaner assembly shown in Figure 1, taken along the line 2-2 in Figure 1, with a filter cartridge of the air cleaner assembly being in a partially installed state.

[0054] Figure 2A is an enlarged portion of the view of the air cleaner assembly shown in Figure 2, as indicated at 2A in Figure 2.

[0055] Figure 3 is a perspective view of a filter cartridge associated with the air cleaner assembly shown in Figure 1 .

[0056] Figure 4 is a top view of the filter cartridge show n in Figure 3.

[0057] Figure 5 is a bottom view- of the filter cartridge shown in Figure 3.

[0058] Figure 6 is a side view of the filter cartridge shown in Figure 3, that is illustrated with cross-sectional cut-away portions.

[0059] Figure 6A is an enlarged portion of the view of the air filter cartridge shown in Figure 6, as indicated at 6A in Figure 6.

[0060] Figure 7 is a perspective view of a support ring associated with the filter cartridge shown at Figure 3.

[0061] Figure 8 is a side view of the support ring shown at Figure 7.

[0062] Figure 9 is a bottom view' of the support ring show n at Figure 7.

[0063] Figure 10 is a cross-sectional side view of the support ring shown at Figure 7, taken along the line 10-10 in Figure 9.

[0064] Figure 1 1 is a perspective view' of a portion of a housing associated with the air cleaner assembly shown in Figure 1.

[0065] Figure 12 is a top view of the housing portion shown in Figure 11.

[0066] Figure 13 is a cross-sectional side view of the housing portion shown in Figure 11, taken along the line 13-13 in Figure 12.

[0067] Figure 14 is a cross-sectional side view of the housing portion shown in Figure 11, taken along the line 14-14 in Figure 12.

[0068] Figure 15 is a schematic view of a second example of an air cleaner assembly having features in accordance with the present disclosure. [0069] Figure 16 is a cross-sectional side view of the air cleaner assembly shown in Figure 15, taken along the line 16-16 in Figure 15.

[0070] Figure 16A is an enlarged portion of the view of the air cleaner assembly shown in Figure 16, as indicated at 16A in Figure 16.

[0071] Figure 17 is a cross-sectional side view of the air cleaner assembly shown in Figure 15, taken along the line 17-17 in Figure 15.

[0072] Figure 18 is a perspective view of a filter cartridge associated with the air cleaner assembly shown in Figure 15.

[0073] Figure 19 is a top view of the filter cartridge shown in Figure 18.

[0074] Figure 20 is a bottom view of the filter cartridge shown in Figure 18.

[0075] Figure 21 is a side view of the filter cartridge shown in Figure 18, that is illustrated with a cross-sectional cut-away portion.

[0076] Figure 22 is a perspective view of a support ring associated with the filter cartridge shown at Figure 18.

[0077] Figure 23 is a side view of the support ring shown at Figure 22.

[0078] Figure 24 is a top view of the support ring shown at Figure 22.

[0079] Figure 25 is a cross-sectional side view of the support ring shown at Figure 22, taken along the line 25-25 in Figure 24.

[0080] Figure 26 is a side view of a portion of a housing associated with the air cleaner assembly shown in Figure 15.

[0081] Figure 27 is a top view of the housing portion shown in Figure 26.

[0082] Figure 28 is a partial cross-sectional side view of the housing portion shown in

Figure 26, taken along the line 28-28 in Figure 27.

[0083] Figure 29 is a schematic view of a third example of an air cleaner assembly having features in accordance with the present disclosure.

[0084] Figure 30 is a bottom view⁷ of the air cleaner assembly shown in Figure 29.

[0085] Figure 31 is a partial cross-sectional side view- of the air cleaner assembly shown in

Figure 29, taken along the line 31-31 in Figure 29.

[0086] Figure 31 A is an enlarged portion of the view of the air cleaner assembly shown in Figure 31, as indicated at 31 A in Figure 31.

[0087] Figure 32 is a cross-sectional side view' of the air cleaner assembly shown in Figure 29, taken along the line 32-32 in Figures 29 and 30.

[0088] Figure 33 is a perspective view of a filter cartridge associated with the air cleaner assembly shown in Figure 29. [0089] Figure 34 is a top view of the filter cartridge shown in Figure 33.

[0090] Figure 35 is a bottom view of the filter cartridge shown in Figure 33.

[0091] Figure 36 is a side view of the filter cartridge shown in Figure 33, that is illustrated with cross-sectional cut-away portions.

[0092] Figure 37 is a perspective view of a support ring associated with the filter cartridge shown at Figure 33.

[0093] Figure 38 is a side view of the support ring shown at Figure 37.

[0094] Figure 39 is a top view of the support ring shown at Figure 37.

[0095] Figure 40 is a cross-sectional side view' of the support ring shown at Figure 37, taken along the line 40-40 in Figure 39.

[0096] Figure 41 is a perspective view of a portion of a housing associated with the air cleaner assembly shown in Figure 29.

[0097] Figure 42 is a top view' of the housing portion show n in Figure 41.

[0098] Figure 43 is a cross-sectional side view of the housing portion shown in Figure 41, taken along the line 43-43 in Figure 42.

[0099] Figure 44 is a cross-sectional side view of the housing portion shown in Figure 41, taken along the line 44-44 in Figure 42.

[0100] Figures 45 and 46 show⁷ a further example filter cartridge usable with the air cleaner concepts described herein.

[0101] Figures 47 and 48 show a further example filter cartridge usable with the air cleaner concepts described herein.

[0102] Figures 49 and 50 show⁷ a further example filter cartridge usable with the air cleaner concepts described herein.

[0103] Figures 51 to 53 show views of a support structure associated with the filter cartridge shown in Figure 49.

[0104] Figures 54 to 56 show' view's of an alternative housing configuration usable with the filter cartridges disclosed herein.

[0105] Figure 57 shows a partial cross-sectional view of the filter cartridge shown in Figure 49 with a variation in the end cap configuration.

[0106] Figure 58 show s a partial cross-sectional view⁷ of the filter cartridge shown in Figure 49 in an installed state with respect to the air cleaner housing depicted at Figure 54.

[0107] Figure 59 is a fragmentary, schematic, perspective view of a first example media type usable in arrangements according to the present disclosure. [0108] Figure 60 is an enlarged, schematic, cross-sectional view of a portion of the media type depicted in Figure 59.

[0109] Figure 61 includes schematic views of examples of various fluted media definitions, for media of the type of Figures 59 and 60.

[0110] Figure 62 is a schematic view of an example process for manufacturing media of the type of Figures 59-61.

[0111] Figure 63 is a schematic cross-sectional view of an optional end dart for media flutes of the type of Figures 59-62.

[0112] Figure 64 is a schematic perspective view of a coiled filter arrangement usable in a filter cartridge having features in accord with the present disclosure, and made with a strip of media for example in accord with Figure 59.

[0113] Figure 65 is a schematic perspective view of a stacked media pack arrangement usable in a filter arrangement having selected features in accord with the present disclosure and made from a strip of media for example in accord with Figure 59.

[0114] Figure 66 is a schematic flow end view of a filter media pack using an alternate media to the media of Figure 59, and alternately usable in selected filter cartridges in accord with the present disclosure.

[0115] Figure 67 is a schematic opposite flow end view to the view of Figure 66.

[0116] Figure 68 is a schematic cross-sectional view of the media pack of Figures 66 and 67. [0117] Figure 69 is a schematic, fragmentary, cross-sectional view of a further alternate media type usable in a media pack of a filter cartridge having features in accord with the present disclosure.

[0118] Figure 70 is a schematic, fragmentary cross-sectional view of a first variation of the media type of Figure 69.

[0119] Figure 71 is a schematic, fragmentary depiction of another usable fluted sheet/facing sheet combination in accord with the present disclosure.

[0120] Figure 72 is a fragmentary, second schematic view of the type of media in Figure 71 shown in a media pack.

[0121] Figure 73 is a schematic, fragmentary, plan view of still another media variation usable in arrangements according to the present disclosure.

[0122] Figure 74 is a schematic view of another variation of usable media in accord with the present disclosure.

[0123] Figure 75 is a schematic depiction of another usable fluted sheet/facing sheet combination in accord with the present disclosure. [0124] Figure 76 is a perspective view of a portion of the usable fluted sheet/facing sheet combination depicted in Figure 75.

[0125] Figure 77 is a perspective view of another media variation usable in arrangements according to the present disclosure.

[0126] Figure 78 is a schematic, perspective view of a portion of a support section of the filter media of Figure 77, illustrated in a folded configuration but expanded or separated for illustrative purposes.

[0127] Figure 79 is a schematic, cross-sectional view of a portion of the support section of the filter media of Figure 77, illustrated in a folded configuration but expanded or separated for illustrative purposes.

[0128] Figure 80 is a perspective view of another media variation useable in arrangements according to the present disclosure.

[0129] Figure 81 is a schematic depiction of an equipment assembly including an air cleaner according to the present disclosure.

[0130] The drawings of the figures are neither drawn to scale nor proportioned. Generally, identical components are denoted by the same reference numerals in the figures. Further, it is noted that many of the drawings presented herein are generated from computer-aided design (CAD) models that show parts in their nominal, undeformed states. In particular, for assembly views showing a filter cartridge installed within the housing, the seal member is depicted in its relaxed condition even though it would actually be compressed and/or stretched when installed against the outlet tube or other sealing surfaces associated with the air cleaner assembly. For example, in some views the seal member may appear to overlap with or intersect the outlet tube or seal plate geometry' since the seal is shown in its pre-installation state rather than its deformed, installed state. A person having ordinary skill in the art would readily understand that such visual overlaps or intersections in the drawings represent the undeformed components and would interpret the drawings taking into account the compressible and/or stretchable nature of the seal member materials during actual installation and use.

DETAILED DESCRIPTION

[0131] The present disclosure will be described in terms of specific embodiments, which are illustrative of the disclosure and not to be construed as limiting. It will be appreciated by persons skilled in the art that the present disclosure is not limited by what has been particularly shown and/or described and that alternatives or modified embodiments could be developed in the light of the overall teaching of this disclosure. The drawings described are only schematic and are non-limiting.

[0132] Use of the verb '‘to comprise’’, as well as the respective conjugations, does not exclude the presence of elements other than those stated. Use of the article “a”, “an” or “the” preceding an element does not exclude the presence of a plurality of such elements.

[0133] Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the disclosure described herein are capable of operation in other sequences than described or illustrated herein.

[0134] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiments is included in one or more embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may refer to different embodiments or combinations of embodiments. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one ordinary skill in the art from this disclosure, in one or more embodiments.

[0135] As used herein, the term “axially” generally refers to a direction that is parallel to the longitudinal axis X while the term “radially” generally refers to a direction that is orthogonal to the longitudinal axis X. As also used herein, the term “radially inward” generally refers to a direction facing towards the longitudinal axis X while the term “radially outward” generally refers to a direction facing away from the longitudinal axis X.

[0136] Although a number of the drawings presented and discussed below are specifically addressing embodiments of a filter element for filtering air, the present disclosure is not limited thereto.

[0137] In Figure 81, a schematic depiction of an engine equipment arrangement 1360 is depicted. The equipment system 1360, in the example, comprises a vehicle or other equipment 361 having an internal combustion engine arrangement 1362 with a combustion air intake 1363. The equipment arrangement 1360 includes an air cleaner system 1365 having a filter arrangement 1366 therein, typically comprising a serviceable (i.e. removable and replaceable) filter cartndge. The air cleaner system 1365 and filter arrangement 1366 can include any of the below-described air cleaners and filter cartridges, and combinations thereof. Intake air to the system is shown at 1367 directed into the air cleaner assembly 1365 before filtering of unfiltered air through media of the filter cartridge arrangement 1366. At 1368, filtered air is shown being directed into the equipment air intake 1363. At 1370, optional equipment such as turbo system is shown. Of course, alternate equipment systems can be represented by arrangements analogous to those of Figure 81. The equipment system can be for example, an industrial air filter, an air cleaner arrangement used in association with a turbine, etc. The use in association with an internal combustion engine is typical, but not specifically required for many of the principles characterized herein.

[0138]

Air Cleaner Assembly 10 - Figures 1-14

[0139] Figures 1-14 illustrate a first example of the present disclosure in a schematic manner. As shown, an air cleaner 10 is presented including a filter cartridge 100 installable within a housing assembly 200.

[0140] In one aspect, the housing assembly 200 includes a main housing 202 defining an interior volume 202a extending along a longitudinal axis XL The housing assembly 200 is further shown as including a cover assembly 204 installable onto the main housing 202 to cover the sendee opening and enclose the interior volume 202a. In one aspect, the main housing 202 further defines an air outlet 202c while the cover assembly 204 defines an air inlet 204a. In some configurations, the main housing 202 may be provided with an air inlet while the cover assembly 204 may be provided with an air outlet. In some configurations, the main housing 202 includes both an air inlet and an air outlet.

[0141] In one aspect, the filter cartridge 100 includes a filter media or filter media pack 102 extending between a first end cap 104 and a second end cap 106. In the particular example shown, the filter media 102 is pleated media arranged in a tubular manner to define a central opening 102c around an axis X. Other media types and configurations are possible, for example, fluted media, depth media, non-pleated media, coiled media, and/or stacked media, etc. In one aspect, the first end cap 104 is an open end cap and is connected to a first axial end 102a of the filter media 102 in a fluid tight manner. In one aspect, the second end cap 106 is a closed end cap and is connected to a second axial end 102b of the filter media 102 in a fluid tight manner. The first and second end caps 104, 106 can for instance be formed and attached to the filter media 102 by a polyurethane potting process. In one aspect, the end caps 104, 106, are generally annular or circular. The filter media 102 is also shown as being provided with an annular or circular shape with a hollow interior. Other shapes for the end caps 104, 106 and filter media 102 are possible, for example, elliptical shapes, obround, oval or race-track shapes, and/or conical shapes. Further, the filter cartridges presented herein can be provided with inner and/or outer support liners or tubes that help maintain the shape and structural integrity of the filter media. For example, the filter media can be arranged in a tubular manner with a hollow center that defines a central opening, where support tubes or liners can be positioned on the inner and/or outer surfaces of the media. The support structures can be formed from materials that are harder and/or stiffer than the seal materials, such as ABS plastic, to provide the necessary structural support. These support structures can include apertured outer support tubes that extend along the length of the media pack, with some configurations having end walls that support reinforcement members. The support tubes can be either permanently secured to the media pack and/or seal member, or in some cases may be removable and reusable.

[0142] In one aspect, the first end cap 104 has a multi-component construction including a support structure 108 and a resilient part 110. In examples, the support structure 108 is formed from a material that has a higher hardness and/or stiffness in comparison to the resilient part 110. With respect to the materials described herein, materials with a higher hardness typically also happen to have a higher stiffness, and vice versa. For reference, hardness refers to a material’s resistance to permanent deformation or indentation while stiffness refers to a material’s resistance to elastic deformation under load. In some examples, the material used for the support structure 108 has a lower coefficient of friction in comparison to the material used for the resilient part 110. According to preferred embodiments, the support structures 108 are made of a relatively hard material. Preferably, the support structures comprise materials which are from medium hard to hard and up to extra hard. To express and measure the hardness of a material, the known shore-A scale or shore-D scale can be used. In embodiments, the support structures have a hardness either measured on a shore-A scale between 60 and 100, preferably between 70 and 100. more preferably between 80 and 100 or, alternatively, when measured on a shore-D scale between 0 and 100, preferably between 15 and 100, more preferably between 30 and 100. In comparison, in examples, the resilient part 110 can be provided with a hardness of less than 20 on the shore-A scale.

[0143] In some examples, the support structure 108 is secured to the media 102 and the resilient part 110 is secured to the support structure 108. In some examples, the resilient part 110 is secured to the media 102 and the support structure 108 is secured to the resilient part 110. In some examples, both the support structure 108 and the resilient part 110 are secured to the media 102 and to each other. As most easily seen at Figures 7 to 10. the support structure 108 includes an annular extension portion 108a from which a plurality of radially flexible reinforcement members 108b extend in an opposite direction. In one aspect, the reinforcement members 108b are circumferentially spaced apart so as to form a gap 108g therebetween. As shown, each of the reinforcement members 108b includes a first portion 108c, extending from the annular extension portion 108a, and an adjoining second portion 108d, extending to a distal end 108e. In one aspect, the first portions 108c are flexible in a radial direction such that a radial force applied to the second portions 108d will cause the reinforcement members 108b to deflect radially in the direction of the applied force. In one aspect, the second portions 108d have a greater width or thickness in comparison to the first portions such that an outer surface 108f of the second portions 108d is located radially beyond the first portions 108c, as is most easily seen at Figures 9 and 10. The outer surface 108f is also shown as being radially beyond the annular extension portion 108a. In one aspect, a distal end 108e defined by the second portion 108d is rounded or chamfered from lateral side to the opposite lateral side and is also tapered or chamfered such that the distal end 108e is narrower in comparison to a lower portion of the second portion 108d. As discussed later, such features enable for easier insertion of the filter cartridge into the housing 200.

[0144] As most easily seen at Figures 6 and 6A, the support structure 108 is partially embedded within the resilient part 110 such that the annular extension portion 108a and the first portion 108c of the reinforcement members 108b are covered by the resilient part 110 and such that the outer surface 108f of the reinforcement members 108b is exposed and uncovered by the resilient part 110. Referring to Figure 6A, the resilient part 110 is also molded such that an outer surface 1 lOd of the resilient part 110 matches with the outer surface 108f to provide a continuous outer appearance of an extension member formed from portions of both the resilient part and support structure 108. This configuration is most easily viewable at Figure 3. As noted above, the end 102a of the media 102 can also be embedded within the resilient part 110. In one example, the support structure 108 is placed into a mold with the end 102a of the media 102 and the material forming the resilient part 1 10 is poured into the mold and subsequently cured. As noted above, the material for the resilient part can be a polyurethane material. In one aspect, the resilient part 110 is formed with a first radial surface 110a and a second radial surface 110b. In one aspect, the first and second radial surfaces 110a, 110b can be said to form an L-shaped seal surface. In some examples, one or both of the surfaces 110a, 1 10b can be provided with a draft angle to make the demolding process easier during manufacture. In the example shown, the first and second radial surfaces 110a, 110b face in a radially inward direction. In one aspect, the first radial surface 110a is configured as a sealing surface which forms a seal against a portion of the housing assembly 200. As shown, the first radial surface 1 10a is located proximate a distal end 110c of the resilient part 110 and is located radially inward of the second radial surface 110b. Accordingly, the second radial surface 110b can be characterized as being recessed from the first radial surface 110a and/or as being an undercut portion of the seal surface or seal member. In examples, a diameter of the second radial surface 110b is larger than a diameter of the first radial surface 110a by 5 mm (millimeters) to 20 mm, such as between 8 and 15 mm. In one aspect, the distal ends 108e of the reinforcement members 108b extend further than the distal end 110c of the resilient part such that the reinforcement members 108b, and thus the support structure 100, define an axial end of the filter cartridge 100. In one aspect, the first radial surface 110a is located opposite of the outer surface 108f of the reinforcement members 108 such that at least a portion of the first radial surface 110a is coplanar with at least a portion of the outer surface 108f along a plane that is orthogonal to the longitudinal axis XI. Accordingly, any radial inward force exerted on the outer surface 108f will generate a radial inward force on the first radial surface 110a of the resilient part 110.

[0145] In one aspect, and as most easily seen at Figures 2A and 11-14, the main housing 202 is provided with a number of structures configured for interaction with the first end cap 104 of the filter cartridge 100. For example, the main housing 202 is provided with an inner wall structure 206, an outer wall structure 208, and an end wall structure 210 that form a pocket or cavifi' 212 for receiving the end of the first end cap 104. As shown, the inner wall structure 206 includes a first radial portion 206a, extending from the end wall 210 to a first ramped portion 206b. a second radial portion 206c extending from the ramped portion 206b to a second ramped portion 206d. As shown, the first and second ramped portions 206b, 206d extend radially inward towards the longitudinal axis XI as they extend in a direction away from an outlet 202c. As shown, the first and second radial portions 206a, 206c face in a radially outward direction. In one aspect, the outer wall structure 208 is provided with a plurality of circumferentially spaced rib members 208a defining gaps or pocket structures 208b therebetween. In one aspect, the rib members 208a are provided with sloped and/or curved surfaces 208c disposed at an oblique angle to the longitudinal axis XI that interact with the sloped and/or curved surfaces associated with the distal ends 108e of the reinforcement members 108b to rotationally guide the filter cartridge 100. In one aspect, the end wall structure 210 is provided with radial ribs 210a that protrude in an axial direction. The ribs 210a are radially aligned yvith the gaps or pocket structures 208b such that the distal ends 108e of the reinforcement members 108 axially contact the ribs 210a when the filter cartridge 100 is fully installed whereby the reinforcement members 108 extend within the gaps or pocket structures 206b. In one aspect, the second radial portion 206c is recessed radially from the ramped portion 206d such that the second radial portion 206c can be characterized as an undercut portion 206c. Portions 206a and 206c can also be characterized as being undercut with respect to the ramped portion 206d as these portions also have a smaller diameter in comparison to portion 206d and are therefore necessarily recessed with respect to portion 206d. In some examples, the undercut portion 206c has a diameter that is between five to ten percent less than the diameter of the ramped portion 206d. With such a feature, and as explained further below, the resilient part 110 of the end cap 104 must initially expand over the ramped portion 206d and subsequently extend back in a radially inward direction towards the second radial portion 206c once past the ramped portion 206d.

[0146] Installation of the filter cartridge 100 onto the main housing 202 will now be described. In a first step, the filter cartridge 100 is axially displaced towards the mam housing which will result in the distal end 110c of the resilient part 110 initially contacting the ramped surface 206d. With further displacement of the filter cartridge 100, the resilient part 110 will expand radially outward around the ramped surface 206d. As noted above, the reinforcement members 108b are radially flexible and therefore do not overly constrain or prevent the resilient part from expanding about the ramped surface 206d. The distal end 1 10c is provided with a chamfer that can provide for easier installation at this stage. As can be seen at Figure 2A, once the filter cartridge 100 has been displaced sufficiently, the resilient part 110 returns towards its natural state such that the first radial surface 110a is generally against the second radial portion 206c. In the position, a full seal is not formed between these surfaces due to the presence of slots 206e located in the inner wall structure 206. In this position, the filter cartridge 100 cannot be further displaced axially towards the outlet 202c unless the reinforcement members 108b are radially aligned with the gaps 208b defined between the rib members 208a. Otherwise, the distal ends 108e will contact the axial ends of the rib members 208a to prevent further displacement. However, to ease installation of the cartridge, and as mentioned previously, the distal ends 108e and the distal ends of the rib members 208a are provided with sloped or ramped surfaces such that any initial contact between these components will cause a rotation of the cartridge 100 until such alignment is obtained, thereby obviating the need for the installer to radially align the cartridge 100 without the aid of such features. Once such an alignment is achieved, the first radial surface 110a will be engaged against the first radial portion 206a to form a seal between the end cap 104 and the main housing 202. To aid in forming this seal, the outer surfaces 108f of the reinforcement members 108 abut or otherwise contact the outer wall structure 208, in a ’hard-to-hard’ plastic contact, which results in the resilient part 110 being compressed betw een the wall structure 208 and the first radial portion 206a. In some examples, the outer wall structure 208 can include radially inwardly extending protrusions at the location of the reinforcement members 108 that further depress the reinforcement members 108 in a direction towards the inner wall structure 206.

[0147] As previously mentioned, the concepts of the present disclosure are not limited to a single configuration or to a single combination of features. For example, many further possible variations exist beyond what is shown for the example shown at Figures 1-14. To further illustrate some of these variations, Figures 15-45 are presented and described below for air cleaner assemblies 20 and 30. Where similarities exist, it is noted that the above-provided description for the example of Figures 1-14 is applicable to the below examples and need not be repeated below. Rather, the descriptions below will primarily focus on the primary differences among the various configurations and/or where combinations of features are different from other disclosed embodiments. It is also noted that the features described below may also be incorporated into the example shown at Figures 1-14, and vice-versa. In each of the examples presented herein, the features shown as being associated with the main housing 202 may be alternatively provided on the cover portion 204 and vice-versa.

Additional Examples

[0148] Figures 15-28 illustrate a second example air cleaner assembly 20 of the present disclosure in a schematic manner. In comparison to air cleaner assembly 10, air cleaner assembly 20 discloses a filter cartridge 100 having relatively fewer and larger reinforcement members 108b on the support structure 108 and similarly corresponding features on the housing 200. The reinforcement members 108b have a generally continuously curved ends that taper to a narrower thickness in a direction towards their distal ends. Such features allow for easier rotational alignment and installation of the filter cartridge 100 within the housing 200. The support structure 108 in this example is also shown as having radially inwardly extending protrusions or shelf members 108h having apertures for receiving material of the seal member 110 to aid in anchoring the reinforcement members 108b at the location of the second portions 108d. The members 108h can also aid in providing support to the seal member 110. The housing 200 is also provided with a correspondingly shaped wall structure and pocket for receiving the end cap of the filter cartridge 100. As can be seen at Figure 16, the air cleaner assembly 20 is shown as also including a safety filter cartridge 150 having an open end cap sealed to a radial inside surface of the outlet 202c and having a closed end cap at the opposite end. Filter cartridge 150 is also shown as having non-woven media supported by an apertured tube. Although not illustrated, a safety filter cartridge 150 of the type show n in Figure 16 may also be provided with air cleaners 10 and 30. Referring to Figure 28, it can also be seen that the wall structure 206 is provided with an alternative configuration in which two ramped structures or protrusions 206d and recessed surfaces 206c are provided.

[0149] Figures 29-45 illustrate a third example air cleaner assembly 30 of the present disclosure in a schematic manner. In comparison to air cleaner assemblies 10 and 20, air cleaner assembly 30 discloses a filter cartridge 100 having an end cap 104 with an outwardly facing, L-shaped radial sealing surface in which the reinforcement members 108b are located radially inward of the sealing surface 110a. The reinforcement members 108b have a generally continuously curved ends that taper to a narrower thickness in a direction towards their distal ends. The lateral sides of the reinforcement members 108b are also shown as being angled towards each other in a direction towards the distal ends of the reinforcement members 108b. In comparison to other shown embodiments, the reinforcement members 108b protrude out from the resilient part 110 to a less degree in the radial direction. Such features allow for easier rotational alignment and installation of the filter cartridge 100 within the housing 200. The housing 200 is also provided with a correspondingly shaped wall structure and pocket for receiving the end cap of the filter cartridge 100. Further, as can be most easily seen at Figures 42 to 44, the ramped surface or radial protrusion 206d can be provided with a segmented, non- continuous configuration in which a plurality of arc-shaped spaced apart protrusions 206d are provided that are spaced apart by gaps 206d-l. In the example shown, three protrusions 206d and three gaps 206d-l are provided in which the gaps 206d-l have a greater arc length than the protrusions 206d. Other arrangements are possible. For example, the gaps 206d-l could have a combined length that is less than the combined length of the protrusion 206d. More or few er protrusions and gaps 206d, 206d-l may be provided. It is noted that this segmented or interrupted feature may also be provided with the other air cleaners disclosed herein in which the protrusion 206d extends in a radially outward direction without departing from the concepts presented herein. One advantage is providing an interrupted undercut feature is that the required service force to install the filter cartridge 100 can be reduced. Another benefit to interrupting the protrusion 206d, particularly when all of the housing features are formed as one body, is that moldability is improved by reducing the required complexity of the sliders used in the molding process.

[0150] Figures 45 and 46 disclose a further example of an air filter cartridge 100 usable with any of the concepts discussed above with respect to the disclosed air cleaner assemblies. As shown, the resilient part 110 has an outwardly facing radial seal with an L-shape and the reinforcement members of the support structure 108 are located on a radially opposite side more proximate the longitudinal axis of the filter cartridge 100. In one example process, the resilient part 110 is molded and cured in a first operation, and is then placed into a second mold along with the filter media 102. Once so placed, material for the support structure 108 can be poured into the mold such that the support structure 108 is overmolded onto the resilient part 110. Figures 47 and 48 show a similarly constructed air filter cartridge 100, but where the resilient part 110 has an inwardly facing radial seal with an L-shape and the reinforcement members of the support structure 108 are located on a radially opposite side further from the longitudinal axis of the filter cartridge 100.

[0151] Figures 49 and 50 disclose a further example of an air filter cartridge 100 usable with any of the concepts discussed above with respect to the disclosed air cleaner assemblies. In the example shown, the resilient part 110 has an inwardly facing radial seal with an L-shape and the reinforcement members of the support structure 108 are located on a radially opposite side further from the longitudinal axis of the filter cartridge 100. However, the opposite arrangement is also possible. With reference to Figures 51 to 53 it can be most easily seen that the support structure 108 is configured such that the outer and inner surfaces of the support members 108b are flat and oriented to align with a twelve-sided polygonal shape, rather than being slightly rounded to fit closer to the shape of a circle as shown in the previous examples. In the example shown at Figures 49 to 53, the support members 108b surround a cylindrical radial seal surface defined by the resilient part 110. However, it is noted that in this embodiment, in addition to all other disclosed embodiments, that the seal surface defined by the resilient part 110 may have a polygonal shape which may seal to a correspondingly or non- correspondingly shaped housing surface.

[0152] With reference to Figures 54 to 56, an alternative housing configuration is presented wi th features usable with the air cleaners and filter cartridges disclosed herein. In the particular example shown at Figures 54 to 56, the wall structures 206 and 208 are configured for sealing with the air filter cartridge 100 shown at Figures 49 and 50. In contrast to the other air cleaner housings disclosed herein, the wall structures 206, 208, and 210 are provided as a multi-part construction in which the parts are joined together to form a single assembly that is rotatable with respect to the main housing 202. As most easily seen at Figure 56, the separate wall structures 206 and 208 may be joined together via a snap-fit type connection via cooperating protrusions and slots which may be provided on either or both w all structures 206, 208. In the example shown, protrusions 208d are provided on wall structure 208 while slots 206f are provided on wall structure 208. Other joining methods may be used as well, such as adhesives, plastic welding techniques (e.g., ultrasonic welding, spin welding, solvent w elding, etc.) and/or mechanical fasteners. As can be seen most easily at Figure 54, the interconnected wall structures 206. 208 are joined to the wall structure 210 at a tongue and groove type joint and are secured together at a weld joint, such as one that could be performed through a spin welding technique. Other plastic welding techniques, such as those mentioned above, may also be utilized as well other joining methods such as adhesives and mechanical fasteners. In the example shown, the wall structures 206, 208 cooperatively form a groove via surfaces 206g, 208e that receive a protrusion 210b associated with the wall structure 210. As each of the wall structures 206, 208 is effectively sealed to the wall structure 210 with a fused or welded attachment, the potential for undesirable leakage is minimized. Further, providing the wall structures 206, 208, and 210 in separate parts allows for greater ease of manufacturing, such as molding, while also advantageously providing for a degree of modularity to accommodate differently sized and/or shaped housings and outlets.

[0153] Referring to Figures 57 and 58, and alternative configuration for the end cap 104 of the filter cartridge shown in Figures 49, 50, and 54 is presented. As most easily seen at Figure 57, the second radial surface 110b is defined by an additional seal member component I lOe located axially between the seal surface 110a and the end of the seal member 110 more proximate to the closed end cap 106. Accordingly, in this example, the first and second radial surfaces 102a, 102b together form a continuous radial or curved surface. In one aspect, the seal member component I lOe is formed from a relatively softer material in comparison to the material used for the remaining part of the seal member 110 and is readily deformable. With such a configuration, and as shown at Figure 58 in w hich the filter cartridge 100 is shown as being installed within the air cleaner housing body 202, the seal member component I lOe can compress and deform to accommodate the presence of the ramped portion 206d of the inner all structure 206. which forms a radial protrusion in the radially outward direction towards the seal member 1 10. Advantageously, the seal member component l l Od is sufficiently compressible with minimal force and does not compromise or prevent the seal surface 110a from forming a seal with the undercut first radial portion 206a of the inner wall structure 206. In some examples, the seal members 110 described herein are polyurethane seals having a Shore OO hardness between about 50 and 70, such as 55, thereby placing them in the “Soft” category of material hardnesses in the Shore Hardness Scale. In contrast, the material for the seal member component 11 Od can be provided w ith a hardness associated with the “Extra Soft” category of the Shore Hardness Scale. Examples of hardnesses in this category suitable for use with the seal member component 1 lOe have a Shore OO hardness in the range from 0 to 40. Example Media Configurations. Generally

[0154] Any type of filter media can be used as the media for filter cartridge 100, 150 for the above-disclosed filter cartridges 100, 150 as further described herein with relation to Figures 59-80. Further, the media type for media pack 100 may be the same type or a different ty pe of media than that for an associated filter cartridge 150 that may also be present in the air cleaner housing. For example, the media pack 100 may have pleated or fluted type media while another filter cartridge 150 may be provided with fluted or pleated type media, respectively.

[0155] The media can be of a variety of ty pes and configurations, and can be made from using a variety⁷ of materials. For example, pleated media arrangements can be used in cartridges according to the principles of the present disclosure, as discussed below.

[0156] The principles are particularly well adapted for use in situations in which the media is quite deep in extension between the inlet and outlet ends of the cartridge, but alternatives are possible. Also, the principles are often used in cartridges having relatively large crossdimension sizes. With such arrangements, alternate media types to pleated media will often be desired.

[0157] In this section, examples of some media arrangements that are usable with the techniques described herein are provided. It will be understood, however, that a variety⁷ of alternate media types can be used. The choice of media type is generally one of preference for: availability, function in a given situation of application, ease of manufacturability, etc., and the choice is not necessarily specifically related to the overall function of selected ones of various filter cartridge/air cleaner interaction features characterized herein.

A. Media Pack Arrangements Using Filter Media Having Media Ridges (flutes) Secured to Facing Media

[0158] Fluted filter media (media having media ridges) can be used to provide fluid filter constructions in a variety of manners. One well known manner is characterized herein as a z- filter construction. The term "z-filter construction" as used herein, is meant to include (but not be limited) a type of filter construction in which individual ones of corrugated, folded or otherwise formed filter flutes are used to define (typically in combination with facing media) sets of longitudinal, typically parallel, inlet and outlet filter flutes for fluid flow⁷ through the media. Some examples of z-filter media are provided in U.S. patents 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210.469; 6.190.432; 6.350,291; 6.179,890; 6,235,195; Des. 399,944; Des. 428,128; Des. 396,098; Des. 398,046; and Des. 437,401; each of these cited references being incorporated herein by reference.

[0159] One type of z-fdter media, utilizes two specific media components joined together, to form the media construction. The two components are: (1) a fluted (typically corrugated) media sheet or sheet section, and (2) a facing media sheet or sheet section. The facing media sheet is typically non-corrugated, however it can be corrugated, for example perpendicularly to the flute direction as described in PCT Publication WO 2005/077487, incorporated herein by reference.

[0160] The fluted media section and facing media section can comprise separate materials between one another. However, they can also be sections of the single media sheet folded to bring the facing media material into appropriate juxtaposition with the fluted media portion of the media. For example, a single continuous sheet of media formed with alternating fluted and flat sections along the length of the media can be folded upon itself in zig-zag fashion to form a fluted media configuration.

[0161] The fluted (typically corrugated) media sheet and the facing media sheet or sheet section together, are ty pically used to define media having parallel flutes. In some instances, the fluted sheet and facing sheet are separate and then secured together and are then coiled, as a media strip, to form a z-filter media construction. Such arrangements are described, for example, in U.S. 6,235.195 and U.S. 6,179.890, each of which is incorporated herein by reference. In certain other arrangements, some non-coiled sections or strips of fluted (typically corrugated) media secured to facing media, are stacked with one another, to create a filter construction. An example of this is described in Figure 11 of U.S. 5,820,646, incorporated herein by reference.

[0162] Herein, strips of material comprising fluted sheet (sheet of media with ridges) secured to corrugated sheet, which are then assembled into stacks to form media packs, are sometimes referred to as "single facer strips,” “single faced strips,” or as “single facer" or “single faced” media. The terms and variants thereof, are meant to refer to a fact that one face, i.e., a single face, of the fluted (typically corrugated) sheet is faced by the facing sheet, in each strip.

[0163] Typically, coiling of a strip of the fluted sheet/facing sheet (i.e., single facer) combination around itself, to create a coiled media pack, is conducted with the facing sheet directed outwardly. Some techniques for coiling are described in PCT Publication WO 2004/082795, which is incorporated herein by reference. The resulting coiled arrangement generally has, as the outer surface of the media pack, a portion of the facing sheet, as a result. [0164] The term "corrugated" used herein to refer to structure in media, is often used to refer to a flute structure resulting from passing the media between two corrugation rollers, i.e., into a nip or bite between two rollers, each of which has surface features appropriate to cause corrugations in the resulting media, he term "corrugation" is however, not meant to be limited to such flutes, unless it is stated that they result from flutes that are by techniques involving passage of media into a bite between corrugation rollers. The term "corrugated" is meant to apply even if the media is further modified or deformed after corrugation, for example by the folding techniques described in PCT Publication WO 2004/007054 incorporated herein by reference.

[0165] Corrugated media is a specific form of fluted media. Fluted media is media which has individual flutes or ridges (for example formed by corrugating or folding) extending thereacross.

[0166] Serviceable filter element or filter cartridge configurations utilizing z-filter media are sometimes referred to as "straight through flow configurations" or by variants thereof. In general, in this context what is meant is that the serviceable filter elements or cartridges generally have an inlet flow end (or face) and an opposite exit flow end (or face), with flow entering and exiting the filter cartridge in generally the same straight through direction. The term "serviceable" in this context is meant to refer to a media containing filter cartridge that is periodically removed and replaced from a corresponding fluid (e.g. air) cleaner. In some instances, each of the inlet flow end (or face) and outlet flow end (or face) will be generally flat or planar, with the two parallel to one another. However, variations from this, for example non-planar faces, are possible.

[0167] A straight through flow configuration (especially for a coiled or stacked media pack) is, for example, in contrast to serviceable filter cartridges such as cylindrical pleated filter cartridges of the type shown in U.S. 6,039,778, incorporated herein by reference, in which the flow generally makes a substantial turn as its passes into and out of the media. That is, in a U.S. 6,039,778 filter, the flow enters the cylindrical filter cartridge through a cylindrical side, and then turns to exit through an open end of the media (in forward-flow systems). In a ty pical reverse-flow system, the flow enters the serviceable cylindrical cartridge through an open end of the media and then turns to exit through a side of the cylindrical filter media. An example of such a reverse-flow system is shown in U.S. 5,613,992, incorporated by reference herein.

[0168] The term "z-filter media construction" and variants thereof as used herein, without more, is meant to include, but not necessarily be limited to. any or all of: a web of corrugated or otherwise fluted media (media having media ridges) secured adjacent to (facing) media, whether the sheets are separate or part of a single web, with appropriate sealing (closure) to allow for definition of inlet and outlet flutes; and/or a media pack constructed or formed from such media into a three dimensional network of inlet and outlet flutes; and/or, a filter cartridge or construction including such a media pack.

[0169] In Figure 59, an example of media 1001 usable in z-filter media construction is shown. The media 1001 is formed from a fluted, in this instance corrugated, sheet 1003 and a facing sheet 1004. A construction such as media 1001 is referred to herein as a single facer or single faced strip.

[0170] Sometimes, the corrugated fluted or ridged sheet 1003, shown in Figure 59, is of a type generally characterized herein as having a regular, curved, wave pattern of flutes, ridges, or corrugations 1007. The term "wave pattern" in this context, is meant to refer to a flute, ridge or corrugated pattern of alternating troughs 1007b and ridges 1007a. The term "regular" in this context is meant to refer to the fact that the pairs of troughs and ridges (1007b, 1007a) alternate with generally the same repeating corrugation (flute or ridge) shape and size. (Also, typically in a regular configuration each trough 1007b is substantially an inverse ridge for each ridge 1007a.) The term "regular" is thus meant to indicate that the corrugation (or flute) pattern comprises troughs (inverted ridges) and ridges with each pair (comprising an adjacent trough and ridge) repeating, without substantial modification in size and shape of the corrugations along at least 70% of the length of the flutes. The term "substantial" in this context, refers to a modification resulting from a change in the process or form used to create the corrugated or fluted sheet, as opposed to minor variations from the fact that the media sheet 1003 is flexible. With respect to the characterization of a repeating pattern, it is not meant that in any given filter construction, an equal number of ridges and troughs is necessarily present. The media 1001 could be terminated, for example, between a pair comprising a ridge and a trough, or partially along a pair comprising a ridge and a trough. (For example, in Figure 59, the media 1001 depicted in fragmentary has eight complete ridges 1007a and seven complete troughs 1007b.) Also, the opposite flute ends (ends of the troughs and ridges) may vary from one another. Such variations in ends are disregarded in these definitions, unless specifically stated. That is, variations in the ends of flutes are intended to be covered by the above definitions.

[0171] In the context of the characterization of a "curved" wave pattern of corrugations, in certain instances the corrugation pattern is not the result of a folded or creased shape provided to the media, but rather the apex of each ridge 1007a and the bottom of each trough 1007b is formed along a radiused curve. A typical radius for such z-filter media would be at least 0.25 mm and typically would be not more than 3 mm. [0172] An additional characteristic of the particular regular, curved, wave pattern depicted in Figure 59. for the corrugated sheet 1003, is that at approximately a midpoint region 1030 between each trough and each adjacent ridge, along most of the length of the flutes 1007, is located a transition region where the curvature inverts. For example, viewing a back side or face 1003a. in Figure 59, trough 1007b is a concave region, and ridge 1007a is a convex region. Of course, when viewed toward front side or face 1003b, trough 1007b of side 1003a forms a ridge; and ridge 1007a of face 1003a, forms a trough. (In some instances, region 1030 can be a straight segment, instead of a point, with curvature inverting at ends of the region 1030.) [0173] A characteristic of the particular regular, wave pattern fluted (in this instance corrugated) sheet 1003 shown in Figure 59, is that the individual corrugations, ridges or flutes are generally straight, although alternatives are possible. By "straight" in this context, it is meant that through at least 70%, typically at least 80% of the length, the ridges 1007a and troughs (or inverted ridges) 1007b do not change substantially in cross-section. The term "straight" in reference to corrugation pattern shown in Figure 59, in part distinguishes the pattern from the tapered flutes of corrugated media described in Figure 1 of PCT Publication WO 97/40918 and PCT Publication 2003/47722, each of which is incorporated herein by reference. The tapered flutes of Figure 1 of WO 97/40918, for example, would be a curved wave pattern, but not a "regular" pattern, or a pattern of straight flutes, as the terms are used herein.

[0174] Referring to Figure 59 and as referenced above, the media 1001 has first and second opposite edges 1008 and 1009. When the media 1001 is formed into a media pack, in general edge 1009 will form an inlet end or face for the media pack and edge 1008 will form an outlet end or face, although an opposite orientation is possible.

[0175] In the example depicted, the various flutes 1007 extend completely between the opposite edges 1008, 1009, but alternatives are possible. For example, they can extend to a location adjacent or near the edges, but not completely therethrough. Also, they can be stopped and started partway through the media, as for example in the media of U.S. Publication 2014/0208705, incorporated herein by reference.

[0176] When the media is as depicted in Figure 59, adjacent edge 1008 can provided a sealant bead 1010, sealing the corrugated sheet 3 and the facing sheet 1004 together. Bead 1010 will sometimes be referred to as a "single facer" or “single face” bead, or by variants, since it is a bead between the corrugated sheet 1003 and facing sheet 1004, which forms the single facer (single faced) media strip 1001. Sealant bead 1010 seals closed individual flutes 1011 adjacent edge 1008, to passage of air therefrom (or thereto in an opposite flow). [0177] In the media depicted in Figure 59, adjacent edge 1009 is provided seal bead 1014. Seal bead 1014 generally closes flutes 1015 to passage of unfiltered fluid therefrom (or flow therein in an opposite flow), adjacent edge 1009. Bead 1014 would typically be applied as media 1001 is configured into a media pack. If the media pack is made from a stack of strips 1001, bead 1014 will form a seal between a backside 1017 of facing sheet 1004, and side 1018 of the next adjacent corrugated sheet 1003. When the media 1001 is cut in strips and stacked, instead of coiled, bead 1014 is referenced as a "stacking bead." (When bead 1014 is used in a coiled arrangement formed from a long strip of media 1001, it may be referenced as a "winding bead.").

[0178] In alternate types of through-flow media, seal material can be located differently, and added sealant or adhesive can even be avoided. For example, in some instances, the media can be folded to form an end or edge seam, or the media can be sealed closed by alternate techniques such as ultrasound application, etc. Further, even when sealant material is used, it need not be adjacent opposite ends.

[0179] Referring to Figure 59. once the filter media 1001 is incorporated into a media pack, for example by stacking or coiling, it can be operated as follows. First, air in the direction of arrows 1012, would enter open flutes 1011 adjacent end 1009. Due to the closure at end 1008, by bead 1010, the air would pass through the filter media 1001, for example as shown by arrows 1013. It could then exit the media or media pack, by passage through open ends 1015a of the flutes 1015, adjacent end 1008 of the media pack. Of course, operation could be conducted with air flow in the opposite direction.

[0180] For the particular arrangement shown herein in Figure 59, the parallel corrugations 1007a, 1007b are generally straight completely across the media, from edge 1008 to edge 1009. Straight flutes, ridges or corrugations can be deformed or folded at selected locations, especially at ends. Modifications at flute ends for closure are generally disregarded in the above definitions of "regular," "curved" and "wave pattern."

[0181] Z-filter constructions which do not utilize straight, regular curved wave pattern corrugation shapes are known. For example, in Yamada et al., U.S. 5,562.825, corrugation patterns which utilize somewhat semicircular (in cross section) inlet flutes adjacent narrow- V- shaped (with curved sides) exit flutes are shown (see Figures 1 and 3, of Yamada ’825). In Matsumoto, et al., U.S. 5,049,326, circular (in cross-section) or tubular flutes defined by one sheet having half tubes attached to another sheet having half tubes, with flat regions between the resulting parallel, straight, flutes are shown, see Figure 2 of Matsumoto '326. In Ishii, et al. U.S., 4,925,561, (Figure 1) flutes folded to have a rectangular cross section are shown, in which the flutes taper along their lengths. In WO 97/40918 (Figure 1), flutes or parallel corrugations which have a curved, wave patterns (from adjacent curved convex and concave troughs) but which taper along their lengths (and thus are not straight) are shown. Also, in WO 97/40918, flutes which have curved wave patterns, but with different sized ridges and troughs, are shown. Yamada '825, Matsumoto '326, Ishii '561, and WO 97/40918 are incorporated herein by reference. Also, flutes, which are modified in shape to include various ridges, are known.

[0182] In general, the filter media is a relatively flexible material, typically a non-woven fibrous material (of cellulose fibers, synthetic fibers or both) often including a resin therein, sometimes treated with additional materials. Thus, it can be conformed or configured into the various corrugated patterns, without unacceptable media damage. Also, it can be readily coiled or otherwise configured for use, again without unacceptable media damage. Of course, it must be of a nature such that it will maintain the required corrugated configuration, during use.

[0183] Typically, in the corrugation process, an inelastic deformation is caused to the media. This prevents the media from returning to its original shape. However, once the tension is released, the flute or corrugations will tend to spring back, recovering only a portion of the stretch and bending that has occurred. The facing media sheet is sometimes tacked to the fluted media sheet, to inhibit this spring back in the corrugated sheet. Such tacking is shown at 1020. [0184] Also, typically, the media contains a resin. During the corrugation process, the media can be heated to above the glass transition point of the resin. When the resin then cools, it will help to maintain the fluted shapes.

[0185] The media of the corrugated (fluted) sheet 1003, facing sheet 1004, or both, can be provided with a fine fiber material on one or both sides thereof, for example in accordance with U.S. 6.673,136, incorporated herein by reference. In some instances, when such fine fiber material is used, it may be desirable to provide the fine fiber on the upstream side of the material and inside the flutes. When this occurs, air flow , during filtering, will typically be into the edge comprising the stacking bead.

[0186] An issue with respect to z-filter constructions relates to closing of the individual flute ends. Although alternatives are possible, typically a sealant or adhesive is provided, to accomplish the closure. As is apparent from the discussion above, in typical z-filter media especially that which uses straight flutes as opposed to tapered flutes and sealant for flute seals, large sealant surface areas (and volume) at both the upstream end and the downstream end are needed. High quality’ seals at these locations are important to proper operation of the media structure that results. The high sealant volume and area, creates issues with respect to this. [0187] Attention is now directed to Figure 60, in which z-fdter media; i.e., a z-fdter media construction 1040. utilizing a regular, curved, wave pattern corrugated sheet 1043. and a noncorrugated flat sheet 1044, i.e., a single facer strip is schematically depicted. A distance DI, between points 1050 and 1051, defines the extension of flat sheet 1044 in region 1052 underneath a given corrugated flute 1053. A length or distance D2 of the arcuate media for the corrugated flute 1053, over the same distance DI is of course larger than DI. due to the shape of the corrugated flute 1053. For a typical regular-shaped media used in fluted filter applications, the linear length D2 of the media 1053 between points 1050 and 1051 will often be at least 1.2 times DI. Typically, D2 would be within a range of 1.2 to 2.0 times DI, inclusive. One particularly convenient arrangement for air filters has a configuration in which D2 is about 1.25 to 1.35 times DI. Such media has, for example, been used commercially in Donaldson Powercore™ Z-filter arrangements. Another potentially convenient size would be one in which D2 is about 1.4 to 1.6 times DI. Herein the ratio D2/D1 will sometimes be characterized as the flute/flat ratio or media draw for the corrugated media.

[0188] In the corrugated cardboard industry, various standard flutes have been defined. For example, the standard E flute, standard X flute, standard B flute, standard C flute and standard A flute. Figure 61 in combination with Table A below provides definitions of these flutes.

[0189] Donaldson Company, Inc., (DCI) the assignee of the present disclosure, has used variations of the standard A and standard B flutes, in a variety of z-filter arrangements.

TABLE A

Of course, other, standard, flutes definitions from the corrugated box industry are known.

[0190] In general, standard flute configurations from the corrugated box industry can be used to define corrugation shapes or approximate corrugation shapes for corrugated media. Comparisons above between the DCI A flute and DCI B flute, and the corrugation industry standard A and standard B flutes, indicate some convenient variations. [0191] It is noted that alternative flute definitions such as those characterized in U.S. Publication 2009/0127211; U.S. Publication 2008/0282890; and/or U.S. Publication 2010/0032365 can be used, with air cleaner features as characterized herein below. The complete disclosures of each of U.S. 2009/0127211, U.S. 2008/0282890, and U.S. 2010/0032365 are incorporated herein by reference.

[0192] Another media variation comprising fluted media with facing media secured thereto, can be used in arrangements according to the present disclosure, in either a stacked or coiled form, is described in U.S. Publication 2014/0208705, owned by Baldwin Filters, Inc. and incorporated herein by reference.

B, Manufacture of Media Pack Configurations Including the Media of Figures 59-61, see Figures 62-65

[0193] In Figure 62, one example of a manufacturing process for making a media strip (single facer) corresponding to strip 1001 of Figure 59 is shown. In general, a facing sheet 1064 and a fluted (corrugated) sheet 1066 having flutes 1068 are brought together to form a media web 1069, with an adhesive bead located therebetween at 1070. The adhesive bead 1070 will form a single facer bead 1010, see Figure 59. An optional darting process occurs at station 1071 to form center darted section 1072 located mid-web. The z-filter media or Z-media strip 1074 can be cut or slit at 1075 along the bead 1070 to create two pieces or strips 1076, 1077 of z-filter media 1074, each of which has an edge with a strip of sealant (single facer bead) extending between the corrugating and facing sheet. Of course, if the optional darting process is used, the edge with a strip of sealant (single facer bead) would also have a set of flutes darted at this location.

[0194] Techniques for conducting a process as characterized with respect to Figure 62 are described in PCT Publication WO 2004/007054, incorporated herein by reference.

[0195] Still in reference to Figure 62, before the z-filter media 1074 is put through the darting station 1071 and eventually slit at 1075. it must be formed. In the schematic shown in Figure 62, this is done by passing a sheet of filter media 1092 through a pair of corrugation rollers 1094, 1095. In the schematic shown in Figure 62, the sheet of filter media 1092 is unrolled from a roll 1096, wound around tension rollers 1098, and then passed through a nip or bite 1102 between the corrugation rollers 1094, 1095. The corrugation rollers 1094, 1095 have teeth 1104 that will give the general desired shape of the corrugations after the flat sheet 1092 passes through the nip 1102. After passing through the nip 1 102, the sheet 1092 becomes corrugated across the machine direction and is referenced at 1066 as the corrugated sheet. The corrugated sheet 1066 is then secured to facing sheet 1064. (The corrugation process may involve heating the media, in some instances.)

[0196] Still in reference to Figure 62, the process also shows the facing sheet 1064 being routed to the darting process station 1071. The facing sheet 1064 is depicted as being stored on a roll 1106 and then directed to the corrugated sheet 1066 to form the Z-media 1074. The corrugated sheet 1066 and the facing sheet 1064 would typically be secured together by adhesive or by other means (for example, by sonic welding).

[0197] Referring to Figure 62, an adhesive line 1070 is shown used to secure corrugated sheet 1066 and facing sheet 1064 together, as the sealant bead. Alternatively, the sealant bead for forming the facing bead could be applied as shown as 1070a. If the sealant is applied at 1070a, it may be desirable to put a gap in the corrugation roller 1095, and possibly in both corrugation rollers 1094, 1095, to accommodate the bead 1070a.

[0198] Of course, the equipment of Figure 62 can be modified to provide for the tack beads 1020 of Figure 59, if desired.

[0199] The type of corrugation provided to the corrugated media is a matter of choice, and will be dictated by the corrugation or corrugation teeth of the corrugation rollers 1094, 1095. One useful corrugation pattern will be a regular curved wave pattern corrugation, of straight flutes or ridges, as defined herein above. A typical regular curved wave pattern used, would be one in which the distance D2, as defined above, in a corrugated pattern is at least 1.2 times the distance DI as defined above. In example applications, typically D2 = 1.25 to 1.35 times DI, although alternatives are possible. In some instances, the techniques may be applied with curved wave patterns that are not "regular," including, for example, ones that do not use straight flutes. Also, variations from the curved wave patterns shown, are possible.

[0200] As described, the process shown in Figure 62 can be used to create the center darted section 1072. Figure 63 show's, in cross-section, one of the flutes 1068 after darting and slitting. [0201] A fold arrangement 1118 can be seen to form a darted flute 1120 with four creases 1121a, 1121b, 1121c, 1121d. The fold arrangement 1118 includes a flat first layer or portion 1122 that is secured to the facing sheet 1064. A second layer or portion 1124 is shown pressed against the first layer or portion 1122. The second layer or portion 1124 is preferably formed from folding opposite outer ends 1126, 1127 of the first layer or portion 1122.

[0202] Still referring to Figure 63, two of the folds or creases 1121a, 1121b will generally be referred to herein as "upper, inwardly directed" folds or creases. The term "upper" in this context is meant to indicate that the creases lie on an upper portion of the entire fold 1120, when the fold 1120 is viewed in the orientation of Figure 63. The term "inwardly directed" is meant to refer to the fact that the fold line or crease line of each crease 1121a, 1121 b, is directed toward the other.

[0203] In Figure 63, creases 1121c, 1121d, will generally be referred to herein as "lower, outwardly directed" creases. The term "lower" in this context refers to the fact that the creases 1121c, 1121 d are not located on the top as are creases 1121a. 1121b, in the orientation of Figure 63. The term "outwardly directed" is meant to indicate that the fold lines of the creases 1 121c, 1121 d are directed away from one another.

[0204] The terms "upper" and "lower" as used in this context are meant specifically to refer to the fold 1120, when viewed from the orientation of Figure 63. That is, they are not meant to be otherwise indicative of direction when the fold 1120 is oriented in an actual product for use. [0205] Based upon these characterizations and review of Figure 63, it can be seen that a regular fold arrangement 1118 according to Figure 63 in this disclosure is one which includes at least two "upper, inwardly directed, creases." These inwardly directed creases are unique and help provide an overall arrangement in which the folding does not cause a significant encroachment on adjacent flutes.

[0206] A third layer or portion 1128 can also be seen pressed against the second layer or portion 1124. The third layer or portion 1128 is formed by folding from opposite inner ends 1134, 1135 of the third layer 1128.

[0207] Another way of viewing the fold arrangement 1118 is in reference to the geometry of alternating ridges and troughs of the corrugated sheet 1066. The first layer or portion 1122 is formed from an inverted ridge. The second layer or portion 1124 corresponds to a double peak (after inverting the ridge) that is folded toward, and in preferred arrangements, folded against the inverted ridge.

[0208] Techniques for providing the optional dart described in connection with Figure 63, in a preferred manner, are described in PCT Publication WO 2004/007054, incorporated herein by reference. Techniques for coiling the media, with application of the winding bead, are described in PCT Publication WO 2004/082795, and incorporated herein by reference.

[0209] Alternate approaches to darting the fluted ends closed are possible. Such approaches can involve, for example: darting which is not centered in each flute; and rolling, pressing or folding over the various flutes. In general, darting involves folding or otherwise manipulating media adjacent to fluted end, to accomplish a compressed, closed, state.

[0210] Techniques described herein are particularly well adapted for use in media packs that result from a step of coiling a single sheet comprising a corrugated sheet/facing sheet combination, i.e., a "single facer" strip. However, they can also be made into stacked arrangements.

[0211] Coiled media or media pack arrangements can be provided with a variety of peripheral perimeter definitions. In this context the term "peripheral, perimeter definition" and variants thereof, is meant to refer to the outside perimeter shape defined, looking at either the inlet end or the outlet end of the media or media pack. Typical shapes are circular as described in PCT Publication WO 2004/007054. Other usable shapes are obround, some examples of obround being oval shape. In general, oval shapes have opposite curved ends attached by a pair of opposite sides. In some oval shapes, the opposite sides are also curved. In other oval shapes, sometimes called racetrack shapes, the opposite sides are generally straight. Racetrack shapes are described, for example, in PCT Publications WO 2004/007054 and WO 2004/082795. each of which is incorporated herein by reference.

[0212] Another way of describing the peripheral or perimeter shape is by defining the perimeter resulting from taking a cross-section through the media pack in a direction orthogonal to the winding access of the coil.

[0213] Opposite flow ends or flow faces of the media or media pack can be provided with a variety of different definitions. In many arrangements, the ends or end faces are generally flat (planer) and perpendicular to one another. In other arrangements, one or both of the end faces include tapered, for example, stepped, portions which can either be defined to project axially outwardly from an axial end of the side wall of the media pack; or. to project axially inwardly from an end of the side wall of the media pack.

[0214] The flute seals (for example from the single facer bead, winding bead or stacking bead) can be formed from a variety of materials. In various ones of the cited and incorporated references, hot melt or polyurethane seals are described as possible for various applications.

[0215] In Figure 64, a coiled media pack (or coiled media) 1 130 constructed by coiling a single strip of single faced media is depicted, generally. The particular coiled media pack depicted is an oval media pack 1130a, specifically a racetrack shaped media pack 1131. The tail end of the media, at the outside of the media pack 1130 is shown at 113 lx. It will be t pical to terminate that tail end along straight section of the media pack 1130 for convenience and sealing. Typically, a hot melt seal bead or seal bead is positioned along that tail end to ensure sealing. In the media pack 130, the opposite flow' (end) faces are designated at 1132, 1133. One would be an inlet flow end or face, the other an outlet flow end or face.

[0216] In Figure 65. there is (schematically) shown a step of forming stacked z-filter media (or media pack) from strips of z-filter media, each strip being a fluted sheet secured to a facing sheet. Referring to Figure 65, single facer strip 1200 is being shown added to a stack 1201 of strips 1202 analogous to strip 1200. Strip 1200 can be cut from either of strips 1076, 1077, Figure 121 . At 1205 in Figure 65, application of a stacking bead 1206 is shown, between each layer corresponding to a strip 1200, 1202 at an opposite edge from the single facer bead or seal. (Stacking can also be done with each layer being added to the bottom of the stack, as opposed to the top.)

[0217] Referring to Figure 65, each strip 1200, 1202 has front and rear edges 1207, 1208 and opposite side edges 1209a, 1209b. Inlet and outlet flutes of the corrugated sheet/facing sheet combination comprising each strip 1200, 1202 generally extend between the front and rear edges 1207, 1208, and parallel to side edges 1209a, 1209b.

[0218] Still referring to Figure 65. in the media or media pack 1201 being formed, opposite flow faces are indicated at 1210, 1211. The selection of which one of faces 1210, 121 1 is the inlet end face and which is the outlet end face, during filtering, is a matter of choice. In some instances, the stacking bead 1206 is positioned adjacent the upstream or inlet face 1211; in others, the opposite is true. The flow faces 1210, 1211, extend between opposite side faces 1220, 1221.

[0219] The stacked media configuration or pack 1201 shown being formed in Figure 65, is sometimes referred to herein as a "blocked" stacked media pack. The term "blocked" in this context, is an indication that the arrangement is formed to a rectangular block in which all faces are 90° relative to all adjoining wall faces. For example, in some instances, the stack can be created with each strip 1200 being slightly offset from alignment with an adjacent strip, to create a parallelogram or slanted block shape, with the inlet face and outlet face parallel to one another, but not perpendicular to upper and bottom surfaces.

[0220] In some instances, the media or media pack will be referenced as having a parallelogram shape in any cross-section, meaning that any two opposite side faces extend generally parallel to one another.

[0221] It is noted that a blocked, stacked arrangement corresponding to Figure 65 is described in the prior art of U.S. 5,820,646. incorporated herein by reference. It is also noted that stacked arrangements are described in U.S. 5,772,883; U.S. 5,792,247; U.S. 7,351,270; and U.S. Publication 2004/0187689. Each of these latter references is incorporated herein by reference. It is noted that a stacked arrangement shown in U.S. Publication 2005/0130508 is a slanted stacked arrangement.

[0222] It is also noted that, in some instances, more than one stack can be incorporated into a single media pack. Also, in some instances, the stack can be generated with one or more flow faces that have a recess therein, for example, as shown in U.S. 7,625,419 incorporated herein by reference.

C. Selected Media or Media Pack Arrangements Comprising Multiple Spaced Coils of Fluted Media; Figures 66-68

[0223] Alternate types of media arrangements or packs that involve flutes between opposite ends extending between can be used with selected principles according to the present disclosure. An example of such alternate media arrangement or pack is depicted in Figures 66-68. The media of Figures 66-68 is analogous to one depicted and described in DE 202008017059; and as can sometimes found in arrangements available under the mark “IQORON” from Mann & Hummel.

[0224] Referring to Figure 66, the media or media pack is indicated generally at 1250. The media or media pack 1250 comprises a first outer pleated (ridged) media loop 1251 and a second, inner, pleated (ridged) media loop 1252, each with pleat tips (or ridges) extending between opposite flow ends. The view of Figure 66 is toward a media pack (flow) end 1255. The end 1255 depicted, can be an inlet (flow) end or an outlet (flow) end, depending on selected flow direction. For many arrangements, using principles characterized having the media pack 1250 would be configured in a filter cartridge such that end 1255 is an inlet flow end.

[0225] Still referring to Figure 66. the outer pleated (ridged) media loop 1251 is configured in an oval shape, though alternatives are possible. At 1260, a pleat end closure, for example molded in place, is depicted closing ends of the pleats or ridges 1251 at media pack end 1255. [0226] Pleats or ridges 1252 (and the related pleat tips) are positioned surrounded by and spaced from loop 1251, and thus pleated media loop 1252 is also depicted in a somewhat oval configuration. In this instance, ends 1252e of individual pleats or ridges 1252p in a loop 1252 are sealed closed. Also, loop 1252 surrounds a center 1252c that is closed by a center strip 1253 of material, ty pically molded-in-place.

[0227] During filtering, when end 1255 is an inlet flow end, air enters gap 1265 between the two loops of media 1251, 1252. The air then flows either through loop 1251 or loop 1252, as it moves through the media pack 1250, with filtering.

[0228] In the example depicted, loop 1251 is configured slanting inwardly toward loop 1252, in extension away from end 1255. Also, spacers 1266 are shown supporting a centering ring 1267 that surrounds an end of the loop 1252, for structural integrity. [0229] In Figure 67, an end 1256 of the cartridge 1250, opposite end 1255 is viewable. Here, an interior of loop 1252 can be seen, surrounding an open gas flow region 1270. When air is directed through cartridge 1250 in a general direction toward end 1256 and away from end 1255, the portion of the air that passes through loop 1252 will enter central region 1270 and exit therefrom at end 1256. Of course, air that has entered media loop 1251, as shown in Figure 66, during filtering would generally pass around (over) an outer perimeter 1256p of end 1256. [0230] In Figure 68, a schematic cross-sectional view of cartridge 1250 is provided. Selected identified and described features are indicated by like reference numerals.

[0231] It will be understood from a review of Figures 65-68, the above description, that the cartridge 1250 described, is generally a cartridge which has media tips extending in a longitudinal direction between opposite flow ends 1255, 1256.

[0232] In the arrangement of Figures 66-68, the media pack 1250 is depicted with an oval, in particular racetrack, shaped perimeter. It is depicted in this manner since the air filter cartridges, in many examples below, also have an oval or racetrack shaped configuration. However, the principles can be embodied in a variety of alternate peripheral shapes.

D. Other Media Variations, Figures 69-74

[0233] Herein, in Figures 69-74, some schematic, fragmentary, cross-sectional views are provided of still further alternate variations of media types that can be used in selected applications of the principles characterized herein. Certain examples are described in PCT Publication WO 2016/077377, owned by the Assignee of the present disclosure, Donaldson Company, Inc. In general, each of the arrangements of Figures 69-74 represents a media type that can be stacked or coiled into an arrangement that has opposite inlet and outlet flow ends (or faces), with straight through flow.

[0234] In Figure 69, an example media arrangement 1301 from PCT Publication WO 2016/077377 is depicted, in which an embossed sheet 1302 is secured to a non-embossed sheet 1303, then stacked and coiled into a media pack, with seals along opposite edges of the type previously described for Figure 59 herein.

[0235] In Figure 70, an alternate example media pack 1310 from PCT Publication WO 2016/077377 is depicted, in which a first embossed sheet 1311 is secured to a second embossed sheet 1312 and then formed into a stacked or coiled media pack arrangement, having edge seals generally in accordance with Figure 59 herein. [0236] Edge seals can be conducted in either the upstream end or the downstream end, or in some instances, both. Especially when the media is likely to encounter chemical material during filtering, it may be desirable to avoid a typical adhesive or sealant.

[0237] In Figure 71, a cross-section is depicted in which the fluted sheet X has various embossments on it for engagement with the facing sheet Y. Again, these can be separate, or sections of the same media sheet.

[0238] In Figure 72, a schematic depiction of such an arrangement between the fluted sheet X and facing sheet Y is also shown.

[0239] In Figure 73, a still further variation of such a principle is shown between a fluted sheet X and a facing sheet Y. These are meant to help understand how a wide variety of approaches are possible.

[0240] In Figure 74, still another possible variation in fluted sheet X and facing sheet Y is shown.

[0241] In Figures 75 and 76, an example media arrangement 6401 is depicted, in which a fluted sheet 6402 is secured to a facing sheet 6403. The facing sheet 6403 may be a flat sheet. The media arrangement 6401 can then be stacked or coiled into a media pack, with seals along opposite edges of the type previously described for Figure 59 herein. In the embodiment shown, flutes 6404 of fluted sheet 6402 have an undulating ridgeline including a series of peaks 6405 and saddles 6406. The peaks 6405 of adjacent flutes 6404 can be either aligned as shown in Figures 75 and 76. or offset. Further the peak height and/or density can increase, decrease, or remain constant along the length of the flutes 6404. The ratio of the peak flute height to saddle flute height can vary from about 1.5, typically from 1.1 to about 1.

[0242] It is noted that there is no specific requirement that the same media be used for the fluted sheet section and the facing sheet section. A different media can be desirable in each, to obtain different effects. For example, one may be a cellulose media, while the other is a media containing some non-cellulose fiber. They may be provided with different porosity or different structural characteristics, to achieve desired results.

[0243] A variety of materials can be used. For example, the fluted sheet section or the facing sheet section can include a cellulose material, synthetic material, or a mixture thereof. In some embodiments, one of the fluted sheet section and the facing sheet section includes a cellulose material and the other of the fluted sheet section and facing sheet section includes a synthetic material.

[0244] Synthetic matenal(s) can include polymenc fibers, such as polyolefin, polyamide, polyester, polyvinyl chloride, polyvinyl alcohol (of various degrees of hydrolysis), and polyvinyl acetate fibers. Suitable synthetic fibers include, for example, polyethylene terephthalate, polyethylene, polypropylene, nylon, and rayon fibers. Other suitable synthetic fibers include those made from thermoplastic polymers, cellulosic and other fibers coated with thermoplastic polymers, and multi-component fibers in which at least one of the components includes a thermoplastic polymer. Single and multi-component fibers can be manufactured from polyester, polyethylene, polypropylene, and other conventional thermoplastic fibrous materials.

[0245] The examples of Figures 59-75, are meant to indicate generally that a variety alternate media packs can be used in accordance with the principles herein. Attention is also directed to PCT Publication WO 2016/077377, incorporated herein by reference, with respect to the general principles of construction and application of some alternates media types.

E, Additional Media Pack Arrangements Including Pleated Media

With Flutes; Figures 77-80

[0246] Additional examples of alternative types of media arrangements or packs that involve filtration media having flutes extending between opposite ends or flow faces in a straight through flow configuration are depicted in Figures 77-80. The flutes can be considered inlet flutes when they are arranged to receive dirty air via an inlet flow face, and they can be considered outlet flutes when they are arranged to permit filtered air to flow out via an outlet flow face.

[0247] The filtration media 6502 depicted in Figures 77-80, which is analogous to ones depicted in U.S. 8.479,924 and U.S. 9,919,256 assigned to Mann+Hummel GmbH, is illustrated in an arrangement that shows how the filtration media 6502 can be formed into a media pack arrangement 6504.

[0248] The media pack arrangement 6504 can be considered as having relatively long or deep pleats from an inlet flow face 6506 to an outlet flow face 6508, and can also have varying pleat depths as illustrated. As the depth of pleats of a media pack increases, there is a tendency of the filtration media to collapse on each other thereby causing masking. Masking is undesirable because masked filtration media tends to no longer be available for filtration thereby decreasing dust holding capacity' and flow through the media pack, and also potentially increasing pressure drop across the media pack. In order to reduce masking and to help the filtration media retain its shape, support structures are known to be applied to pleated media. In Figures 78 and 79, support sections or spacers 6510 are provided. It should be appreciated that Figures 78 and 79are illustrated in a folded configuration 6512 having pleat folds 6514, but are expanded or separated to show how the filtration media 6502 and the support sections or spacers 6510 can be arranged.

[0249] As illustrated in Figures 78 and 79, the filtration media 6502 extends between a first side 6516 and a second side 6518. Although only one support section 6510 is shown on each pleat face 6520, it should be appreciated that multiple support sections 6510 can be arranged along each pleat face 6520 so that when the filtration media 6502 is arranged into a media pack, as illustrated in Figure 80 as media pack 6604, the volume between each of the support sections 6510 can be considered flutes extending between the inlet flow face 6506 and the outlet flow⁷ face 6508. The support sections 6510 can be arranged on each flow face 6520 so that opposite support sections 6510 contact or engage each other to help maintain the media pack shape while also limiting the amount of filtration media that would be contacted by the support sections 6510, as illustrated in Figure 79. Furthermore, by providing that the support sections 6510 have adhesive properties, the support sections 6510 can be provided so that opposing support sections 6510 can adhere to each other when the filtration media 6502 is arranged into the media pack 6504.

[0250] The support sections 6510 can be arranged in a tapered configuration where support sections 6510 have a cross section at an interior fold 6522 and wherein the cross section increases toward an exterior fold 6524. In this context, the phrase "‘interior fold"’ refers to the side of the media that forms an acute angle, and the phrase “exterior fold⁷’ refers to the side of the media that forms an obtuse angle when the media is arranged into a media pack. Furthermore, the reference to changing the cross section of the support sections 6510 can refer to one or both of the height that the support section extends away from the media to which it is adhered and also to the width along the media to which it is adhered to in a direction toward or away from other support sections across adjacent flutes. Changing the shape of the support sections 6510 can help maintain the shape of the media pack and the resulting flutes, and can help reduce the amount of media that w ould otherwise be contacted by the support sections 6510 if they were not arranged in a tapered configuration. In addition, the support sections 6510 can be arranged in a non-tapered configuration. As illustrated in Figure 79, the support sections 6510 can be provided so that they extend over the exterior folds 6524, although it is not necessary⁷ for the support sections 6510 to extend over the exterior folds. In addition, it is not necessary for the support sections 6510 to extend into the interior folds 6522, although, if desired, the support sections 6510 can be provided so that they extend into the interior folds 6522. [0251] The support sections 6510 can be applied to the filtration media 6502 as adhesive extruded onto the filtration media 6502 where the adhesive forms the support sections 6510. Before the adhesive has a chance to fully cure, the filtration media 6502 can be folded into the media pack arrangement 6504, which may or may not have varying pleat depths. By forming the media pack arrangement 6504 before the adhesive has fully cured, the opposing support sections 6510 can become bonded or adhered to each other thereby forming flutes extending between the inlet flow face 6506 and the outlet flow face 6508.

[0252] It should be appreciated that the filtration media 6502 can be provided with deformation, such as corrugations, extending across the media. The direction of deformation, such as corrugation, can be parallel or perpendicular to the pleat fold direction.

[0253] The filtration media 6602 depicted in Figure 80 is analogous to filtration media depicted in U.S. Publication 2018/0207566, assigned to Champion Laboratories, Inc., as another example of a media pack arrangement 6604 having inlet and outlet flutes in a straight through flow arrangement.

[0254] The filtration media pack arrangement 6604 can be formed by folding the filtration media 6602 to form an inlet flow face 6606 and an outlet flow face 6608. Pleat tips 6610 form the inlet flow face 6606, and pleat tips 6612 form the outlet flow face 6608. Adhesive beads 6616 and 6618, which may be continuous or discontinuous, extend along the filtration media 6602 in multiple lines across the filtration media 6602 from a media first side 6620 to a media second side 6622. The adhesive beads 6616 and 6618 along the media first side 6620 and along the media second side 6620 can be thickened, if desired, and can be arranged to provide an edge seal along the media first side 6620 and the media second side 6622. By providing that the adhesive beads 6616 and 6618 adhere to each other as the filtration media 6602 is folded, inlet flutes 6630 and outlet flutes 6632 can be formed in the straight through media pack arrangement 6604.

[0255] A similar type of filtration media pack arrangement is commercially available under the name Enduracube from Baldwin Filters, Inc. The filtration media pack available under the name Enduracube from Baldwin Filters, Inc. is arranged in a pleated configuration forming inlet flutes and outlet flutes extending between an inlet flow face and an outlet flow face.

F, Still Further Media Types

[0256] Many of the techniques characterized herein will preferably be applied when the media is oriented for filtering between opposite flow ends of the cartridge is media having flutes or pleat tips that extend in a direction between those opposite ends. However, alternatives are possible. The techniques characterized herein with respect to seal arrangement definition can be applied in filter cartridges that have opposite flow ends, with media positioned to filter fluid flow between those ends, even when the media does not include flutes or pleat tips extending in a direction betw een those ends. The media, for example, can be depth media, can be pleated in an alternate direction, or it can be a non-pleated material.

[0257] It is indeed the case, however, that the techniques characterized herein are particularly advantageous for use with cartridges that are relatively deep in extension between flow ends, usually at least 100mm, typically at least 150mm , often at least 200 mm, sometimes at least 250mm, and in some instances 300mm or more, and are configured for large loading volume during use. These types of systems w ill typically be ones in which the media is configured with pleat tips or flutes extending in a direction between opposite flow- ends.

[0258] It is also noted that while the techniques described herein were typically developed for advantageous application and arrangements involving media packs with straight through flow configurations, the techniques can be applied to advantage in other systems. For example, the techniques can be applied when the cartridge comprises media surrounding a central interior, in which the cartridge has an open end. Such arrangements can involve '‘forward flow'” in which air to be filtered enters the central open interior by passage through the media, and the exits through the open end; or, with reverse flow in which air to be filtered enters the open end and then turns and passes through the media. A variety of such arrangements are possible, including pleated media and alternate types of media. Configurations usable would include cylindrical and conical, among others.

Aspects

[0259] The present disclosure includes various aspects that may be claimed in the future. The following aspects are intended to highlight certain features without limiting the scope of protection. It should be understood that any of the following aspects may be claimed in a patent application claiming priority to the present disclosure, either alone or in combination with other aspects. Further, the following aspects may be modified or combined in any suitable manner apparent to one skilled in the art in light of the teachings herein. Features which are described in the context of separate aspects and embodiments of the disclosure may be used together and/or be interchangeable. Similarly, features described in the context of a single embodiment may also be provided separately or in any suitable subcombination. The aspects are numbered for convenience only and should not be construed as requiring a particular order or limiting the scope of what may be claimed. In various aspects, an air cleaner housing and related filter cartridges are provided that include features and components as described in one or more of the following aspects. The aspects may be combined or modified in ways apparent to those skilled in the art based on the teachings herein. While specific materials, dimensions, and configurations are described for certain aspects, these are exemplary only and other materials, dimensions and configurations may be used within the scope of the disclosure.

[0260] Aspect 1: An air filter cartridge including a media pack having media extending between a first end and a second end along a longitudinal axis; and an end cap operably secured to the media pack first end and including: a seal member presenting a radially inward or outward facing seal surface and an undercut portion radially recessed from the seal surface and located axially closer to the media pack second end in comparison to the seal surface, the seal member being formed from a first material; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material; wherein the seal surface and an exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through a portion of the plurality of flexible extensions.

[0261] Aspect 2: The air filter cartridge according to Aspect 1, or any of Aspects 3 to 43, wherein the plurality of flexible extensions define a distal end of the filter cartridge.

[0262] Aspect 3: The air filter cartridge according to any of Aspects 1-2 or 4-43, wherein each of the plurality of flexible extensions have a distal end that is rounded or chamfered.

[0263] Aspect 4: The air filter cartridge according to any of Aspects 1-3 or 5-43, wherein the plurality of flexible extensions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

[0264] Aspect 5: The air filter cartridge according to any of Aspects 1-4 or 6-43, wherein the first material is a polyurethane material.

[0265] Aspect 6: The air filter cartridge according to any of Aspects 1-5 or 7-43, wherein, the support structure has a lower coefficient of friction in comparison to the seal member.

[0266] Aspect 7: The air filter cartridge according to any of Aspects 1-6 or 8-43, wherein the flexible extensions include a first portion extending from the base part and an adjoining second portion extending to a distal end. [0267] Aspect 8: The air filter cartridge according to Aspect 7, or any of Aspects 1 to 6 or 9 to 43, wherein the first portions are flexible in a radial direction such that a radial force applied to the second portions will cause the reinforcement members to deflect radially in the direction of the applied force.

[0268] Aspect 9: The air filter cartridge according to Aspect 7, or any of Aspects 1-6, 8, and 10-43, wherein the second portions have a greater width or thickness in comparison to the first portions.

[0269] Aspect 10: The air filter cartridge according to Aspect 7, or any of Aspects 1-6, 8-9, and 11-43, wherein each of the second portions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

[0270] Aspect 11 : The air filter cartridge according to any of Aspects 1-10 or 12-43, wherein the seal surface is located proximate a distal end of the seal member.

[0271] Aspect 12: The air filter cartridge according to any of Aspects 1-11 or 13-43, wherein the seal surface and the undercut together form an L-shaped cross-section.

[0272] Aspect 13: The air filter cartridge according to any of Aspects 1-12 or 14-43, wherein the media is pleated media arranged in a tubular manner to define a central opening around the longitudinal axis.

[0273] Aspect 14: The air filter cartridge according to any of Aspects 1-13 or 15-43, wherein the seal member is overmolded onto the support structure and media pack.

[0274] Aspect 15: The air filter cartridge according to any of Aspects 1-14 or 16-43, wherein the seal surface faces in a radially inward direction.

[0275] Aspect 16: The air filter cartridge according to any of Aspects 1-14, characterized in that the seal surface faces in a radially outward direction.

[0276] Aspect 17 : The air filter cartridge according to any of Aspects 1 -16 or 18-43, wherein the flexible extensions protrude radially from a circumferential surface of the seal member.

[0277] Aspect 18: An air filter cartridge, characterized in that: the filter cartridge includes a media pack having media extending between a first end and a second end along a longitudinal axis; and an end cap secured to the media pack and including: a seal member presenting a radially inward or outward facing seal surface, the seal member being formed from a first material; and a support structure including a base part and a plurality' of spaced apart, radially flexible extensions at least partially embedded within the first material, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by⁷ and/or embedded within the first material, the plurality' of flexible extensions including an exposed portion that is uncovered by the first material; wherein the seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through the exposed portion of the plurality⁷ of flexible extensions.

[0278] Aspect 19: The air filter cartridge according to Aspect 18, or any of Aspects 1-17 and 20-43, wherein the plurality of flexible extensions define a distal end of the filter cartridge.

[0279] Aspect 20: The air filter cartridge according to any of Aspects 18-19, or any of Aspects 1-17 and 21-43, wherein the plurality of flexible extensions have a distal end that is rounded or chamfered.

[0280] Aspect 21: The air filter cartridge according to any of Aspects 18-20, or any of Aspects 1-17 and 22-43, wherein the plurality of flexible extensions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

[0281] Aspect 22: The air filter cartridge according to any of Aspects 18-21, or any of Aspects 1-17 and 23-43, wherein the first material is a polyurethane material.

[0282] Aspect 23 : The air filter cartridge according to any of Aspects 18-22 or any of Aspects 1-17 and 24-43, wherein the support structure has a lower coefficient of friction in comparison to the seal member.

[0283] Aspect 24: The air filter cartridge according to any of Aspects 18-23 or any of Aspects 1-17 and 24-43, wherein the flexible extensions include a first portion extending from the base part and an adjoining second portion extending to a distal end.

[0284] Aspect 25: The air filter cartridge according to Aspect 24, or any of Aspects 1-23 and

26-43, wherein the first portions are flexible in a radial direction such that a radial force applied to the second portions will cause the reinforcement members to deflect radially in the direction of the applied force.

[0285] Aspect 26: The air filter cartridge according to Aspect 24, or any of Aspects 1-23 and

27-43, wherein the second portions have a greater width or thickness in comparison to the first portions.

[0286] Aspect 27: The air filter cartridge according to Aspect 24, or any of Aspects 1-23 and

28-43, wherein each of the second portions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension. [0287] Aspect 28: The air filter cartridge according to any of Aspects 18-27, or any of Aspects 1-17 and 29-43. wherein the seal surface is located proximate a distal end of the seal member.

[0288] Aspect 29: The air filter cartridge according to any of Aspects 18-28, or any of Aspects 1-17 and 30-43, wherein the seal surface is a portion of an L-shaped surface of the seal member.

[0289] Aspect 30: The air filter cartridge according to any of Aspects 18-29, or any of Aspects 1-17 and 31-43, wherein the media is pleated media arranged in a tubular manner to define a central opening around the longitudinal axis.

[0290] Aspect 31 : The air filter cartridge according to Aspect 18, or any of Aspects 1-17 and 32-43, wherein the seal member is overmolded onto the support structure and media pack.

[0291] Aspect 32: The air filter cartridge according to any of Aspects 18-31, or any of Aspects 1-17 and 33-43, wherein the seal surface faces in a radially inward direction.

[0292] Aspect 33: The air filter cartridge according to any of Aspects 18-31, or any of Aspects 1-17 and 34-43, wherein the seal surface faces in a radially outward direction.

[0293] Aspect 34: The air filter cartridge according to any of Aspects 18-33, or any of Aspects 1-17 and 35-43, wherein the flexible extensions protrude radially from a circumferential surface of the seal member.

[0294] Aspect 35: An air cleaner, characterized in that: the air cleaner includes a housing assembly defining an internal volume and defining an air outlet and air inlet in fluid communication with the internal volume, the housing assembly including an outlet structure defining a first seal surface proximate the air outlet; and a filter cartridge disposed within the internal volume, the filter cartridge including: a media pack including media extending between a first end and a second end along a longitudinal axis; and an end cap operably secured to the media pack first end and including: a seal member formed from a first material and presenting a radially inward or outward facing second seal surface and an undercut portion radially recessed from the second seal surface and located axially closer to the media pack second end in comparison to the second seal surface, the second seal surface being sealed against the first seal surface; and a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material; wherein the second seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through a portion of the plurality of flexible extensions. [0295] Aspect 36: The air cleaner according to Aspect 35. or any of Aspects 1-34 and 37-43, wherein the housing assembly defines a plurality of circumferentially aligned, spaced apart pocket structures receiving the support structure flexible extensions.

[0296] Aspect 37: The air cleaner according to any of Aspects 35-3 , or any of Aspects 1-34 and 38-43, wherein the second seal surface faces in a radially inward direction and the flexible extensions and plurality of pocket structures are located radially outward from the second seal surface.

[0297] Aspect 38: The air cleaner according to any of Aspects 35-37, or any of Aspects 1-34 and 39-43, wherein the housing assembly includes a plurality' of circumferentially spaced rib structures located between the plurality of pockets and arranged to rotationally guide the flexible extensions into the pocket structures.

[0298] Aspect 39: The air cleaner according to any of Aspects 35-38, or any of Aspects 1-34 and 40-43, wherein the outlet structure includes a distal circumferential protrusion that is axially aligned with the seal member undercut portion.

[0299] Aspect 40: The air cleaner according to Aspect 39. or any of Aspects 1-38 and 41-43, wherein the distal circumferential protrusion includes a ramped surface.

[0300] Aspect 41 : The air cleaner according to any of Aspects 35-40, or any of Aspects 1-34 and 41-43, wherein the outlet structure is rotatable with respect to a main body of the housing assembly.

[0301] Aspect 42: The air cleaner according to any of Aspects 35-41. or any of Aspects 1-41 and 43, wherein the plurality of pocket structures and the seal surface are provided on the outlet structure.

[0302] Aspect 43: The air cleaner according to any of Aspects 35 to 42, or any of Aspects 1-42. wherein the circumferential protrusion is configured as a plurality of arc-shaped segments interrupted by gaps therebetween.

Conclusion

[0303] The principles described herein can be applied in a variety of filter assemblies. Examples described in which the principles applied to (air) gas filter assemblies. Examples are described include air filters, for example, air filters used for treating engine intake airflows. The principles can be applied to a variety of alternate gas filtration arrangements, in some instances even with liquid filter assemblies. Again, the principles, techniques, and features described herein can be applied in a variety of systems, and there is no requirement that all of the advantageous features identified be incorporated in an assembly, system or component to obtain some benefit according to the present disclosure.

Claims

What is claimed is:

1 . A filter cartridge comprising: a) a media pack including media extending between a first end and a second end along a longitudinal axis: and b) an end cap operably secured to the media pack first end and including: i) a seal member presenting a radially inward or outward facing seal surface and an undercut portion radially recessed from the seal surface and located axially closer to the media pack second end in comparison to the seal surface, the seal member being formed from a first material: and ii) a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material; iii) wherein the seal surface and an exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through a portion of the plurality of flexible extensions.

2. The filter cartridge of claim 1. wherein the plurality of flexible extensions define a distal end of the filter cartridge.

3. The filter cartridge of claim 1 or 2. wherein each of the plurality of flexible extensions have a distal end that is rounded or chamfered.

4. The filter cartridge of claim 1, or any other preceding claim, wherein each of the plurality' of flexible extensions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

5. The filter cartridge of claim 1, or any other preceding claim, wherein the first material is a polyurethane material.

6. The filter cartridge of claim 1, or any other preceding claim, wherein the support structure has a lower coefficient of friction in comparison to the seal member.

7. The filter cartridge of claim 1, or any other preceding claim, wherein the flexible extensions include a first portion extending from the base part and an adjoining second portion extending to a distal end.

8. The filter cartridge of claim 7, wherein the first portions are flexible in a radial direction such that a radial force applied to the second portions will cause the reinforcement members to deflect radially in the direction of the applied force.

9. The filter cartridge of claim 7, wherein the second portions have a greater width or thickness in comparison to the first portions.

10. The filter cartridge of claim 7, wherein each of the second portions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

11. The filter cartridge of claim 1, or any other preceding claim, wherein the seal surface is located proximate a distal end of the seal member.

12. The filter cartridge of claim 12, or any other preceding claim, wherein the seal surface and the undercut together form an L-shaped cross-section.

13. The filter cartridge of claim 1 , or any other preceding claim, wherein the media is pleated media arranged in a tubular manner to define a central opening around the longitudinal axis.

14. The filter cartridge of claim 1, or any other preceding claim, wherein the seal member is overmolded onto the support structure and media pack.

15. The filter cartridge of claim 1, or any other preceding claim, wherein the seal surface faces in a radiallv inward direction.

16. The filter cartridge of claim 1, or any other preceding claim, wherein the seal surface faces in a radially outward direction.

17. The filter cartridge of claim 1, or any other preceding claim, wherein the flexible extensions protrude radially from a circumferential surface of the seal member.

18. A filter cartridge comprising: a) a media pack including media extending between a first end and a second end along a longitudinal axis; and b) an end cap secured to the media pack and including: i) a seal member presenting a radially inward or outward facing seal surface, the seal member being formed from a first material; and ii) a support structure including a base part and a pl urali ty of spaced apart, radially flexible extensions at least partially embedded within the first material, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material, the plurality of flexible extensions including an exposed portion that is uncovered by the first material; iii) wherein the seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through the exposed portion of the plurality of flexible extensions.

19. The filter cartridge of claim 18, wherein the plurality of flexible extensions define a distal end of the filter cartridge.

20. The filter cartridge of claim 18 or 19, wherein each of the plurality of flexible extensions have a distal end that is rounded or chamfered.

21. The filter cartridge of any of claims 18-20, wherein each of the plurality of flexible extensions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

22. The filter cartridge of any of claims 18-21, wherein the first material is a polyurethane material.

23. The filter cartridge any of claims 18-22, wherein the support structure has a lower coefficient of friction in comparison to the seal member.

24. The filter cartridge of any of claims 18-23, wherein the flexible extensions include a first portion extending from the base part and an adjoining second portion extending to a distal end.

25. The filter cartridge of claim 24, wherein the first portions are flexible in a radial direction such that a radial force applied to the second portions will cause the reinforcement members to deflect radially in the direction of the applied force.

26. The filter cartridge of claim 24, wherein the second portions have a greater width or thickness in comparison to the first portions.

27. The filter cartridge of claim 24, wherein each of the second portions have a distal end that tapers in an axial direction such that a distal end of the flexible extension is narrower in comparison to a lower portion of the flexible extension.

28. The filter cartridge of any of claims 18-27, wherein the seal surface is located proximate a distal end of the seal member.

29. The filter cartridge of claim any of claims 18-28, wherein the seal surface is a portion of an L-shaped surface of the seal member.

30. The filter cartridge of claim any of claims 18-29, wherein the media is pleated media arranged in a tubular manner to define a central opening around the longitudinal axis.

31. The filter cartridge of claim 18, wherein the seal member is overmolded onto the support structure and media pack.

32. The filter cartridge of claim 1, or any other preceding claim, wherein the seal surface faces in a radially inward direction.

33. The filter cartridge of claim 1, or any other preceding claim, wherein the seal surface faces in a radially outward direction.

34. The filter cartridge of claim 1, or any other preceding claim, wherein the flexible extensions protrude radially from a circumferential surface of the seal member.

35. An air cleaner comprising: a) a housing assembly defining an internal volume and defining an air outlet and air inlet in fluid communication with the internal volume, the housing assembly including an outlet structure defining a first seal surface proximate the air outlet; and b) a filter cartridge disposed within the internal volume, the filter cartridge including: i) a media pack including media extending between a first end and a second end along a longitudinal axis; and ii) an end cap operably secured to the media pack first end and including:

A) a seal member formed from a first material and presenting a radially inward or outward facing second seal surface and an undercut portion radially recessed from the second seal surface and located axially closer to the media pack second end in comparison to the second seal surface, the second seal surface being sealed against the first seal surface; and

B) a support structure including a base part and a plurality of spaced apart, radially flexible extensions, the support structure being formed from a second material harder than the first material, wherein at least a portion of the base part is covered by and/or embedded within the first material;

C) wherein the second seal surface and the exposed portion of the flexible extensions are axially aligned such that a plane orthogonal to the longitudinal axis can pass through the seal member and through a portion of the plurality of flexible extensions.

36. The air cleaner of claim 35, wherein the housing assembly defines a plurality of circumferentially aligned, spaced apart pocket structures receiving the support structure flexible extensions.

37. The air cleaner of claim 35 or 36, wherein the second seal surface faces in a radially inward direction and the flexible extensions and plurality of pocket structures are located radially outward from the second seal surface.

38. The air cleaner of any of claims 35-37, wherein the housing assembly includes a plurality of circumferentially spaced rib structures located between the plurality of pockets and arranged to rotationally guide the flexible extensions into the pocket structures.

39. The air cleaner of any of claims 35-38, wherein the outlet structure includes a distal circumferential protrusion that is axially aligned with the seal member undercut portion.

40. The air cleaner of claim 39, wherein the distal circumferential protrusion includes a ramped surface.

41. The air cleaner of claim any of claims 35-40, wherein the outlet structure is rotatable with respect to a main body of the housing assembly.

42. The air cleaner of claim 41, or any other preceding claim, wherein the plurality of pocket structures and the seal surface are provided on the outlet structure.

43. The air cleaner of claim 39, wherein the circumferential protrusion is configured as a plurality of arc-shaped segments interrupted by gaps therebetween.