TECHNICAL FIELD

[0001] The present invention relates to air cleaner filter systems for an internal combustion engine and, more particularly, relates to an air cleaner filter assembly for holding a secondary filter element in a sealing position during vehicle operation.

BACKGROUND ART

[0002] An air cleaner filter system generally includes a filter element used for filtration of induction air of an internal combustion engine and consists of a housing and a cover for access to the filter element accommodated in the interior for maintenance. The filter element may therefore be dismantled and either replaced by a new filter element, overhauled and reused or exchanged with a used but overhauled filter element.

[0003] Conventional air cleaner filter assemblies have a round or oval-shaped primary and secondary air filter elements mounted in an air filter housing by a releasable attachment that passes through the air filter housing and is attached to the engine. The secondary air filter element is nested within the primary air filter element. Air is drawn from the atmosphere, radially through the primary and secondary filter elements and into the cylindrical space within the secondary filter. The filtered air then passes to the engine for mixture with fuel in the combustion chamber of the engine.

[0004] Majority of problems associated with such prior art air cleaner filter assemblies resides in the manner in which the air filter elements are connected with the filter housing. Such prior art air filter assemblies do not provide a simple way of dismantling the air filter elements for maintenance. Also, the secondary air filter element is supported by the primary filter element at the bottom area as the secondary filter element is equal in length to the primary filter element hence side serviceability of the filter elements is not possible. Furthermore, the secondary filter element sealing position is easily disturbed by external vibrations and under relatively large pressure differential conditions resulting in disconnections of the secondary filter element.

[0005] Hence, there is a need in that art to provide a solution to address all the above- mentioned problems. The present invention relates to an air cleaner filter assembly for holding the secondary filter element in a sealing position during vehicle operation and providing easy serviceability of the filter elements in constrained spaces of the housing in the vehicle.

SUMMARY

[0006] The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole. [0007] An object of the present invention is to provide an air cleaner filter assembly that is capable of holding a secondary filter element in a sealing position during vehicle operation and providing easy serviceability of the filter elements in constrained spaces of a filter housing in a vehicle.

[0008] Another object of the present invention is to provide an air cleaner filter assembly that is capable of providing side serviceability of the filter elements and foolproof design of the secondary element assembly under relatively large pressure differential conditions.

[0009] Yet another object of the present invention is to provide an air cleaner filter assembly that is capable of supporting the secondary filter element axially and radially by a primary filter element. [0010] Yet another object of the present invention is to provide an air cleaner filter assembly that is capable of easily and quickly removed and replaced, and is easy to install and permits a great variability in replacement.

[0011] According to first embodiment of the present invention, an air cleaner filter assembly is disclosed which includes a filter housing having an inlet port through which external air is entered and an outlet port through which filtered air is discharged. A primary filter element is positioned inside the filter housing and has a center support pipe arranged in an interior and an end of the primary filter element and radially supporting the primary filter element. The center support pipe comprises a crown projection feature extending axially from a center of the support pipe. A secondary filter element is lesser in height than the primary filter element and has a center pipe with a groove at one end and an end cap at another end. The crown projection feature of the primary filter element is adapted to interlock with the groove of the secondary filter element, and the end cap is attached radially and axially to the center support pipe and the housing, to provide a leak-tight seal and permit side serviceability of the filter elements.

[0012] The end cap is made of a resilient material comprises polyurethane or internally threaded plastic material. The end cap is secured onto an axial end face of the filter housing and radially with the center support pipe such that the secondary filter element is enclosed in the housing therein. The support pipe of the primary and secondary filter elements is composed of a plurality of rodshaped members that are disposed to intersect each other and are integrally coupled to each other. The primary filter element is adapted to support the shorter secondary filter element at the bottom side and hold the secondary filter element in the sealing position during the vehicle operation. The primary filter element comprises a half center support pipe or a full center support pipe for holding the secondary filter element thereby providing easy serviceability of the filter elements in constrained spaces of the filter housing in the vehicle.

[0013] According to second and third embodiments of the present invention, an air cleaner filter assembly is disclosed which includes a filter housing having an inlet port through which external air is entered and an outlet port through which filtered air is discharged. A primary filter element is positioned inside the filter housing and has a center support pipe arranged in an interior and an end of the primary filter element and radially supporting the primary filter element. The center support pipe comprises a circumferential projection feature or a vertical projection feature from an inner circumference of the center support pipe. A secondary filter element is lesser in height than the primary filter element and has a center pipe with an end cap at one end. The circumferential projection feature or the vertical projection feature of the primary filter element is adapted to support the secondary filter element in a sealing position, and the end cap is attached radially and axially to the center support pipe and the housing, to provide a leak-tight seal and permit side serviceability of the filter elements.

[0014] The end cap is made of a resilient material comprises polyurethane or internally threaded plastic material. The end cap is secured onto an axial end face of the filter housing and radially with the center support pipe such that the secondary filter element is enclosed in the housing therein. The support pipe of the primary and secondary filter elements is composed of a plurality of rodshaped members that are disposed to intersect each other and are integrally coupled to each other. The primary filter element is adapted to support with the shorter secondary filter element at the bottom side and hold the secondary filter element in the sealing position during the vehicle operation. The primary filter element comprises a half center support pipe or a full center support pipe for holding the secondary filter element thereby providing easy serviceability of the filter elements in constrained spaces of the filter housing in the vehicle.

BRIEF DESCRIPTION OF DRAWINGS

[0015] The disclosed embodiments may be better understood by referring to the figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.

[0016] FIG. 1 illustrates a perspective view of an air cleaner filter assembly having a primary filter element and a secondary filter element, in accordance with an exemplary embodiment of the present invention.

[0017] FIG. 2 illustrates a perspective view of the primary filter element, in accordance with an exemplary first embodiment of the present invention.

[0018] FIG. 3 illustrates a sectional view of the primary filter element having a half center support pipe, in accordance with an exemplary first embodiment of the present invention.

[0019] FIG. 4 illustrates a perspective view of the half center support pipe having a projection feature, in accordance with an exemplary first embodiment of the present invention.

[0020] FIG. 5 illustrates a sectional view of the shorter secondary filter element having a center pipe, in accordance with an exemplary first embodiment of the present invention.

[0021] FIG. 6 illustrates an assembled sectional view of the primary filter element interlocked with the secondary filter element to provide a leak-tight seal, in accordance with an exemplary first embodiment of the present invention. [0022] FIG. 7 illustrates an exploded view of the primary filter element interlocked with the secondary filter element to provide the leak-tight seal, in accordance with an exemplary first embodiment of the present invention.

[0023] FIG. 8 illustrates a perspective view of a primary filter element of an air cleaner filter assembly, in accordance with an exemplary second embodiment of the present invention.

[0024] FIG. 9 illustrates a sectional view of the primary filter element having a center support pipe, in accordance with an exemplary second embodiment of the present invention.

[0025] FIG. 10 illustrates a perspective view of the center support pipe of the primary filter element showing a vertical projection feature, in accordance with an exemplary second embodiment of the present invention.

[0026] FIG. 11 illustrates a sectional view of the center support pipe of the primary filter element showing the vertical projection feature, in accordance with an exemplary second embodiment of the present invention.

[0027] FIG. 12 illustrates a perspective view of a secondary filter element, in accordance with an exemplary second embodiment of the present invention.

[0028] FIG. 13 illustrates a sectional view of the secondary filter element having a center pipe, in accordance with an exemplary second embodiment of the present invention.

[0029] FIG. 14 illustrates an assembled sectional view of the primary filter element supporting the secondary filter element to provide a leak-tight seal, in accordance with an exemplary second embodiment of the present invention.

[0030] FIG. 15 illustrates an exploded view of the primary filter element supporting the secondary filter element to provide the leak-tight seal, in accordance with an exemplary second embodiment of the present invention.

[0031] FIG. 16 illustrates a perspective view of the center support pipe of the primary filter element showing a circumferential projection feature, in accordance with an exemplary third embodiment of the present invention.

[0032] FIG. 17 illustrates a sectional view of the center support pipe of the primary filter element showing the circumferential projection feature, in accordance with an exemplary third embodiment of the present invention.

[0033] FIG. 18 illustrates an assembled sectional view of the primary filter element supporting the secondary filter element to provide a leak-tight seal, in accordance with an exemplary third embodiment of the present invention.

[0034] FIG. 19 illustrates an exploded view of the primary filter element supporting the secondary filter element to provide the leak-tight seal, in accordance with an exemplary third embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS [0035] The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.

[0036] In the following, numerous specific details are set forth to provide a thorough description of various embodiments. Certain embodiments may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.

[0037] The claimed subject matter has been provided here with reference to one or more features or embodiments. Those skilled in the art will recognize and appreciate that, despite of the detailed nature of the exemplary embodiments provided here; changes and modifications may be applied to said embodiments without limiting or departing from the generally intended scope. These and various other adaptations and combinations of the embodiments provided here are within the scope of the disclosed subject matter as defined by the claims and their full set of equivalents. Like numbers refer to like elements throughout.

[0038] The present invention relates to an air cleaner filter assembly that is capable of holding a secondary filter element in a sealing position during vehicle operation and providing easy serviceability of filter elements in constrained spaces of a filter housing in a vehicle. The air cleaner filter assembly is capable of providing side serviceability of the filter elements and foolproof design of the secondary element assembly under relatively large pressure differential conditions. This present invention is capable of supporting the secondary filter element axially and radially by the primary filter element. The air cleaner filter assembly is capable of easily and quickly removed and replaced, and is easy to install and permits a great variability in replacement.

[0039] Referring to FIG. 1 a perspective view of an air cleaner filter assembly (10, 10a) having a primary filter element (22, 22a) and a secondary filter element (32, 32a) is illustrated, in accordance with an exemplary embodiment of the present invention. Note that in FIGS. 1-16, identical or similar parts or components are generally indicated by identical reference numerals. The filter assembly (10, 10a) generally includes a filter housing (12) having an inlet port (13) through which external air is entered and an outlet port (15) through which filtered air is discharged. The air cleaner filter assembly (10, 10a) further includes the primary filter element (22, 22a) and the secondary filter element (32, 32a) that aligned with the outlet port (15) of the filter housing (12).

[0040] The filter housing (12) is made of any suitable structure configured to house the primary filter element (22, 22a), the secondary filter element (32, 32a), and other air cleaner components, based on design consideration. In a preferred embodiment the primary air filter element (22, 22a) is taller and longer than the secondary air filter element (32, 32a). Furthermore, the primary air filter element (22, 22a) may be longer, wider and/or taller than the secondary air filter element (32, 32a) in the various embodiments of the present invention. The secondary filter element (32, 32a) is interlocked or supporting with the primary filter element (22, 22a) so that air flowing through the inlet port (13) fills the space between the primary filter element (22, 22a) and the cylindrical wall of the housing (12). The air then flows radially through the primary filter element (22, 22a) and the secondary filter element (32, 32a) before flowing through the outlet port (15).

[0041] The housing (12) includes an open, frame-like structure from which the primary filter element (22, 22a) and the secondary filter element (32, 32a) are suspended from above. The term “primary” generally refers to a filter element which conducts majority of the filtering within the air cleaner filter assembly (10, 10a). In this instance by “filtering” refers to filtration of air drawn from the atmosphere, radially through the primary and secondary filter elements (22, 22a) (32, 32a) and into the cylindrical space within the secondary filter element (32, 32a). The filtered air then passes to an engine for mixture with fuel in a combustion chamber of the engine.

[0042] In a preferred embodiment, the air cleaner filter assembly (10, 10a) is intended to be used as a heavy-duty truck air cleaner. However, the present invention is also intended to encompass a wide variety of other embodiments of air cleaners of different sizes, shapes and composition, including air cleaners that are applicable with respect to other types of engines as well as with respect to other devices that require air filtration. The secondary filter element (32, 32a) keeps the outlet of the filter system closed during the replacement of the primary filter element (22, 22a) and side servicing of the primary filter element (22, 22a), preventing any contamination from getting inside while the primary filter element (22, 22a) is being cleaned or replaced.

[0043] Referring to FIG. 2 a perspective view of the primary filter element (22) is illustrated, in accordance with an exemplary first embodiment of the present invention. Note that in FIGS. 2-7, identical or similar parts or components are generally indicated by identical reference numerals. The primary filter element (22) is positioned inside the filter housing (12) and has a center support pipe (24) arranged in an interior of the primary filter element (22) at its end and radially supporting the primary filter element (22). The center support pipe (24) comprises a crown projection feature (26) extending axially from a center of the support pipe (24), as shown in FIG. 3.

[0044] Referring to FIG. 4 a perspective view of the half center support pipe (24) having a crown projection feature (26) is illustrated, in accordance with an exemplary first embodiment of the present invention. The center support pipe (24) of the primary filter element (22) is composed of a plurality of rod-shaped members (42) that are disposed to intersect each other and are integrally coupled to each other. In a preferred embodiment the primary filter element (22) consists of a half center pipe (24) or full center pipe which acts as a part of the housing (12) and the filter element (22), based on design consideration.

[0045] Referring to FIG. 5 a sectional view of the shorter secondary filter element (32) having a center pipe (34) is illustrated, in accordance with an exemplary first embodiment of the present invention. The secondary filter element (32) is lesser in height than the primary filter element (22). The center pipe (34) of the secondary filter element (32) includes a groove (36) at one end and an end cap (38) at its other end. The center pipe (34) of the secondary filter element (32) is composed of a plurality of rod-shaped members (42) that are disposed to intersect each other and are integrally coupled to each other. The end cap (38) is secured onto an axial end face of the filter housing (12) and radially with the center support pipe (24) such that the secondary filter element (32) is enclosed in the housing (12) therein. The half center support pipe (24) of the primary filter element (22) have supporting feature that supports axially and radially to the secondary filter element (32).

[0046] Referring to FIG. 6 an assembled sectional view of the primary filter element (22) interlocked with the secondary filter element (32) to provide a leak-tight seal is illustrated, in accordance with an exemplary first embodiment of the present invention. The crown projection feature (26) of the primary filter element (22) is adapted to interlock with the groove (36) of the secondary filter element (32), and the end cap (38) is attached radially and axially to the center support pipe (24) and the housing (12), to provide a leak-tight seal and permit side serviceability of the filter elements (22, 32). The term “serviceable” in this context is meant to refer to a filter element that is configured to be periodically removed and replaced. The air cleaner filter assembly (10) is side-serviced by removing one filter element and installing another as the secondary filter element (32) is shorter than the primary filter element (22). The secondary filter element (32) helps to protect components of the equipment on which the air cleaner filter assembly (10) is installed, in case of failure of the primary filter element (22).

[0047] FIG. 7 illustrates an exploded view (70) of the primary filter element (22) interlocked with the secondary filter element (32) to provide the leak-tight seal, in accordance with an exemplary first embodiment of the present invention. The primary filter element (22) is adapted to interlock with the shorter secondary filter element (32) at the bottom side and hold the secondary filter element (32) in the sealing position during the vehicle operation. Again as reminder, the primary filter element (22) comprises a half center support pipe or a full center support pipe for holding the secondary filter element (32) thereby providing easy serviceability of the filter elements (22, 32) in constrained spaces of the filter housing (12) in the vehicle. The lock between the crown projection feature (26) and the groove (36) may help to keep the primary filter element (22) interlocked with the secondary filter element (32) in place despite motor-vehicle vibrations, dimensional changes over time, etc.

[0048] In a preferred embodiment, the end cap (38) is made of a resilient material comprises polyurethane or internally threaded plastic material, based on design consideration. The primary filter element (22) includes a counter feature to receive the end cap (38) to get support axially and radially. The primary filter element (22) supports the shorter secondary filter element (32) at the bottom side and hold the secondary filter element (32) in the sealing position during vehicle operation. The filter element center support pipe (24) acts as a poka yoke and supporting feature to the secondary filter element (32) in assembly condition.

[0049] Referring to FIG. 8 a perspective view of a primary filter element (22a) of the air cleaner filter assembly (10a) is illustrated, in accordance with an exemplary second embodiment of the present invention. Note that in FIGS. 8-16, identical or similar parts or components are generally indicated by identical reference numerals. The primary filter element (22a) is positioned inside the filter housing (12) and has a center support pipe (24a) arranged in an interior of the primary filter element (22a) at its end and radially supporting the primary filter element (22a).

[0050] FIG. 9 illustrates a sectional view of the primary filter element (22a) having the center support pipe (24a), in accordance with an exemplary second embodiment of the present invention. The center support pipe (24a) of the primary filter element (22a) is composed of a plurality of rod-shaped members (42a) that are disposed to intersect each other and are integrally coupled to each other. In a preferred embodiment the primary filter element (22a) consists of a half center pipe (24a) or full center pipe which acts as a part of the housing (12) and the filter element (22a), based on design consideration. The half center support pipe (24a) is part of the housing (12) and part of the primary filter element (22a). [0051] Referring to FIG. 10 a perspective view of the center support pipe (24a) of the primary filter element (22a) showing a vertical projection feature (27a) is illustrated, in accordance with an exemplary second embodiment of the present invention. The primary filter element (22a) with full or short center pipe has the vertical projection feature (27a) from an inner circumference of the center support pipe (24a), as shown in FIG. 11 .

[0052] Referring to FIG. 12 a perspective view of a secondary filter element (32a) is illustrated, in accordance with an exemplary second embodiment of the present invention. The secondary filter element (32a) lesser in height than the primary filter element (22a). The secondary filter element (32a) includes a center pipe (34a) with a groove (36a) at one end and an end cap (38a) at its other end. The end cap (38a) is secured onto an axial end face of the filter housing (12) and radially with the center support pipe (24a) such that the secondary filter element (32a) is enclosed in the housing (12) therein. The center pipe (34a) of the secondary filter element (32a) is composed of a plurality of rod-shaped members (42a) which are disposed to intersect each other and are integrally coupled to each other, as shown in FIG. 13. The primary filter element (22a) consists of the half center pipe or full center pipe which have supporting feature from the center pipe (34a), which in turn supports axially and radially to the secondary filter element (32a).

[0053] FIG. 14 illustrates an assembled sectional view of the primary filter element (22a) supporting the secondary filter element (32a) to provide a leak-tight seal, in accordance with an exemplary second embodiment of the present invention. The vertical projection feature (27a) of the primary filter element (22a) is adapted to support the secondary filter element (32a) in a sealing position, and the end cap (38a) is attached radially and axially to the center support pipe (24a) and the housing (12), to provide a leak-tight seal and permit side serviceability of the filter elements (22a, 32a).

[0054] The air cleaner filter assembly (10a) is side-serviced by removing one filter element and installing another as the secondary filter element (32a) is shorter than the primary filter element (22a). The secondary filter element (32a) helps to protect components of equipment on which the air cleaner filter assembly (10a) is installed, in case of failure of the primary filter element (22a). The support between the vertical projection feature (27a) with the secondary filter element (32a) may help to keep the primary filter element (22a) supporting the secondary filter element (32a) in place despite motorvehicle vibrations, dimensional changes over time, etc.

[0055] Referring to FIG. 15 an exploded view (75) of the primary filter element (22a) supporting the secondary filter element (32a) to provide a leak-tight seal is illustrated, in accordance with an exemplary second embodiment of the present invention. The vertical projection feature (27a) of the primary filter element (22a) is adapted to support the shorter secondary filter element (32a) at the bottom side and hold the secondary filter element (32a) in the sealing position during the vehicle operation. The half center support pipe or a full center support pipe holds the secondary filter element (32a) thereby providing easy serviceability of the filter elements (22a, 32a) in constrained spaces of the filter housing (12) in the vehicle.

[0056] Referring to FIG. 16 a perspective view of the center support pipe (24a) of the primary filter element (22a) showing a circumferential projection feature (26a) is illustrated, in accordance with an exemplary third embodiment of the present invention. The primary filter element (22a) with full or short center pipe has the circumferential projection feature (26a) from the inner circumference of the center support pipe (24a), as shown in FIG. 17.

[0057] FIG. 18 illustrates an assembled sectional view of the primary filter element (22a) supporting the secondary filter element (32a) to provide a leak-tight seal, in accordance with an exemplary third embodiment of the present invention. The circumferential projection feature (26a) of the primary filter element (22a) is adapted to support the secondary filter element (32a) in a sealing position, and the end cap (38a) is attached radially and axially to the center support pipe (24a) and the housing (12), to provide a leak-tight seal and permit side serviceability of the filter elements (22a, 32a).

[0058] Referring to FIG. 15 an exploded view (80) of the primary filter element (22a) supporting the secondary filter element (32a) to provide a leak-tight seal is illustrated, in accordance with an exemplary third embodiment of the present invention. The circumferential projection feature (26a) of the primary filter element (22a) is adapted to support the shorter secondary filter element (32a) at the bottom side and hold the secondary filter element (32a) in the sealing position during the vehicle operation. The half center support pipe or a full center support pipe holds the secondary filter element (32a) thereby providing easy serviceability of the filter elements (22a, 32a) in constrained spaces of the filter housing (12) in the vehicle.

[0059] In a preferred embodiment, the end cap (38a) is made of a resilient material comprises polyurethane or internally threaded plastic material, based on design consideration. The primary filter element (22a) includes a counter feature to receive the end cap (38a) to get support axially and radially. The filter element center support pipe (24a) acts as a poka yoke and supporting feature to the secondary filter element (32a) in assembly condition. The side servicing of the filter elements (22a, 32a) is feasible as the secondary filter element (32a) is lesser in length than the primary filter element (22a). The alignment of primary filter element (22a) to center axis is easy and the secondary filter element (32a) sealing position is retained even with vibrations. The fool-proof air cleaner filter assembly (10a) ensures secondary filter element (32a) into sealing possible after assembly. Further, the present air cleaner filter assembly (10, 10a) is simple, cost-effective and user-friendly with high connectivity performance where side serviceability of the filter elements and foolproof design of the secondary filter element positioning is possible. [0060] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

REFERENCE SIGNS LIST

12 - Filter housing

13 - Inlet port

15 - Outlet port

First Embodiment

10 - Air cleaner filter assembly

22 - Primary filter element

24 - Center support pipe

26 - Crown projection feature

32 - Secondary filter element

34 - Center pipe

36 - Groove

38 - End cap

42 - Rod shape member

70 - Exploded view

Second and Third Embodiments

10a - Air cleaner filter assembly

22a - Primary filter element

24a - Center support pipe

26a - Circumferential projection feature

27a - Vertical projection feature

32a - Secondary filter element

34a - Center pipe

36a - Groove

38a - End cap

42a - Rod shape member

75 - Exploded view

80 - Exploded view