Air cleaner; replaceable filter cartridges; and, methods

1. An air filter cartridge comprising:

(a) first and second, opposite, ends;

(i) the first end having an air flow exit aperture therethrough;

(b) a conical extension of filter media, extending between the first and second ends, surrounding an open interior and defining a central cartridge axis;

(c) a first, open, end cap adjacent the first end of the filter cartridge;

(d) a housing seal positioned on the first end cap and including a seal surface directed radially, with respect to the cartridge central axis, to form a removable seal with a portion of an air cleaner, in use; and,

(e) a second, closed, end cap adjacent the second end of the filter cartridge;

(i) the second end cap having a central portion including: an inner surface portion in overlap with the central interior and directed toward the first end cap; and, an outer surface opposite the inner surface portion;

(ii) the second end cap central portion axially projecting inwardly of the filter cartridge to a location surrounded by media and defining an outer surface recess in the outer surface thereof;

(iii) the central portion including a central projection on the outer surface surrounding and defining an inner recess in the inner surface that is open toward the first end cap; and,

(iv) the outer surface recess surrounding the central projection on the outer surface.

2. An air filter cartridge according to claim 1 wherein:

(a) the first, open, end cap includes a molded-in-place portion with the housing seal formed integral therewith.

3. An air filter cartridge according to claim 2 wherein:

(a) the inner recess in the inner surface extends at least 10 mm.

4. An air filter cartridge according to claim 2 wherein:

(a) the central projection on the outer surface has a conical sidewall.

5. An air filter cartridge according to claim 2 wherein:

(a) the second end cap includes a molded-in-place portion in which the second end of the media is embedded.

6. An air filter cartridge according to claim 5 wherein:

(a) the second end cap comprises a preformed central section that includes a portion embedded in the molded-in-place portion.

7. An air filter cartridge according to claim 6 wherein:

(a) the filter cartridge includes a liner extending from the first end cap to the second end cap.

8. An air filter cartridge according to claim 7 wherein:

(a) the preformed central section is integral with the liner.

9. An air filter cartridge according to claim 7 wherein:

(a) the liner is an outer liner.

10. An air filter cartridge according to claim 2 wherein:

(a) the central portion of the second end cap extends inwardly of the filter cartridge a distance of at least 20 mm.

11. An air filter cartridge according to claim 1 wherein:

(a) the media has a conical angle of 1-10°.

12. An air filter cartridge according to claim 1 wherein:

(a) the media has a conical angle of 2-7°.

13. An air filter cartridge according to claim 1 wherein:

(a) (a) the second, closed, end cap includes a preform including:

(i) a central, imperforate, end region; and,

(ii) an outer perforate region embedded in, and closed by, a molded-in-place portion of the second end cap.

14. An air filter cartridge according to claim 1 wherein:

(a) the media is pleated.

15. An air filter cartridge according to claim 1 wherein:

(a) the housing seal is a radially outwardly directed seal.

16. An air filter cartridge according to claim 14 wherein:

(a) the first end cap has a larger outer perimeter cross-dimension than the second end cap.

17. An air cleaner comprising:

(a) a housing having an interior and comprising a body section with an open end closed by a removable access cover; and,

(b) a main filter cartridge operably positioned within the housing interior; the main filter cartridge comprising:

(i) first and second, opposite, ends;

(A) the first end having an air flow exit aperture therethrough;

(ii) a conical extension of filter media, extending between the first and second ends, surrounding an open interior and defining a central cartridge axis;

(iii) a first, open, end cap adjacent the first end of the main filter cartridge;

(iv) a housing seal positioned on the first end cap and including a seal surface directed radially with respect to the cartridge central axis and forming a removable seal with a portion of an air cleaner; and,

(v) a second, closed, end cap adjacent the second end of the filter cartridge;

(A) the second end cap having a central portion including: an inner surface portion in overlap with the central interior and directed toward the first end cap; and, an outer surface opposite the inner surface portion;

(B) the second end cap central portion axially projecting inwardly of the filter cartridge to a location surrounded by media and defining an outer surface recess in the outer surface thereof;

(C) the central portion including a central projection on the outer surface surrounding and defining an inner recess in the inner surface portion that is open toward the first end cap; and,

(D) the outer surface recess surrounding the central projection on the outer surface.

18. An air cleaner according to claim 17 wherein:

(a) the access cover includes a projection extending into the outer surface recess to a location surrounding the central projection on the outer surface.

19. An air cleaner according to claim 17 wherein:

(a) the projection on the access cover extends at least 15 mm into the cartridge; and,

(b) the central projection on the outer surface extends at least 10 mm.

20. An air cleaner according to claim 17 including:

(a) a safety filter cartridge having a conical extension of media and positioned with the media of the safety filter surrounded by the media of the main filter cartridge; the safety filter having an end with a central projection extending into the inner recess of the central projection on the main filter cartridge second end cap.

21. A method of preparing an air filter cartridge for use in an air cleaner assembly; the method comprising steps of:

(a) forming pleated media around an open center and into a conical shape having first and second, opposite, ends;

(i) the first end of the media having a larger outer perimeter size than a second end of the media;

(b) molding a first open end cap onto the first end of the media;

(i) the step of molding a first open end cap including molding a housing seal, with a radially directed housing seal surface, as part of the first end cap; and,

(c) positioning a second end cap on the second end of the media;

(i) the step of positioning including positioning a central preform, with a central closed section, at the second end of the media;

(ii) the step of positioning including molding in place a portion of the second end cap to the first end of the media, with the media embedded therein, while securing the central preform in place; and,

(iii) the step of positioning a central preform at the second end comprises positioning a preform having:

(A) a central portion including: an inner surface portion facing toward the first end of the media; and, an opposite outer surface portion;

(B) a portion extending toward the first end of the media a maximum distance of at least 15 mm; and,

(C) the central portion including a central projection on the outer surface portion extending away from the first end of the media and surrounding an inner recess on the inner surface portion.

22. A method according to claim 21 wherein:

(a) the step of molding a first open end cap is conducted before the step of positioning the second end cap.

23. A method according to claim 21 wherein:

(a) the step of molding a first open end cap is conducted after the step of positioning the second end cap.

24. A method according to claim 21 wherein:

(a) the step of molding the first end cap comprises molding the first end cap from foamed polyurethane; and,

(b) the step of molding in place a portion of the second end cap comprises molding that portion from foamed polyurethane.