Air cleaner; replaceable filter cartridges; and, methods
The disclosure concern air cleaners. Preferred air cleaners are shown which include a housing and a removable and replacement primary filter cartridge. Optional and advantageous features are shown. An optional mechanical interlock, operated with a non-threaded, movement of the cartridge, is provided between the primary filter cartridge and the housing. The preferred primary filter cartridge is conical in shape. A preferred optional safety or secondary filter cartridge is shown. Preferred methods of assembly and use are provided.
1. An air filter cartridge comprising:
(a) first and second, opposite, end caps;
(i) the first end cap comprising a molded-in-place portion having an air flow exit aperture therethrough; and,
(ii) the first end cap having a housing seal member integrally molded with the molded-in-place portion of the first end cap;
(b) pleated filter media extending between the first and second end caps;
(i) the pleated filter media having a tapered outer perimeter in extension between the first and second end caps, with a larger perimeter adjacent the first end cap; and,
(ii) the second end cap comprising a molded-in-place portion having an end of the pleated media embedded therein; and,
(c) a preform comprising:
(i) a portion embedded in the molded-in-place portion of the second end cap;
(ii) an inner portion surrounded by the pleated media and extending toward the first end cap;
(iii) a central portion extending from the inner portion in a direction across the open interior surrounded by the media; and,
(iv) a receiver recess formed by a portion of the preform projecting toward the first end cap from the central portion and the first end cap.
2. An air filter cartridge according to claim 1 wherein:
(a) the preform includes a perforated portion: extending in a direction across an end of the pleated media, adjacent the second end, from the inner portion; and, embedded in the molded-in-place portion of the second end cap.
3. An air filter cartridge according to claim 1 wherein:
(a) the preform includes a conical extension that extends from the first end cap to the second end cap.
4. An air filter cartridge according to claim 2 wherein:
(a) the conical extension of the preform is positioned surrounding the media.
5. An air filter cartridge according to claim 3 including:
(a) an imperforate shield surrounding the media and extending a distance of at least 10% of a distance between the first and second end caps.
6. An air filter cartridge according to claim 5 wherein:
(a) the imperforate shield does not extend over a distance of more than 40% of a distance between the first and second end caps.
7. An air filter cartridge according to claim 5 wherein:
(a) the imperforate shield in positioned adjacent the first end cap.
8. An air filter cartridge according to claim 5 wherein:
(a) the imperforate shield comprises a portion of the preform.
9. An air filter cartridge according to claim 1 wherein:
(a) the receiver recess has a non-circular shape in cross-section in a plane perpendicular to the open filter interior and a direction between the first end cap and the second end cap.
10. An air filter cartridge according to claim 9 wherein:
(a) the receiver recess defines an open receiver facing a direction away from the first end cap.
11. An air filter cartridge according to claim 1 including:
(a) a first member of a non-continuously threaded rotational engagement mechanism positioned adjacent to, and spaced from, the first end cap.
12. An air filter cartridge according to claim 11 wherein:
(a) the first member of a non-continuously threaded rotational engagement mechanism comprises a plurality of spaced, radial, projections surrounding the media.
13. An air filter cartridge according to claim 12 wherein:
(a) the seal member comprises an axial seal member.
14. An air filter cartridge according to claim 1 wherein:
(a) the seal member comprises an axial seal member.
15. An air filter cartridge according to claim 1 wherein:
(a) the molded-in-place portion of the first end cap has a hardness, Shore A, of no greater than 22.
16. An air filter cartridge according to claim 15 wherein:
(a) the molded-in-place portion of the second end cap has a hardness, Shore A, of no greater than 22.
17. An air filter cartridge according to claim 1 wherein:
(a) the filter cartridge includes a liner extending between the first and second end caps at a conical angle of at least 1°.
18. An air filter cartridge according to claim 17 wherein:
(a) the filter cartridge includes a liner extending between the first and second end caps at a conical angle within the range of 1° to 4°.
19. An air filter cartridge comprising:
(a) first and second, opposite, end caps;
(i) the first end cap comprising a molded-in-place portion having an air flow exit aperture therethrough; and,
(ii) the first end cap having a housing seal member integrally molded with the molded-in-place portion of the first end cap;
(b) pleated filter media extending between the first and second end caps;
(i) the pleated filter media having a tapered outer perimeter in extension between the first and second end caps, with a larger perimeter adjacent the first end cap; and,
(ii) the second end cap comprising a molded-in-place portion having an end of the pleated media embedded therein; and,
(c) a preform comprising:
(i) a portion embedded in the molded-in-place portion of the second end cap;
(ii) an inner portion surrounded by the pleated media and projecting toward the first end cap;
(iii) a receiver recess defined by a portion of the preform projecting toward the first end cap; and,
(iv) a liner portion extending at a conical angle from the first end cap to the second end cap;
(v) the preform comprising a single member formed from plastic.
20. An air filter cartridge according to claim 19 wherein:
(a) the liner portion comprises an outer liner.