Panel type air filter element with integral baffle

• US 20040011010A1
• Filed: 07/18/2002
• Published: 01/22/2004
• Est. Priority Date: 07/18/2002
• Status: Active Grant

• Current Assignee: Kohler Company
• Original Assignee: Kohler Company
• Inventors: Rotter, Terrence M., Bonde, Kevin G., Wehrman, Theodore E.
• Granted Patent: US 6,752,846 B2
• Time in Patent Office: Days
• US Class Current: 55/320
• CPC Class Codes: B01D 2201/313 Means for protecting the filter from the incoming fluid, e.g. shields
• CPC Class Codes: B01D 2271/02 Gaskets, sealings
• CPC Class Codes: B01D 2279/60 for the intake of internal combustion engines or turbines intake systems for vehicles comprising filters F02M35/024
• CPC Class Codes: B01D 46/10 Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 50/20 Combinations of devices covered by groups B01D45/00 and B01D46/00
• CPC Class Codes: F02M 35/0203 by using clamps, catches, locks or the like, e.g. for disposable plug-in filter cartridges
• CPC Class Codes: F02M 35/024 using filters, e.g. moistened F02M35/026 takes precedence; cleaning of the filtering material F02M35/08

Abstract

An air filter and corresponding filter element for use in an internal combustion engine are disclosed. The filter element has a seal bead made of an elastomeric material that forms the frame of the filter element. A pleat block, made of a filter media, is molded into the seal bead in a first area of the filter element and a baffle is located in a second area of the filter element to protect the pleat block from wetting. A channel is formed in one side of the seal bead which allows the filter element to be retained during assembly without the use of fasteners and a surface is formed opposite the seal bead that in conjunction with the channel seals the filter element within the air filter when the air filter is fully assembled. The air filter has an intake silencing chamber that is located to receive outside air before it is provided to the pleat block and a sealed flow path is created from the intake silencing chamber to the pleat block by a third area of the filter element.

Claims

1. A filter element for use in an internal combustion engine, comprising:

a) a seal bead defining an outer perimeter of the filter element and at least two inner areas within the outer perimeter;

b) filter media disposed within one of the at least two inner areas; and

c) a baffle disposed within another of the at least two inner areas.

2. A filter element, as recited in claim 1, wherein the filter media is a pleat block.

3. A filter element, as recited in claim 1, further comprising a stiffening member disposed within the same inner area as the filter media.

4. A filter element, as recited in claim 3, wherein the stiffening member is a screen.

5. A filter element, as recited in claim 1, wherein the seal bead defines a third inner area within the outer perimeter.

6. A filter element, as recited in claim 5, wherein the third inner area is substantially clear of obstructions and creates a sealed flow path for unfiltered air.

7. A filter element, as recited in claim 1, wherein the filter media is molded into the seal bead.

8. A filter element, as recited in claim 1, wherein the baffle is formed as an integral part of the seal bead.

9. A filter element, as recited in claim 1, wherein the baffle is molded into the seal bead.

10. A filter element, as recited in claim 1, wherein a channel is formed in a first side of at least a portion of the seal bead for receiving a sealing rib of a filter housing and retaining the filter element.

11. A filter element for use in an internal combustion engine, comprising:

a) a seal bead defining an outer perimeter of the filter element and at least three inner areas within the outer perimeter, wherein a channel is formed in a first side of at least a portion of the seal bead for receiving a sealing rib of a filter housing and retaining the filter element;

b) a pleat block molded into the seal bead within one of the at least three inner areas;

c) a screen molded into the seal bead within the same inner area as the pleat block;

d) a baffle molded into the seal bead within another of the at least three inner areas; and

wherein

e) the inner area not having disposed therein the pleat block or the baffle is substantially clear of obstructions and creates a sealed flow path for unfiltered air.

12. An air filter assembly for an internal combustion engine, comprising:

a) an air filter housing having a base and a cover, the air filter housing defining an air flow path from an air inlet to a carburetor inlet;

b) a first sealing rib formed on the base;

c) a second sealing rib formed on the cover;

d) a filter element, disposed within the air filter housing, including a seal bead defining an outer perimeter of the filter element, which engages the first sealing rib and the second sealing rib to seal the air flow path in the air filter housing, and further defining at least two inner areas within the outer perimeter;

e) filter media disposed within on of the at least two inner areas; and

f) a baffle, disposed within another of the at least two inner areas, facing the carburetor inlet.

13. An air filter assembly, as recited in claim 12, wherein the filter media is a pleat block.

14. An air filter assembly, as recited in claim 12, further comprising a stiffening member disposed within the same inner area as the filter media.

15. An air filter assembly, as recited in claim 14, wherein the stiffening member is a screen.

16. An air filter assembly, as recited in claim 12, wherein the filter media is molded into the seal bead.

17. An air filter assembly, as recited in claim 12, wherein the baffle is formed as an integral part of the seal bead.

18. An air filter assembly, as recited in claim 12, wherein the baffle is molded into the seal bead.

19. An air filter assembly, as recited in claim 12, wherein a channel is formed in a first side of at least a portion of the seal bead for receiving the first sealing rib and retaining the filter element.

20. An air filter assembly, as recited in claim 12, wherein the seal bead defines a third inner area within the outer perimeter.

21. An air filter assembly, as recited in claim 20, wherein the third inner area is substantially clear of obstructions and creates a sealed flow path for unfiltered air.

22. An air filter assembly, as recited in claim 12, wherein the air filter housing includes an intake silencing chamber within the air flow path and upstream of the filter media.

23. An air filter assembly, as recited in claim 20, wherein:

a) the air filter housing includes an intake silencing chamber within the airflow path and upstream of the filter media; and

wherein

b) a first portion of the intake silencing chamber is disposed in the cover and a second portion of the intake silencing chamber is disposed in the base, wherein the third inner area is substantially clear of obstructions and the portion of the seal bead defining the third inner area engages between the first and second portions of the intake silencing chamber.

24. An air filter assembly for an internal combustion engine, comprising:

a) an air filter housing having a base and a cover, the air filter housing defining an air flow path from an air inlet through an intake silencing chamber to a carburetor inlet;

b) a first sealing rib formed on the base;

c) a second sealing rib formed on the cover;

d) a filter element, disposed with the air filter housing in the air flow path downstream of the intake silencing chamber, including a seal bead defining an outer perimeter of the filter element, which engages the first sealing rib and the second sealing rib to seal the air flow path in the air filter housing, and further defining at least three inner areas within the outer perimeter;

e) a pleat block molded into the seal bead within a first of the at least three inner areas;

f) a screen molded into the seal bead within the same inner area as the filter media; and

g) a baffle molded into the seal bead within a second of the at least three inner areas, facing the carburetor inlet;

wherein

h) a channel is formed in a first side of at least a portion of the seal bead for receiving the first sealing rib and retaining the filter element; and

i) a first portion of the intake silencing chamber is disposed in the cover and a second portion of the intake silencing chamber is disposed in the base, wherein the the third of the at least three inner areas is substantially clear of obstructions and portion of the seal bead defining the third inner area engages between the first and second portions of the intake silencing chamber.