DESC:HYBRID AIR FILTER ELEMENT

Field of the invention:

The present invention generally relates to air filtration systems and more particularly, to an improved hybrid air filter element used in internal combustion engines, automotives and air cleaners.

Background of the invention:

Conventional cylindrical filter elements having end caps are not completely suitable for internal combustion engines, automotives and air cleaners. The seals provided between the filter elements and the end caps are prone to leakage due to opening or rupture of the seals at high internal fluid pressure differentials, specifically at high operating temperatures.

In prior art, EP0329659 patent discloses a rounded air filter element comprising ends caps. The ends caps are made of Polyurethane foam material having an axial sealing surface as well as a radial sealing surface that come into contact with housing walls.
Another prior art patent EP0740574 also discloses a rounded filter element provided with plastic end caps. Axial and radial sealing surfaces are arranged on the one piece end cap to ensure a good tightness between the clean side and the dirty side. The protection was on means for assembling the two parts of the housing. It comprises recesses for receiving lugs of the cover.

Further in the prior art, EP1258 278 patent discloses a rounded filter element that is provided with two end caps. The end caps are made of the Polyurethane foam material. One of the end caps has an opening for the air flow exit. This end cap is further provided with two sealing surfaces, a radial sealing surface and an axial sealing surface. The end cap further includes a rigid insert, in the form of a collar on which a radial seal is molded. This insert contributes to the enhancement of the rigidity of the end cap. The insert aims to preserve the integrity of the radial seal against vibration and temperature variation.

Another US prior patent US8361181 discloses a very specific design in which the tubular portion forming an air entry port (71) is integral with the filter element. The filter element comprises an end cap provided with an axial sealing surface (90, 91) and a radial sealing surface (92y) that engages the inner entry tube. All the parts of the end caps are made of foamed Polyurethane. The opposite end cap is made of plastic material.

However, following drawbacks incurred in prior art air filter elements:
1. Improper fitment during serviceability
2. Vulnerable sealing between clean side and dirty side
3. Rigidity of the element is susceptible
4. High cost

Further, customer demands ease in serviceability, increase in sealing and rigidity of the air filter element for easy removal and assembly, adherence of sealing with housing.

Accordingly, there exists a need to provide an improved hybrid air filter element that overcomes abovementioned drawbacks of the prior art.

Objects of the invention:

An object of the present invention is to ensure proper sealing between clean side and dirty side of a hybrid air filter element.

Another object of the present invention is to avoid improper fitment during serviceability of the hybrid air filter element.

Yet, another object of the present invention is to increase rigidity of the element for easy removal and assembly of the hybrid air filter element.

Summary of the invention:

Accordingly, the present invention provides a hybrid air filter element that comprises of a paper media, a first end cap assembly, a second end cap assembly and a mesh. The paper media is glued to the first end cap assembly cured for safe removal provision of the hybrid air filter element. The first end cap assembly is a metal end cap assembly. The first end cap assembly comprises metallic end plate with provision to remove the hybrid air filter element for servicing and rigidity. The second end cap assembly is made of molded Polyurethane (PU) foam for increasing sealing area. The second end cap assembly is used for axial sealing and radial sealing. The Polyurethane (PU) foam is moldable in any shape as per the requirement of sealing between housing interfaces and despite of shape and size of an outlet spigot. The mesh is configured at inner side of the hybrid air filter element. The mesh is metallic perforated mesh that is served as a flame retardant. The mesh provides structural support to the hybrid air filter element and prevents the hybrid air filter element from collapse.

The hybrid air filter element includes a combination of Polyurethane foam end cap at one end and a metal end cap at another end to eliminate a rubber spigot that gets detached during service and to facilitate ease in serviceability cleaning and replacing with proper sealing interface between housing and the hybrid air filter element. Sealing profile is provided on the hybrid air filter element.

Brief description of the drawings:

Figure 1 shows a front view of a conventional air filter element, in accordance with the prior art;

Figure 2 shows a front view of a hybrid air filter element, in accordance with the present invention;

Figure 3 shows an exploded view of the hybrid air filter element, in accordance with the present invention;

Figure 4 shows another exploded view of the hybrid air filter element without PU end cap, in accordance with the present invention; and

Figure 5 shows an assembled view of the hybrid air filter element, in accordance with the present invention.

Detailed description of the embodiments:

The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.

The present invention provides an improved hybrid air filter element used in internal combustion engines, automotives and air cleaners. The hybrid air filter element includes a combination of Polyurethane foam end cap at one end and a metal end cap at another end. The present invention facilitates ease in service and replacement of the air filter element.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.

Referring to figure 1, an air filter element (10) in accordance with the prior art is shown. The air filter element (10) comprises a paper media (1), a sub-assembly metal end cap (2), a flame retardant (3) made up of metallic perforated mesh, a plastic housing (4), a rubber spigot (5) and a synthetic filter (6). However, the air filter element (10) leads to improper fitment during serviceability. The air filter element (10) does not provide proper sealing and rigidity.

Referring to figures 2 to 5, a hybrid air filter element (100) in accordance with the present invention is shown. The hybrid air filter element (100) comprises a paper media (20), a first end cap assembly (40), a second end cap assembly (60) and a mesh (80).

The paper media (20) is glued to the first end cap assembly (40) (cured) for safe removal provision of the hybrid air filter element (100).

The first end cap assembly (40) is a metal end cap assembly. The first end cap assembly (40) comprises metallic end plate with provision to remove the hybrid air filter element (100) for servicing and rigidity.

The second end cap assembly (60) is a Polyurethane (PU) end cap. The second end cap assembly (60) is made of molded PU foam for increasing sealing area. The second end cap assembly (60) is used for axial sealing and radial sealing. In an embodiment, despite of shape and size of outlet spigot, the Polyurethane (PU) foam can be molded as required. 10% to 20% sealing can be achieved at both axial and radial sealing of the hybrid air filter element (100).

The mesh (80) is configured at inner side of the hybrid air filter element (100). The mesh (80) is metallic perforated mesh. The mesh (80) is served as a flame retardant. The mesh (80) provides structural support to the hybrid air filter element (100). The mesh (80) prevents the hybrid air filter element (100) from collapse.

The hybrid air filter element (100) includes a combination of Polyurethane foam end cap at one end and a metal end cap at another end. This integrated feature introduced to eliminate the rubber spigot (5) that gets detached during service. The elimination of the rubber spigot (5) eliminates the metal end cap at one end. Hence, total number of components is reduced, thereby reducing use of the metal and overall cost of the hybrid air filter element (100). Extra cost for sealing the rubber spigot (5) is also eliminated.

The hybrid air filter element (100) facilitates ease in serviceability (cleaning and replacing) with proper sealing interface between housing and the element. Sealing profile is provided on the hybrid air filter element (100). If the sealing is damaged, only the hybrid air filter element (100) needs to be replaced in air filtration system. This leads to saves the cost for end user. The rigidity of the hybrid air filter element (100) due to the first end cap assembly (40) which is metallic and the mesh (80) which is metallic perforated flame retardant.

Advantages of the invention:

1. Assurance for adequate sealing (axial and radial) between housing and the hybrid air filter element (100) in any severe conditions.
2. The second end cap assembly (60) includes Polyurethane (PU) foam that can be molded in any shape as per the requirement of the sealing between housing interfaces.
3. Rigidity during functioning and service due to the first end cap assembly (40) which is metallic and the mesh (80) which is metallic perforated flame retardant.
4. The hybrid air filter element (100) can be formed in different shapes including of triangular, round, elliptical and square.
5. Number of the parts in assembly reduced with improved sealing.
6. Eliminates loosening of the hybrid air filter element (100).
7. Damage of the hybrid air filter element (100) can be eliminated due to metal contact at sealing area.
8. The hybrid air filter element (100) facilitates easy removal and assembly during service.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention. ,CLAIMS:We claim:

1. A hybrid air filter element (100) comprising:
a paper media (20);
a first end cap assembly (40) having metallic end plate with provision to remove the hybrid air filter element (100) for servicing and rigidity;
a second end cap assembly (60) having molded Polyurethane (PU) foam for increasing sealing area, thereby providing axial sealing and radial sealing; and
a mesh (80) configured at inner side of the hybrid air filter element (100), wherein the mesh (80) is metallic perforated mesh that is served as a flame retardant;
wherein, the hybrid air filter element (100) includes a combination of Polyurethane foam end cap at one end and a metal end cap at another end to eliminate rubber spigot that gets detached during service and to facilitate ease in serviceability (cleaning and replacing) with proper sealing interface between housing and the hybrid air filter element (100).

2. The hybrid air filter element (100) as claimed in claim 1, wherein the paper media (20) is glued to the first end cap assembly (40) (cured) for safe removal provision of the hybrid air filter element (100).

3. The hybrid air filter element (100) as claimed in claim 1, wherein the first end cap assembly (40) is metallic.

4. The hybrid air filter element (100) as claimed in claim 1, wherein the second end cap assembly (60) includes Polyurethane (PU) foam that is moldable in any shape as per the requirement of sealing between housing interfaces and despite of shape and size of an outlet spigot.

5. The hybrid air filter element (100) as claimed in claim 1, wherein the mesh (80) provides structural support to the hybrid air filter element (100) and further prevents the hybrid air filter element (100) from collapse.

6. The hybrid air filter element (100) as claimed in claim 1, wherein a sealing profile is provided on the hybrid air filter element (100).

Dated this 14th day of December 2017

Madhavi Vajirakar
(Agent for the applicant)
(IN/PA-2337)