Note: Descriptions are shown in the official language in which they were submitted.
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FUEL FILTER CARTRIDGE AND METHOD OF USE THEREOF
Background of the Disclosure
[0001] The
present disclosure relates generally to devices for filtering
and separating liquids. More particularly, the present disclosure relates to
fuel filters for removing foreign particles and separating water from fuel in
an
internal combustion engine.
[0002] It is
well-documented that significant quantities of
contaminants such as water and various abrasive particles are found in
diesel fuel. In addition to corroding metal components, water may obstruct
the fuel lines when environmental temperatures fall below freezing.
Likewise, abrasive particles may damage sensitive engine components such
as the fuel injection pump.
[0003] Fuel
filter cartridges are a well-known solution for removing
water and abrasive particles from diesel fuel before the fuel is pumped into
sensitive engine systems. Prior art fuel filter cartridges typically have a
housing having a threaded or bayonet-type connection to a filter base. The
housing typically comprises two housing portions joined at a peripheral
shoulder, one of which defines an axial opening to provide fuel
communication between the filter base and a filter element disposed within
the housing. Customarily, fuel filter cartridges are either replaceable as an
entire unit, or the filter element may be coupled to the housing such that the
filter unit may be individually replaced.
Summary
[0004] Briefly
stated, a fuel filter cartridge in connection with the
current disclosure comprises a housing, a filter element and a collar. The
housing has a generally cylindrical sidewall and defines an open first end
and an axially-opposite second end. The sidewall has inner and outer
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surfaces and a flange which projects radially away from the outer surface at
the first end.
[0005] The
filter element includes a ring of filter media, which
circumscribes the longitudinal axis. The media extends axially between first
and second end caps. The first end cap defines a fluid flow opening coaxial
with the longitudinal axis. A
generally cylindrical wall extends axially
between first and second peripheral rims, is disposed at a circumferential
periphery of the first end cap, and defines first and second seal glands
adjacent the first and second peripheral rims, respectively. The first and
second seal glands are oriented radially away from the longitudinal axis and
receive first and second seal members. A ledge projects radially outwardly
from the cylindrical wall intermediate the first and second peripheral rims.
[0006] The
collar has an annular sidewall, including first and second
axial ends. A circumferential shoulder which projects from an inner surface
of the sidewall intermediate the first and second axial ends radially overlaps
with the upper end cap ledge. The collar circumscribes the housing, and the
ledge and the shoulder cooperate to trap the flange. In one embodiment, a
wave spring received in a circumferential pocket defined by the collar
provides additional axial retention.
[0007] A method
of using the filter cartridge of the current disclosure
is also contemplated. Briefly stated, the method comprises dismounting the
filter cartridge from a filter base, disengaging the first end cap and collar,
axially withdrawing the filter element from the housing, axially inserting a
replacement element, reengaging the first end cap of the replacement
element with the collar, and remounting the filter cartridge to the base.
[0008] The
filter cartridge is dismounted from the filter base by
uncoupling a connection between the collar and a skirt of the filter base.
Uncoupling the filter cartridge and the base breaks a first seal between the
first seal member and an inner surface of the filter base skirt. In one
embodiment dismounting the filter cartridge from the base comprises
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uncoupling a threaded connection, while one alternative embodiment may
involve uncoupling a bayonet connection. The remounting step involves
reversing the dismounting step, coupling the connection between the collar
and the skirt, thereby creating the first seal.
[0009]
Disengaging the first end cap and the collar includes breaking
a second seal between the second seal member and the inner surface of
the housing. Engaging the ledge of the replacement filter element and the
shoulder of the collar traps the flange of the housing between the ledge and
the shoulder.
[0010] In one
embodiment engaging the ledge and shoulder
comprises coupling male and female portions of a threaded connector
system, the male portion disposed on the cylindrical wall and the female
portion defined on the inner surface of the collar. In another embodiment
the engaging step involves coupling a bayonet connection between the
cylindrical wall and the collar.
[0011] The
apparatus and method of the present disclosure provides
advantages over and relative to the prior art. For example, the composite
filter is easy to manufacture, yet the structural features of the filter
element,
housing and collar ensure that the connection between the components is
robust enough to resist the adverse effects of engine or road vibration.
Furthermore, the first and second seal members provide strong seals with
the filter base and the inner surface of the housing.
Brief Description of the Drawing
[0012] Aspects
of the preferred embodiment will be described in
reference to the Figures, where like numerals reflect like elements:
[0013] Fig. 1
shows a cross-sectional view of one embodiment of a
filter cartridge of the present disclosure;
[0014] Fig. 2
shows an enlarged cross-sectional view of one
embodiment of a connection between a collar, a housing and a first end cap;
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[0015] Fig. 3
shows a cross-sectional view of one embodiment of the
collar of the assembly of Figs. 1 and 2;
[0016] Fig. 4
shows an enlarged cross-sectional view of an alternate
embodiment of the connection between the collar, the housing and the first
end cap;
[0017] Fig. 5
shows a cross-sectional view of an alternate
embodiment of the collar of the assembly of Fig. 4;
[0018] Fig. 6
shows an enlarged cross-sectional view of the collar
shown in Fig. 5 with particular emphasis on an axial slot, a circumferential
pocket and a barb;
[0019] Fig. 7
shows an enlarged cross-sectional view of an alternate
embodiment of the connection between the collar, the housing and the first
end cap;
[0020] Fig. 8
shows a cross-sectional view of an alternate
embodiment of the collar of the assembly of Fig. 7;
[0021] Fig. 9
shows an enlarged cross-sectional view of the collar of
Fig. 8 with particular emphasis on a female portion of a threaded connector
system and slots defined between snap fingers at a first axial end of the
collar;
[0022] Fig. 10
shows an enlarged cross-sectional view of an alternate
embodiment of the connection between the collar, the housing and the first
end cap;
[0023] Fig. 11
shows a cross-sectional view of an alternate
embodiment of the collar of the assembly of Fig. 10;
[0024] Fig. 12
shows an enlarged cross-sectional view of the collar of
Fig. 11 with particular emphasis on a circumferential pocket, female portion
of a threaded connector system and slots defined between snap fingers at a
first axial end of the collar;
[0025] Fig. 13
shows a cross-sectional view of an alternate
embodiment of the filter element;
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[0026] Fig. 14
shows a perspective view of a second end cap of the
filter element of Fig. 13;
[0027] Fig. 15
shows an enlarged cross-sectional view of a
connection between the housing and the second end cap;
[0028] Fig. 16
shows a top-plan view of one embodiment of the
housing;
[0029] Fig. 17
shows a cross-sectional view of an alternate
embodiment of the housing;
[0030] Fig. 18
shows an enlarged cross-sectional view of the
embodiment of the housing depicted in Fig. 17 with particular emphasis on a
ring between a seat and an open first end of the housing;
[0031] Fig. 19
shows a cross-sectional view of one embodiment of the
filter cartridge as installed with a compatible filter base ; and
[0032] Fig. 20
shows a perspective view of one embodiment of a
wave spring in accordance with certain aspects of the present disclosure.
Detailed Description of the Preferred Embodiment
[0033]
Embodiments of a filter cartridge will now be described with
reference to the Figures, wherein like numerals represent like parts
throughout the Figures 1-20. Fig. 1 illustrates one embodiment of a filter
cartridge 100 according to aspects of the disclosure. The filter cartridge 100
has a longitudinal axis A-A and includes a filter element 102, a housing 104
and a collar 106. The filter cartridge 100 is contemplated for use with a
filter
base 108 (see Fig. 19).
[0034] The
filter element 102 includes first and second end caps 110
and 112, respectively. The first end cap 110 defines a fluid flow opening
114 coaxial with the longitudinal axis A-A. As also shown in Fig. 2, a
generally cylindrical wall 116 is disposed at a circumferential periphery of
the first end cap 110. The first end cap 110 includes first and second
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surfaces 117 and 119, respectively, which extend between the
circumferential periphery and the fluid flow opening 114.
[0035] The
cylindrical wall 116 extends between a first and second
peripheral rim 118 and 120, respectively, and defines first and second seal
glands 122 and 124, respectively. In the embodiment shown in Figs. 1 and
13, the cylindrical wall 116 of the upper end cap 110 tapers between the first
and second peripheral rims 118 and 120. The first and second seal glands
122 and 124 are respectively defined adjacent the first and second
peripheral rims 118 and 120, and oriented radially away from the
longitudinal axis A-A. The first and second seal glands 122 and 124 receive
first and second seal members 126 and 128, respectively. A ledge 130
projects radially outwardly from the cylindrical wall 116 intermediate the
first
and second peripheral rims 118 and 120.
[0036] In one
embodiment best seen in Fig. 19, an annular inner wall
121 projects axially away from the first end cap 110 first surface 117. The
annular inner wall is disposed adjacent the fluid flow opening 114 and
radially inward of and concentric with the cylindrical wall 116. A third seal
gland 123 is oriented radially away from the longitudinal axis A-A, and sized
to receive a third seal member 125. The inner wall 121 and third seal gland
123 are configured to sealingly mate with a fuel conduit 107 of the filter
base
108. The fuel conduit is disposed radially inwardly of a skirt 109 which
sealingly mates with the first seal member 126.
[0037] Fuel
entering the filter base 108 flows from inlet ports 127 as
designated by the arrows. The first seal between the first seal member 126
and the skirt 109 prevents fuel leaking out between the first end cap 102
collar 105 and skirt 109. "Dirty" fuel flows into a plurality of filter ports
129
defined at the circumferential periphery, and subsequently into a space
between the filter media 111 and a generally cylindrical housing sidewall
132. Water and other abrasive impurities are filtered from the "dirty" fuel as
the fuel flows through the filter media 111, and filtered "clean" fuel flows
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through the fluid flow opening 114 and out the fuel filter base 108. The third
seal between the third seal member 125 and the fuel conduit 107 separates
filtered "clean" fuel destined for the fuel injectors and/or other downstream
engine components from "dirty" fuel pumped in from the fuel tank.
[0038]
Referring to Figs. 1 and 17, the sidewall 132 is coaxial with the
longitudinal axis A-A. The sidewall 132 has inner and outer surfaces 134
and 136 and defines an open first end 138 and an axially-opposite second
end 140. A flange 144 projects radially away from the outer surface 136 at
the open first end 138. As will be described in further detail below, the
flange cooperates with the first end cap 110 and the collar 106 to retain the
filter element 102 within the housing 104.
[0039] The
second seal member 128 creates a second seal with the
inner surface of the sidewall 134, fluidly sealing the cartridge and
preventing
leakage between the first end cap 110 and the housing 104. In the
embodiment shown in Fig. 17 and 18, the sidewall 132 of the housing 104
flares slightly radially outwardly adjacent the first open end 138. A ring 131
of the sidewall 132 located at the radially outward flare is disposed between
a seat 133 and the first open end 138, and the inner surface 134 of the ring
131 creates the second seal with the second seal member 128. The seat
133 and first end cap cylindrical wall 116 are configured such that the seat
133 supports the second peripheral rim 120, thereby axially supporting the
filter element 102 within the housing 104.
[0040] In the
embodiment shown in Figs. 1 and 17, the housing
second end 140 defines a drain 142. The drain 142 has generally cylindrical
sides 146 and defines a drain port 148. As shown in Fig. 1, the drain sides
146 and the drain port 148 may receive a cylindrical washer 150 which is
configured to mate with a valve (not shown) via a threaded, bayonet, or
similar connector system.
[0041] As shown
in Fig. 16, the flange may define an aperture 145
configured to receive an anti-rotation member 147 projecting from the
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circumferential shoulder 158 of the collar 106 (see Figs. 3, 5, 8 and 11).
The anti-rotation member 147 is preferably a raised projection having a
rectangular sectional configuration. The aperture 145 and anti-rotation
member 147 cooperate to rotationally secure the housing 104 within the
collar 106 and ensure that the housing does not rotate relative to the collar
106.
[0042]
Referring to Figs. 3, 5, 8 and 11, the collar 106 includes an
annular sidewall 152 having first and second axial ends 154 and 156,
respectively. A shoulder 158 projects radially inwardly from an inner surface
160 of the annular sidewall 152 axially intermediate the first and second
axial ends 154 and 156. The annular sidewall 152 is sized to receive and
circumscribe the sidewall 132 of the housing 104, while the shoulder 158 of
the collar 106 and the ledge 130 of the upper end cap 110 are sized to
radially overlap. The radial overlap between the ledge 130 and the shoulder
158 traps the flange 144 between the two structures (see Figs. 2, 4, 7 and
10). The filter element 102 is thus axially supported within the cartridge 100
by the upper end cap 110. As will be discussed in further detail below, a
plurality of embodiments are contemplated to provide a connection between
the element 102, housing 104 and/or collar 106. The connection further
secures the element 102 within the cartridge 100 and prevents relative
movement between the components.
[0043] In one
embodiment shown in Figs. 6 and 12, an axially-
oriented surface 151 extends between first and second radially-oriented
surfaces 153 and 155, respectively, intermediate the first and second axial
ends 154 and 156. The axially-oriented surface and first and second
radially-oriented surfaces 153 and 155 define a circumferential pocket 162.
The second radially-oriented surface 155 is contiguous with the shoulder
158.
[0044] As shown
in Figs. 2, 4, 10 and 19, the pocket 162 may receive
a wave spring 164. Referring to Fig. 20, the wave spring 164 undulates
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between a plurality of crests 166 and a plurality of troughs 168. The crests
and troughs 166 and 168 secure the wave spring 164 partially radially within
pocket 162. The crests 166 also engage the ledge 130 and the crests 168
engage the flange 144 and provide axial forces to secure the housing 104
against the second radially-oriented wall 155 and the shoulder 158.
[0045] A number
of different embodiments for securing the filter
element 102, the housing 104 and the collar 106 are also contemplated in
connection with the present disclosure. Figs. 1-3 show an embodiment
where a snap connector system is provided between the filter element 102
to the collar 106; Figs. 4-6 show an embodiment where a bayonet
connection is provided between the filter element 102 to the collar 106; Figs.
7-9 show an embodiment where a threaded connection is provided between
the filter element 102 to the collar 106; Figs. 10-12 show an alternate
embodiment of the threaded connection depicted in Figs. 7-9; and Figs. 13-
15 show an embodiment where a crimped connection is provided between
the filter element 102 and the housing 104.
I. The Embodiments of Figs. 1-3
[0046] As shown
in Figs. 1-3, a snap connector system secures the
upper end cap 110 to the collar 106. Referring specifically to Fig. 3, a
plurality of axial slots 170 separate snap fingers 172 projecting from the
collar first axial end 154.
[0047] The snap
connector mating system includes a male and a
female connector portion, 174 and 176, respectively. In the embodiment
shown in Figs. 2 and 3, the male snap connector portion 174 projects from
the snap fingers 172 radially toward the longitudinal axis A-A, while the
female connector portion 176 is defined on an outer surface of the cylindrical
wall 116 and oriented radially away from the longitudinal axis A-A. In
another embodiment of the snap connector mating system (not shown), the
female connector portions 176 is defined on the snap fingers 172 and the
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male snap connector portion projects radially away from the outer surface of
the cylindrical wall 116.
[0048] Once the
male snap connector portion 174 engages the
female snap connector portion 176, the upper end cap 110, the collar 106
and the housing 104 cooperate to secure the filter element within the
housing. In the embodiment where a wave spring 164 is received in a
circumferential pocket 162, the wave spring crests and troughs 166 and 168
provide additional axial forces securing the flange 144 against the shoulder
158. The wave spring 164 secures the collar 106 to the housing 104.
[0049] The snap
connector mating system provides a robust
connection between the filter element 102 and the collar 106. In the
embodiment shown in Figs. 1-3, the male and female snap connector
portions 174 and 176 are configured such that the filter element 102 cannot
be replaced once the male snap connector portion 174 engages the female
snap connector portion 176 without breaking the snap fingers 172. One of
ordinary skill in the art will appreciate that subtle changes in the
structural
configuration of the male and female snap connector portions 174 and 176
and/or the collar 106 will produce a cartridge 100 that is replaceable once
the consumable filter element 102 has reached the end of its usable
I ifespan .
[0050] The
collar 106 supports the cartridge 100 relative to the base
108, so the base/cartridge connection is not dependent upon the snap
connector.
II. The Embodiments of Figs. 4-6
[0051] In the
embodiments shown in Figs. 4-6, a bayonet connection
secures the upper end cap 110 to the collar 106. The bayonet connector is
configured for use with the embodiment of the collar 106 defining the
circumferential pocket 162. As shown in Fig. 4, a plurality of tabs 178
project radially outwardly from the cylindrical wall 116. Referring to Figs. 5
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and 6, a corresponding plurality of axially oriented slots 180 are defined on
an inner surface of the collar 106.
[0052] The
axial slots 180 communicate with the circumferential
pocket 162. A plurality of barbs 182 project into the pocket 162 from the
first
radially-oriented surface 153 at the point of communication between the
axial slots 180 and the pocket 162. Referring specifically to Fig. 6, each
barb 182 includes a ramp surface 184 and a retention shoulder 186.
[0053] In the
embodiment shown in Fig. 4, the wave spring 164
provides additional axial retention forces, which urge the tabs 178 against
the first radially-oriented surface 153. The wave spring 164 ensures that the
tabs 178 are secured within the pocket 162, and cooperate with the barbs
182 to prevent the first end cap 110 from rotating past the retention shoulder
186 and disengaging the firs end cap 110 from the collar 106.
[0054] To
engage the ledge 130 with the shoulder 158 and trap the
flange 144, the tabs 178 are first inserted into the axially oriented slots
180.
The first end cap 110 is subsequently axially pushed until the tabs 178 are
received in the pocket 162. Once the pocket 162 receives the tabs 178, the
first end cap 110 is rotated until the tabs 178 ride up the ramp surface 184
and past the retention shoulder 186. As the tabs 178 ride up the ramp
surface 184, the tabs 178 and the ledge 158 axially compress the wave
spring 164. Once the tabs 178 rotate past the retention shoulder 186 the
wave spring 164 rebounds, urging the ledge 158 and tabs 178 against the
first radially-oriented surface 153, and urging the flange 144 against the
second radially-oriented surface 155. To disengage the first end cap 110
from the collar 106, the previously mentioned steps are sequentially
repeated in reverse-order.
III. The Embodiments of Figs. 7-9
[0055] In the
embodiments shown in Figs. 7-9 a threaded connector
system secures the upper end cap 110 to the collar 106. The inner surface
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160 of the collar defines a female portion 188 of the threaded connector
system. A male portion 190 of the threaded connector system projects from
the cylindrical wall 116.
[0056] A
chamfer 192 is provided between the ledge 130 and the
cylindrical wall 116. The chamfer 192 aids in installation of a replacement
filter element 102. A sharp transition between the ledge 130 and the
cylindrical wall 116 may catch the first axial end 154 or the inner surface
160
of the collar 106 during axial insertion of the element 102 or engagement of
the male and female connector portions 188 and 190. Thus, the chamfer
192 ensures that axially inserting of the replacement element 102 within the
housing 104 and engagement of the threaded connector system between
the upper end cap 110 and the collar 106 is relatively smooth.
[0057] In the
embodiment shown in Figs. 7-9, the collar 106 also
includes the axial slots 170 defined between the snap connector fingers 172.
Male and female snap connector portions 176 and 178, similar to those
provided in the embodiment of Figs. 1-3, are also included. In comparison
with the snap connector system shown in Figs. 1-3, the male snap
connector portion 176 and the female snap connector portion 178 are
shorter and shallower in the embodiment of Figs. 7-9. A detent and a
corresponding receptacle (not shown) may alternatively be provided on the
snap fingers 172 and the cylindrical wall 116, respectively. The snap
connector system provides positive feedback during engagement of the
threaded connector system. When the male and female connector portions
188 and 190 are completely engaged, the male snap connector portion 176
will simultaneously engage the female snap connector portion 178, providing
an audible and tactile indication that the first end cap 110 is completely
engaged with the collar 106.
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IV. The Embodiments of Figs. 10-12
[0058] The
embodiments shown in Figs. 10-12 employ a similar
threaded connector system to the one depicted in Figs. 7-9. The collar 106
in the embodiment of Figs. 10-12 includes the pocket 162 and wave spring
164 in addition to the snap fingers 172, and male and female connector
portions 188 and 190. The wave spring 164 secures the collar 106 to the
housing 104.
[0059] As seen
in Fig. 10, the shoulder 130 of the first end cap 110
has a sharper transition than the chamfer 192 shown in the embodiment in
Figs. 7-9. While the shoulder 130 may have a chamfer 192, the shoulder
130 in the embodiment shown in Fig. 10 projects from the cylindrical wall
116 axially closer to the first peripheral rim 118 to accommodate the wave
spring 164.
V. The Embodiments of Figs. 13-15
[0060] As seen
in Figs. 13-15, a crimped connection may secure the
filter element 102 within the housing 104. Preferably, it is the second end of
the housing 140 which is crimped to axially secure the filter element 102
within the housing 104. An alternate embodiment of the second end cap
112 best seen in Figs. 13 and 14 creates a strong connection between the
filter housing 104 and the filter element 102. A plurality of supports 194
project axially away from the second end cap 112. The supports 194 may
comprise struts, or fins, or other similar structural feature which axially
position the filter element 102, and define fuel flow paths 196 between the
supports 194, allowing water run-off from the filter media 111 to pass
through the drain port 148.
[0061] The
supports 194 are connected to the cylindrical washer 150
axially opposite the filter second end cap 112. The washer 150 defines a
radially-outwardly facing circumferential groove 198. The cylindrical sides
146 of the drain 142 receive the washer 150. The sidewalls 146 of the drain
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are crimped into the circumferential groove 198, retaining the filter element
102 within the housing 104 at the second end 140.
[0062] An inner
surface 200 of the washer 150 is configured to mate
with the valve (not shown). As shown in Figs. 13 and 15, the inner surface
200 may define one half of a threaded connector system. Alternatively, a
bayonet connector system (not shown) may be utilized to connect the valve
to the washer 150.
[0063] While a
preferred embodiment has been set forth for purposes
of illustration, the foregoing description should not be deemed a limitation
of
the invention herein. Accordingly, various modifications, adaptations and
alternatives may occur to one skilled in the art without departing from the
spirit of the invention and scope of the claimed coverage.
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