Abstract:
A magnetic device for attachment on an exterior wall of a canister where the canister is mounted within a liquid flow path. The purpose of the device is to attract ferrous particulate matter flowing within the flow path and cause that ferrous particulate matter to be fixed to the inside surface of the canister therefore no longer flowing in the flow path. The device has a frame which includes a cavity and within that cavity is mounted a baseplate. Mounted on the baseplate are a pair of blocks. Mounted on each of the blocks is a plurality of magnets with the magnets mounted in a side abutting relationship in conjunction with each block. Between the blocks is located a bridge. The bridge permits limited flexing of the frame so the frame can be used to accommodate to different diameters of canisters within about a one-half inch range.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The structure of the present invention relates to a device for removing submicron to micron size ferrous particles from moving liquids. The device uses a series of magnets that are mounted within a frame. The device is to be mounted on the exterior surface of a filter canister. A magnetic force attracts ferrous particles entrained within liquid passing through the canister and hold such against the inside surface of the canister preventing continued circulation of these particles within the liquid flow path which includes the canister and thereby prevents these particles from being distributed to be wedged between the working parts of the engine which is to be lubricated by the liquid. The device can also be used to remove ferrous particles from a fuel line flow path and from the flow path of a crankcase. 
   2. Description of the Related Art 
   The subject matter of the present invention is deemed to be an improvement over the structure defined within U.S. Pat. Nos. 5,556,540 and 6,554,999. There has been a license agreement by the assignee of the present invention concerning these patents. 
   Internal combustion engines are used in automobiles, trucks, boats, air compressors, robotics, motorcycles and lawnmowers. All such engines usually include a cylindrical shaped filter canister in conjunction with the lubricating oil flow path of the engine. Also, there may be a second filter canister utilized in conjunction with the fuel flow path of the engine. To eliminate the larger particles of particulate foreign matter that become entrained within the oil due to engine shedding, the engine oil is typically forced through a filter canister which includes a porous filtering medium that is to allow the oil to pass therethrough but allegedly does not allow the passage of the particulate matter. In this manner, the larger particles of particulate matter can be removed from the engine lubricating oil. However, because of this separation technique relies upon filtration through a porous material, particles that are smaller than the openings in the porous material are not removed by the filtering medium. One particularly harmful type of foreign matter in lubricating oil is small metallic (ferrous) particulates which are created by the frictional contact between the moving metal parts of the engine. These particles are actually shards of metal from the metal parts of the engine that are dislodged during the operation of the engine (shedding). These metallic particulates can damage important engine components as such circulate through the engine. 
   Small metallic particles often have a cross-sectional dimension smaller than the openings in the porous filter material of the filter canister which means that the oil filter is ineffective in the removing of these particles. When not removed by the oil filter, these small metallic particles will freely circulate through the engine until they are finally removed when the oil is changed. Typically, the porous material used in oil filters consists of a fibrous material that has openings greater than twenty microns. Hence, metallic particles with a cross-dimension of twenty microns or smaller are not trapped by the filter. There have been reports that have been prepared in the past that have stated that the vast majority of wear in an engine are caused by metallic particles in the oil that are less than twenty microns. SAE studies have shown that there is a seventy percent wear reduction within an engine when particulates that are fifteen micron and larger are removed. A further huge advance is anticipated when particles down to two micron are removed. This particulate matter is small enough to get wedged between the metallic working members of the engine, and as the engine continues to operate, these metallic particulates causes scoring to occur on the metal working members of the engine. Also, many of these larger metallic particles (twenty microns and above) have sharp edges. Movement of these large particles by the force of the flow of the oil will cause the particles to “slice” like a knife through the filter canister medium producing holes greater than twenty microns thereby decreasing the filtering effectiveness of the filter canister resulting in the filter being ineffective for particulates larger than twenty microns. 
   The micron and submicron sized metallic particles are the major cause of wear of the moving components of the engine. Specifically, as oil is circulated throughout the engine to lubricate the various moving components, the metallic particles entrained in the oil are carried to be interfaced between the moving components. At these locations, the hardness of the metallic particles causes metal to bear against metal, and reliance is placed solely upon the oil to maintain a lubricating film. When these metallic particles are brought to the interfaces, damage to the adjoining surfaces are likely. This damage eventually results in a degradation of the close tolerances between the moving parts, causing a loss in operating engine efficiency and more frequent maintenance in the form of repair. By some estimates, these metallic particles are the cause of more than one-half of the wear on the engine. 
   In the past, one approach taken by the prior art to eliminate these particles is to install a magnetized drain plug in the crankcase of the engine. The magnetized drain plug generates a magnetic field around the drain plug which is to attract and remove some of the metallic particles from the lubricating oil that flow through the crankcase. When the engine is running, the flow of oil through the crankcase is at a high flow rate. The magnetized drain plug has a very weak magnetic field and only collects particles when the flow of the oil stops. So whatever particles happen to be in close proximity of the drain plug are then caused to adhere to the drain plug. Once the engine is restarted, those particles that are on that drain plug are merely washed away and then recirculated throughout the entire engine to then be wedged between the working parts. 
   Other prior approaches to solve this problem is to attach a magnet to the oil filter canister tending to create a magnetic field within the filter to attract and hold the ferrous particles against the inside wall of the filter. Unfortunately, prior art attempts did not generate a sufficiently strong magnetic field to attract and hold any significant number of metallic particles from the oil to the inside wall of the filter canister. The metallic particles contained in the oil, even if such passed through the magnetic field continued to circulate through the engine. However, the magnetic devices of U.S. Pat. Nos. 5,556,540 and 6,554,999 have a sufficiently strong field to be effective generally between one-hundred twenty five pounds and five hundred pounds of force against the canister. 
   SUMMARY OF THE INVENTION 
   The basic embodiment of magnetic device for attachment on an exterior wall of a filter canister of the present invention comprises incorporating a resting curvature in the magnetic device. The device includes a non-ferrous frame having an internal cavity. A single ferrous baseplate is mounted within the cavity completely covering the cavity. The ferrous baseplate has an exterior surface and an interior surface with the exterior surface being exposed to ambient. The plate has a peripheral edge and this peripheral edge is embedded within the frame. A pair of ferrous blocks are mounted on the interior surface of the plate. The ferrous blocks are spaced apart forming a bridge between the blocks. The bridge functions as a fulcrum permitting flexing of the frame to assume different curvatures of the frame from the resting curvature permitting the magnetic device to be mounted flush against a size range of canister filters. A plurality of magnets are mounted within the cavity with the magnets being mounted against the blocks. The magnets substantially cover the blocks dividing the magnets into a pair of spaced apart zones separated by the bridge. The magnets have an exposed surface adapted to be placed flush against a filter canister. Whereby the magnets generate a magnetic field which not only secures the magnetic device to the filter canister but generates a magnetic field within the canister which attracts and holds ferrous particulate matter which is flowing through a closed fluid flow path against an interior sidewall of the canister preventing such from exiting from the canister. 
   A further embodiment of the present invention is where the basic embodiment is modified by having the frame to be enclosing. 
   A further embodiment of the present invention is where the basic embodiment is modified by the ferrous blocks being fixedly mounted onto the single ferrous baseplate. 
   A further embodiment of the present invention is where the basic embodiment is modified by the ferrous blocks being of the same size. 
   A further embodiment of the present invention is where the basic embodiment is modified by the ferrous blocks being defined as being constructed of a solid material. 
   A further embodiment of the present invention is where the basic embodiment is modified by the ferrous blocks being defined as being constructed of a resilient material impregnated with ferrous particulate matter. 
   A further embodiment of the present invention is where the just previous embodiment is modified by the resilient material being defined as being a plastic. 
   A further embodiment of the present invention is where a previous embodiment is modified by the resilient material being defined as being a rubber. 
   A further embodiment of the present invention is where a previous embodiment is modified by the resilient material being defined as comprising a combination of rubber and plastic. 
   A further embodiment of the present invention is where the basic embodiment is modified by defining that the resting curvature comprises an arc of a circle. 
   A further embodiment of the present invention is where the basic embodiment is modified by the resting curvature being defined as comprising one hundred twenty degrees or greater. 
   A further embodiment of the present invention is where the basic embodiment is modified by having the single ferrous baseplate to be of a thickness of 0.022 to 0.043 inches. 
   A further embodiment of the present invention is where the basic embodiment is modified by constructing the block of a plastic insulative material which uses a pair of spaced apart inner metallic plates on which the magnets are mounted. 
   A further embodiment of the present invention is where the just previous embodiment is modified by the plastic insulative blocks being of the same thickness. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the present invention, reference is to be made to the accompanying drawings. It is to be understood that the present invention is not limited to the precise arrangement shown in the drawings. 
       FIG. 1  is an exploded isometric view of a portion of the first embodiment of magnetic device of the present invention showing how the device is to be constructed; 
       FIG. 2  is an isometric view of portion of the first embodiment of magnetic device of the present invention showing the portion assembled; 
       FIG. 3  is an isometric view depicting the forming of the enclosing frame which is to be secured around the portion shown in  FIG. 2 ; 
       FIG. 4  is an exploded isometric view depicting installation of the magnets in conjunction with the enclosing frame and the portion of the first embodiment of magnetic device of the present invention; 
       FIG. 5  is an isometric view of the completely assembled first embodiment of magnetic device of the present invention; 
       FIG. 6  is a transverse cross-sectional view taken along line  6 — 6  of  FIG. 5 ; 
       FIG. 7  is an isometric view of a portion of the second embodiment of magnetic device of the present invention not mounted in an enclosing frame; 
       FIG. 8  is an isometric view of the second embodiment of magnetic device of the present invention showing the device completely assembled with the enclosing frame; and 
       FIG. 9  is a cross-sectional view of the second embodiment of magnetic device of the present invention taken along  9 — 9  of  FIG. 8 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring particularly to  FIGS. 1–6  of the drawings, there is shown the first embodiment  10  of the present invention. First embodiment  10  utilizes a baseplate  12 . The baseplate  12  is to be constructed of a low-carbon steel with a thickness generally in the range of 0.022 to 0.027 inches. The baseplate  12  is to be coated with a galvanic coating for corrosion resistance. The baseplate  12  could also be made of stainless steel. The baseplate  12  has a resting curvature that is an arc of a circle. A typical circle would be the arc of a circle that has a diameter of between two and one-half to seven inches. The baseplate  12 , if it was placed flat before it had the resting curvature, would assume a rectangular configuration. The baseplate  12  has a peripheral edge  14 . Baseplate  12  has an exterior surface  13  and an interior surface  15 . 
   The baseplate  12  has a transverse center area that is to be defined as the bridge  16 . The baseplate  12  has four in number of holes  18 ,  20 ,  22  and  24 . The holes  18 ,  20 ,  22  and  24  are each to respectively connect with a rivet  26 ,  28 ,  30  and  32 . The rivets  26  and  28  pass through respective holes  36  and  38  that are formed within a block  34 . The rivets  36  and  38  wedge tightly with their respective holes  18  and  20  to secure the block  34  to the baseplate  12 . The block  34  will have the same resting curvature as the baseplate  12 . The rivets  30  and  32  pass respectively through holes  40  and  42  that are formed within a block  44 . Rivets  30  and  32  wedge tightly with their respective holes  22  and  24 . Block  44  is identical to block  34 . Blocks  34  and  44  are mounted on the interior surface  15 . The blocks  34  and  44  are to be constructed of steel and having a thickness of 0.096 to 0.101 inches. Each of the blocks  34  and  44  are basically rectangular in shape except, of course, having the curvature. The blocks  34  and  44  are to be made of low-carbon sheet steel. The blocks  34  and  44  are coated with a zinc plating as a corrosion preventor. Typical thickness of the coating is between 0.0001 and 0.0002 inches thick. 
   The assembly shown in  FIG. 2  is then to be placed within a mold  46 . Into the mold  46  is to be poured hot liquid plastic  48  through an injection port  50 . When the plastic  48  hardens and the mold  46  is opened, there is to be removed from the mold a plastic frame  52  which has on its inner surface a pair of spaced apart openings  54  and  56  which are separated by means of a bridge strip  58 . 
   There is to be placed within the opening  54  five in number of strip magnets  60 . There is also to be placed within the opening  56  five in number of strip magnets  62 . Each of the strip magnets  60  and  62  are identical. It is to be understood that the number of the strip magnets  60  and  62  employed can vary without departing from the scope of this invention. The strip magnets  60  and  62  have a slight transverse curvature that is equal to the resting curvature of the baseplate  22  which is also assumed in the frame  52 . The magnets  60  and  62  are to be made of neodymium and will have a strength of around forty to forty-five Mg.Oe. The longitudinal axis of the strip magnets  60  and  62  are located transversely within the frame  52 . Each of the strip magnets  60  and  62  are magnetically held onto the blocks  34  and  44 . 
   The use of the blocks  34  and  44  as well as the baseplate  12  is to direct the magnetic energy in a direction outward from the inside surface of the first embodiment  10 . There will be essentially no magnetic energy being emitted from the exterior surface  13  of the baseplate  12 . Typically, the magnets will have a longitudinal length of one and three quarters to two inches, a width of approximately five-sixteenths of an inch and a thickness of three thirty seconds of an inch. However, it is considered to be within the scope of this invention that the size of the magnets can readily vary. It is to be noted by noticing  FIG. 6  that the peripheral edge  14  of the baseplate  12  is embedded within the frame  52 . 
   In referring to  FIG. 5 , it can be seen that the frame  52  is capable of movement, as indicated by the dotted lines in  FIG. 5 . This movement is depicted by arrows  61  and  63  so that the frame  52  can be used to accommodate to a range of diameter variations of the filter canister  65 . Typically, the adjustment would be so as to have the first embodiment  10  to accommodate to about a one-half inch variance in diameter of the filter canister  65 . This adjustment is permitted by a flexing due to the creating of a fulcrum within the bridge  16  of the baseplate  12 . The bridge strip  58  extends entirely across the bridge  16 . The thickness of the blocks  34  and  44  prevents bending or flexing of the baseplate  12  in the area of the blocks  34  and  44  but flexing will be permitted in the area of bridge  16  due to the thinness of the baseplate  12 . There is also a gap located between the blocks  34  and  44  which is located at the bridge  16 . 
   Referring particularly to  FIGS. 7–9  of the drawings, there is shown the second embodiment  64  of magnetic device of the present invention. The second embodiment  64  includes a baseplate  66  which is basically identical to baseplate  12 . The baseplate  66  has a transverse center section defined as a bridge  68  which is basically identical to the bridge  16 . There are a pair of blocks  70  and  72  which are mounted by rivet fasteners  74 ,  76 ,  78  and  80  to the baseplate  66 . On the exterior surface of the block  70  there is mounted an inner plate  82 , and on the exterior surface of the block  72  is mounted an inner plate  84 . The inner plates  82  and  84  are constructed to be of the same thickness as the baseplate  66  and also is formed to have an inherent resting curvature which the baseplate  66  also has. Each of the blocks  70  and  72  are to be identical and are to be constructed of either a rubber, a plastic or a combination of rubber and plastic material within which is embedded ferrous particulate matter. The thickness of the blocks  70  and  72  will normally be within the range of 0.040 to 0.065 inches. Typically, the percentage of ferrous material within each of the blocks  70  and  72  will be about ninety percent. The sandwich configuration shown in  FIG. 7  is then to be placed within the mold, as previously described, and the frame  86  is then formed around this sandwich configuration. The peripheral edge  88  of the sandwich configuration of  FIG. 7  will be embedded within the frame  86 , as is clearly shown in  FIG. 9 . 
   After extraction of the frame  86  from the mold, there is located a pair of cavities  90  and  92 . Cavity  90  is separated from cavity  92  by a bridge strip  94 . The bridge strip  94  is located directly adjacent the bridge  68 . It is to be understood that the frame  86  which includes the bridge strip  94  will be constructed entirely of a resilient material, such as plastic. Also by observing of  FIG. 8 , it is to be seen that the second embodiment  64  is adjustable with a fulcrum occurring in the area of the bridge  68 , as is clearly represented by movement of the second embodiment  64  to the dotted line configuration shown in  FIG. 8 . Arrows  96  and  98  depict movement of the second embodiment  64  to the expanded configuration which would be to accommodate a slightly larger diameter in size of cylindrical filter canister  104  on which the second embodiment  64  is to be located. 
   Within the cavity  90 , there is to be located five in number of strip magnets  100 , and within the cavity  92 , there are to be mounted five in number of strip magnets  102 . The strip magnets  100  and  102  are basically identical and are identical to the previously described strip magnets  60  and  62 . 
   Within both the first embodiment  10  and the second embodiment  64  there is created a pair of zones of magnetism by the strip magnets  60 ,  62 ,  100  and  102 . The zones of magnetism in the first embodiment  10  are separated by the bridge strip  58 , and in the second embodiment  64  they are separated by the bridge strip  94 . It is these zones of magnetism that emit an exceedingly powerful magnetic force that is extended to within the fluid flow path that is being conducted through the oil filter canister  65  or  104 . 
   The discussion included in this patent is intended to serve as a basic description. The reader should be aware that the specific discussion may not explicitly describe all embodiments possible and alternatives are implicit. Also, this discussion may not fully explain the generic nature of the invention and may not explicitly show how each feature or element can actually be representative of a broader function or of a great variety of alternative or equivalent elements. Again, these are implicitly included in this disclosure. Where the invention is described in device-oriented terminology, each element of the device implicitly performs a function. It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. These changes still fall within the scope of this invention. 
   Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation. Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms if only the function or result is the same. Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled. It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action. Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates. Such changes and alternative terms are to be understood to be explicitly included in the description.