Filter assembly

A filter assembly for filtering contaminants from liquid. A housing has a filtering chamber and an inlet port and an outlet port communicating with the chamber for flow of liquid therethrough. Filter media is located in the filtering chamber for filtering contaminants from liquid flowing through the chamber. A sump region is provided in the filtering chamber for collection of contaminants from the liquid, and a separator member is located in the filtering chamber and substantially separating the filter media and sump region. The separator member provides for communication of the contaminants into the sump region but tends to trap contaminants from the liquid received in the sump region.

This invention relates generally to filtration of contaminants from 
liquids, and more particularly to a filter assembly for filtering 
contaminants from liquid fuels. The filter assembly is applicable for 
filtering petroleum and other hydrocarbon based fuels used to power 
internal combustion engines, such as vehicle engines, and it will be 
convenient to hereinafter describe the invention in relation to that 
exemplary application. It is to be appreciated, however, that the 
invention is not limited to that application. 
It is common practice to install a fuel filter assembly in a fuel line of 
petrol and diesel powered internal combustion engines. The function of the 
assembly is to remove particulate contiminants, such as dirt, from the 
fuel before the fuel is delivered to the combustion chambers of the 
engine. If such contaminants are allowed to enter the combustion chambers 
then engine damage may be caused. 
Filter assemblies which are currently used suffer the disadvantage that 
when the fuel contains more contaminants than can be trapped by the 
assembly, that assembly becomes clogged and no longer functions 
effectively. This can cause particulate contaminants to pass to the engine 
causing damage. Further, filter assemblies currently used are generally 
ineffective in removing liquid contaminants, such as water, from the fuel. 
It is an object of the present invention to provide an improved filter 
assembly which overcomes, or at least alleviates, the problems of known 
filter assemblies. 
With that object in mind, the present invention provides a filter assembly 
for filtering contaminants from liquid, including: a housing providing a 
filtering chamber and having an inlet port and an outlet port 
communicating with the chamber for flow of liquid therethrough; filter 
media in the filtering chamber for filtering contaminants from liquid 
flowing through the chamber; a sump region in the filtering chamber for 
collection of contaminants from the liquid; and, a separator member 
located in the filtering chamber and substantially separating the filter 
media and sump region, the separator member providing for communication of 
the contaminants into the sump region and tending to trap the contaminants 
from the liquid received in the sump region. 
Preferably, the separator member moves relative to the housing during use 
of the filter assembly. This movement facilitate separation of the 
contaminants from the liquid and their collection in the sump region. The 
separator member is preferably retained in the filtering chamber for 
vibratory movement caused by housing movement during use of the filter 
assembly. 
In one arrangement, the separator member is preferably connected to the 
housing for its location within the filtering chamber. However, that 
connection permits the separator member to move during use of the filter 
assembly. In another arrangement the separator member is preferably 
loosely nested in the filtering chamber, and particularly in the sump 
region thereof. 
Preferably, the separator member includes a separator plate. That plate 
preferably extends across the filtering chamber between the filter media 
and sump region. The plate may extend entirely across that chamber. 
In one embodiment the separator plate has an edge region pivotably 
connected to the housing for location of the plate within the filtering 
chamber. In an alternative arrangement, the separator member has a 
plurality of legs extending from the separator plate and on which the 
separator member stands in the filtering chamber. 
Preferably, the separator member has an array of openings therethrough 
providing communication for the contaminants into the sump region. 
The filter assembly may further include a baffle member located in the 
filtering chamber between the inlet port and the filter media. In this way 
liquid flowing into the filtering chamber impinges upon the baffle member 
causing at least some contaminants entrained in the liquid to deflect 
toward the sump region for collection therein. That baffle member may be 
fixed above the sump region and may extend across the filtering chamber 
generally perpendicular to a longitudinal axis of the inlet port. The 
baffle member may have an array of openings therethrough providing liquid 
communication between the inlet port and filter media. 
The following description refers to preferred embodiments of the filter 
assembly of the present invention. To facilitate an understanding of the 
invention, reference is made in the description to the accompanying 
drawings where the assembly is illustrated in those preferred embodiments. 
It is to be understood that the assembly is not limited to the embodiments 
as hereinafter described and as illustrated in the drawings.

Referring to the drawings there is generally shown alternative embodiments 
of filter assembly 1. Assembly 1 has housing 2 defining filtering chamber 
3. Housing 2 has an inlet tube 4 providing inlet port 5 communication with 
chamber 3, and also outlet tube 6 providing outlet port 7 communicating 
with chamber 3. As shown, inlet tube 4 and/or outlet tube 6 may project a 
short distance into chamber 3 so that inlet port 5 and/or outlet port 7 
are located within chamber 3. 
Tubes 4, 6 are constructed for connection to liquid flow lines (not shown) 
so that liquid in the flow lines can flow through port 5 into chamber 3 
and therefrom through port 7. 
Inlet and outlet ports 5, 7 are co-axial and located toward opposite ends 
of housing 2. As shown, filter assembly 1 of FIGS. 1 to 5 is intended for 
generally vertical, upward flow of liquid, whilst filter assemblies 1 of 
FIGS. 6 to 9, and FIG. 10 are intended for generally horizontal flow of 
liquid. 
Housing 2 is of a generally enclosed cylindrical shape, although other 
shapes may be equally suitable. Housing 2 includes open ended body 8 and 
closure cap 9, which may be removable for access to filtering chamber 3, 
such as for maintenance. Cap 9 can be secured to body 8 through any 
suitable connection arrangement, such as by means of snap connection 10, 
or a screw thread connection (not shown). 
Housing 2 is of a generally integral construction. To that end, inlet tube 
4 can be molded or cast integral with body 8, whilst outlet tube 6 can be 
molded or cast integral with cap 9. It should be appreciated that, in 
particular, tubes 4, 6 may be otherwise connected to body 8 and cap 9. 
Housing 2 may be constructed of any suitable materials. Selection of 
materials may depend on the liquid to be filtered. In these embodiments, 
housing 2 is composed at least in part of transparent or translucent 
material to allow at least partial visual inspection of filtering chamber 
3. Conveniently, housing 2 is composed of plastics material. 
Filter assembly 1 includes filter media 11 in chamber 3 for filtering 
contaminants from liquid flowing therethough. Filter media 11 is 
particularly constructed for removing solid Particulates from the liquid. 
Filter media 11 is in the form of filter cartridge 12 in these embodiments. 
Cartridge 12 is mounted in chamber 3 and includes generally annular filter 
member 13 and end caps 14, 15. In these embodiments, filter member 13 is 
composed of filter sheet material corrugated or pleated into its annular 
configuration so as to define inner chamber 16. Filter member 13 may be of 
any other suitable construction and, by way of example, may be composed of 
foam material. 
End caps 14, 15 may be interferingly fitted over filter member 13 to assist 
in retaining the filter sheet material in the corrugated or pleated 
configuration. The filter sheet material may be paper or cardboard based 
material. 
End cap 14 is closed, whilst end cap 15 has aperture 17 therein into which 
outlet tube 6 projects for communication with inner chamber 16 of filter 
member 13. Filter member 13 is fixed in position in chamber 3 by 
connection of end cap 15 to outlet tube 6, although may be removable 
therefrom for cleaning and/or replacement. With this arrangement, liquid 
entering through inlet port 5 into chamber 3 can flow through filter 
member 13 into inner chamber 16 and then to outlet port 7. In flowing 
through filter member 13, contaminants entrained in the liquid are trapped 
by filter member 13 in a typical filtering action. 
Included within filtering chamber 13 is sump region 18 into which 
contaminants in the liquid can be collected clear of filter member 13. 
Housing 2 is suitably shaped to accomodate sump region 18. To that end, 
sump region 18 may be located entirely in housing body 8 (as shown in the 
assembly assemblies of FIGS. 6 to 9 and FIG. 10). 
Sump region 18 is generally located at the bottom of chamber 3, beneath 
filter media 11 and also below inlet port 5. Thus, contaminants entrained 
in liquid entering chamber 3 can move under influence of gravity toward 
sump region 18. 
Assembly 1 also includes separator member 19 separating filter media 11 
from sump region 18. Separator member 19 facilitates separation of 
contaminants from the liquid and also acts to trap or retain contaminants 
received in sump region 18. 
Separator member 19 includes separator plate 20 extending across chamber 3, 
dividing filter media 11 from sump region 18. Plate 20 has an array of 
openings 21 therethrough for communication into sump region 18. In these 
embodiments, openings 21 are a regular grid array of circular holes 
between about 1 and 3 mm in diameter, although other opening arrays, 
shapes and sizes are envisaged, depending at least to some extent on the 
type of liquid and contaminants flowing through assembly 1. In an 
alternative embodiment (not shown) separator plate 20 may be composed of 
suitable graded mesh material. 
Separator member 19 is located in chamber 3 for limited movement during use 
of assembly 1. That movement is continuous vibration and is caused by 
vibration of housing 2 during use of assembly 1. In the exemplary 
application of assembly 1, vibration will be the result of associated 
engine operation and/or engine movement. Vibration of separator member 19 
will be in directions of a general plane of member 19 and/or laterally of 
that plane. 
The vibratory movement of separator member 19, and particularly Plate 20, 
assists in separating contaminants from the liquid. In that regard, 
contaminants contacting plate 20 may be broken down by the vibratory 
effect. That is particularly so when the contaminants are conglomerates of 
particulate material. Moreover, the vibratory movement tends to cause any 
contaminants resting on plate 20 to gravitate toward and pass through 
openings 21. Once collected in sump region 18, the continuous movement of 
Plate 20 reduces the likelihood of contaminants re-aligning with openings 
21 and passing back through them out of sump region 18. That vibratory 
movement also inhibits purging of sump region 18 of collected contaminants 
by flow of liquid around filter media 11. That is particularly so in view 
of the small size of openings 21 and the rapid continuous vibration of 
separator member 19, even though some liquid will flow through openings 21 
into and out of sump region 18 on its way through filter assembly 1. 
Trapping of contaminants in sump region 18 removes those contaminants from 
filter media 11. That in turn may preserve the filtering integrity of 
filter member 13, thereby prolonging the operational life of assembly 1. 
In particular, removal of contaminants from filter member 13 prevents 
those contaminants from clogging, damaging or otherwise inhibiting the 
filtering effect of member 13. 
In the embodiments shown in FIGS. 1 to 5 and FIGS. 6 to 9, separator member 
19 is shaped and sized so as to be loosely located in chamber 3. In this 
way, member 19 will tend to rattle during use of assembly 1 to cause the 
necessary vibratory movement. 
In those assembly embodiments, separator member 19 includes a plurality of 
support legs 22 (such as two as shown) projecting from separator Plate 20. 
Plate 20 stands on support legs 22 which bear on housing 2 in order to 
correctly locate separator plate 20. In an alternative arrangement (not 
shown) the support legs may be provided by housing 2 so that plate 20 
bears on them. 
The location of member 19 is such that plate 20 will vibrate without 
rotating in its general plane. In the assembly embodiment of FIGS. 1 to 5 
that is achieved by Providing housing 2 with location legs 23 which 
loosely engage in cut outs 24 in plate 20, whilst in the assembly 
embodiment of FIGS. 6 to 9 that is achieved by suitable shaping of plate 
20. Where assembly 1 can be dismantled for cleaning or other maintenance, 
then separator member 19 is removable from housing 2. 
It should be appreciated that separator member 19 may be otherwise located 
in chamber 3. By way of example, in one further assembly embodiment shown 
in FIG. 10, separator plate 20 has one edge region 25 hingedly connected 
through connection 26 to housing 2 so as to generally locate member 19 but 
permit vibratory movement thereof. Member 19 may include at least one 
support leg (not shown) extending from plate 20 remote from connection 26 
in order to support plate 20. 
Conveniently, separator member 19 is of a one-piece construction. Member 19 
may be composed of any suitable material, such as plastics material or 
metal. 
Assembly 1 may optionally include baffle member 27 in filtering chamber 3 
to assist in removing contaminants from the liquid. Baffle member 27 is 
fixed between inlet port 5 and end cap 14 of filter cartridge 12, and 
extends at least substantially perpendicular to the flow of liquid 
entering through inlet port 5. In this way, liquid flowing into chamber 3 
tends to impinge upon member 27. This can have an effect on some 
contaminants that they are immediately redirected downwardly toward sump 
region 18, rather than onto protected against contact from those 
contaminants, which may in turn prolong filter assembly life. 
Baffle member 27 has an array of openings 28 for communication of liquid 
therethrough to filter media 11. Openings 28 may be of a similar 
configuration to openings 21. 
In operation of filter assembly 1, liquid with entrained contaminants flows 
through inlet port 5 and initially impacts upon end cap 14 (and/or baffle 
member 27 if present). Thereafter, the liquid flows around and through 
filter cartridge 12 into inner chamber 16 before passing through outlet 
port 7. During passage of the liquid through chamber 3, entrained 
contaminants are progressively removed from the liquid by action of filter 
media 11, separator member 19 and baffle member 27. Many of the 
contaminants will collect in sump region 18, with the remaining 
contaminants collecting on filter member 13. 
The filter assembly of the present invention has an extended effective or 
operational life when compared with prior similar assemblies. 
Finally, it should be appreciated that various modifications and/or 
alterations may be made to the filter assembly without departing from the 
ambit of the present invention as defined in the claims appended hereto.