SYSTEM AND METHOD FOR OIL FILTRATION IN BYPASS MODE

A filter cartridge having a bypass filtration media is described. The filter cartridge includes main filtration media. In some arrangements, the main filtration media includes first filtration media and second filtration media that has a different filtering efficiency than the first filtration media. The filter cartridge is configured to be installed in a filtration system having a bypass mode. While in the bypass mode, fluid passing through the filtration system is allowed to bypass the main filtration media. To avoid unfiltered fluid from passing from the inlet of filtration system to the outlet (e.g., and on to an internal combustion engine), the fluid flows through the bypass filtration media (e.g., during cold start conditions). In some arrangements, the bypass filtration media has a lower filtering efficiency than the main filtration media.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to and claims priority to U.S. Provisional Patent Application No. 62/222,975, entitled “SYSTEM AND METHOD FOR OIL FILTRATION IN BYPASS MODE,” filed on Sep. 24, 2015, by Bisurkar et al., the contents of which are herein incorporated by reference in the entirety and for all purposes.

TECHNICAL FIELD

The present application relates to filtration systems.

BACKGROUND

Internal combustion engines generally combust a mixture of fuel (e.g., gasoline, diesel, natural gas, etc.) and air. Lubrication oil is also supplied to the engine to lubricate the various moving components of the engine. Either prior to entering the engine or during engine operation, the intake air, fuel, lubrication oil, and other fluids are typically passed through filtration systems to remove contaminants (e.g., dust, water, oil, etc.) from the fluids. The filtration systems include filter elements having filter media. As the fluid passes through the filter media, the filter media removes at least a portion of the contaminants in the fluid.

Some filtration systems, such as oil filtration systems, may include a bypass valve. When the bypass valve is opened, the filtration system is operating in a bypass mode. While in the bypass mode, the fluid being filtered (e.g., oil) is allowed to bypass at least a primary filter element of the filtration system. For example, some oil filtration systems utilize a bypass mode on cold start while the oil is viscous and not easily passed through the primary filter element. In such systems, the bypass mode ends once the oil warms up and becomes thin enough to efficiently pass through the primary filter element. However, if dirty fluid bypasses the filter element during the bypass mode, the dirty fluid may damage the internal combustion engine.

SUMMARY

One example embodiment relates to a filtration system. The filtration system includes a housing having a fluid inlet and a fluid outlet, a filter element, and a bypass valve. The filter element is positioned within the housing and is configured to filter a fluid. The filter element includes a main filter cartridge having a main filter media. The main filter media may be formed into a cylindrical shape. The main filter media is positioned between a first endplate and a second endplate. The first endplate includes a bypass opening. The filter element further includes bypass filter media coupled to the first endplate and covering the bypass opening. The filtration system includes a bypass valve that can be opened and closed to toggle between a normal operation mode and a bypass operation mode. When the bypass valve is open, the bypass operation mode is activated, and fluid being passed through the filtration system can bypass the main filter cartridge by flowing through the bypass filter media and through the bypass opening.

Another example embodiment relates to a filter element. The filter element includes a main filter cartridge having main filter media. The main filter media is positioned between a first endplate and a second endplate. The first endplate includes a bypass opening. The filter element further includes bypass filter media coupled to the first endplate and covering the bypass opening. The filtration system includes a bypass valve that can be opened and closed to toggle between a normal operation mode and a bypass operation mode. When the bypass valve is open, the bypass operation mode is activated and fluid being passed through the filtration system can bypass the main filter cartridge by flowing through the bypass filter media and through the bypass opening.

A further example embodiment relates to a filter element. The filter element includes a first endplate, a second endplate, and a first filter media positioned between the first endplate and the second endplate. The filter element further includes a third endplate positioned on an opposite side of the second endplate, a fourth endplate, and a second filter media positioned between the third endplate and the fourth endplate. The second filter media has a different filtering efficiency than the first filter media. The filter element includes a bypass valve positioned within a central opening of the filter element. The bypass valve can be opened and closed to toggle between a normal operation mode and a bypass operation mode. When the bypass valve is open, the bypass operation mode is activated and fluid being passed through the filter element can bypass the first filter media by flowing through the second filter media. When the bypass valve is closed, the normal operation mode is activated and fluid being passed through the filter element does not bypass the first filter media.

DETAILED DESCRIPTION

Referring to the figures generally, a filter cartridge having a bypass filtration media is described. The filter cartridge includes main filtration media. In some arrangements, the main filtration media includes first filtration media and second filtration media that has a different filtering efficiency than the first filtration media. The filter cartridge is configured to be installed in a filtration system having a bypass mode. While in the bypass mode, fluid passing through the filtration system is allowed to bypass the main filtration media. To avoid unfiltered fluid from passing from the inlet of filtration system to the outlet (e.g., and on to an internal combustion engine), the fluid flows through the bypass filtration media (e.g., during cold start conditions). In some arrangements, the bypass filtration media has a lower filtering efficiency than the main filtration media.

Referring toFIG. 1, a cross-sectional view of a filtration system100is shown according to an example embodiment. The filtration system includes a housing comprising a housing body101and a housing lid102that receives a filter element104. The housing lid102is removably threaded to the housing body101. The filter element104depicted inFIG. 1is a substantially cylindrical filter element. However, the filter element104may possess other shapes in different embodiments. In some arrangements, the filter element104includes two filter cartridges: a first main filtration cartridge106and a second main filtration cartridge108. The first main filtration cartridge106includes first main filtration media positioned between a first endplate and a second endplate. The second main filtration cartridge108includes second main filtration media positioned between a third endplate and a fourth endplate. In some arrangements, the third endplate and the second endplate are opposing sides of a single endplate. The second main filtration media may have a different filtering efficiency than the first main filtration media. The main filtration cartridges106and108are coupled to a center tube110. In other arrangements, the filter element104includes a single main filter cartridge. When the filter element104is received within the housing body101(e.g., as shown inFIG. 1), the center tube110surrounds a standpipe112of the filtration system100.

The filtration system100includes a bypass valve114that is opened and closed to toggle between a normal operation mode and a bypass operation mode. As described in further detail below with respect toFIGS. 5 and 6, when the bypass valve114is open, the filtration system100is placed in a bypass mode. While in the bypass operation mode, fluid being passed through the filtration system100can bypass the main filtration cartridges106and108. During the bypass mode, the fluid passes through a bypass opening in the first or top endplate of the first main filtration cartridge106that is covered by bypass filtration media116. The bypass filtration media116is a porous media that is integrated along a top axial end of the filter element104to ensure that liquid passing through the filtration system100is filtered when the filtration system100is in the bypass mode. The bypass filtration media116is positioned on an axial end of the filter element between the housing lid102and a top endplate of the first main filtration cartridge106. In some arrangements, a bypass media endplate118is used to secure the bypass filtration media116to the top endplate of the first main filtration cartridge106. The porous media selected for the bypass filtration media116can vary based on application and cleanliness requirements. The porous media selected for the bypass filtration media116may be sponge media, layered wire mesh, stacked media, a layer of solid porous media, or the like. In some arrangements, the bypass filtration media116has a lower filtration efficiency than the first and second filtration media. The bypass filtration media116is integrated with the filter element104and thus is changed during each filter element change service.

The filtration system100also includes an X-seal120. The X-seal120forms a seal between the filter element104and the standpipe112, which prevents fluid from bypassing the filter element104. When the filter element104is being removed from the housing body101(e.g., during a service or filter element replacement operation), the X-seal120may permit residual fluid remaining in the housing body101to drain out of the housing body101(e.g., back to a fluid tank, such as an oil or fuel tank).

Referring toFIG. 2, a perspective view of the filter element104is shown. In the embodiment depicted herein, the first main filtration cartridge106and the second main filtration cartridge108are substantially cylindrical in shape. The bypass filtration media116is disc-shaped. The bypass filtration media116is secured to a first end of the first main filtration cartridge106through the bypass media endplate118. Perspective views of the bypass filtration media116and the bypass media endplate118are shown inFIGS. 3 and 4, respectively.

Referring toFIGS. 5 and 6show cross-sectional views of the filtration system100during bypass mode operation. Accordingly,FIGS. 5 and 6show the bypass valve114in the open position. During operation, fluid to be filtered (e.g., oil; designated by the non-hashed dots/arrows) flows into the housing body101via an inlet502. The fluid to be filtered pass through the filter element104(e.g., through the first and second main filtration cartridges106and108during normal operation, through the bypass filtration media116during bypass mode operation). The filtered fluid (designated by the hashed dots/arrows) exits the housing through an outlet504. The bypass valve114is normally biased to the closed position by a spring506. During certain operating conditions where the fluid being filtered is viscous and/or thick (e.g., when the oil is cold during a cold start operation), the pressure between the housing body101and the filter element104forces the bypass valve114into an open position thereby toggling the bypass mode operation. Once the oil warms and thins, the oil can pass through the main filtration cartridges106and108thereby reducing the pressure between the housing body101and the filter element104, which allows the bypass valve114to close. During the bypass mode operation, the fluid passing through the filtration system100is still filtered through the bypass filtration media116.

Referring toFIGS. 7A and 7B, a filtration system700is shown according to another example embodiment. The filtration system700includes a shell housing702that defines a filtering compartment. A filter element704is received within the filtering compartment. In the particular embodiment shown inFIGS. 7A and 7B, the filter element704is a substantially cylindrical filter element. In some arrangements, the shell housing702and the filter element704form a spin-on type filter assembly. However, the filter element704may possess other shapes in different embodiments. In some arrangements, the filter element704includes two filter cartridges: a first main filtration cartridge706and a second main filtration cartridge708. The first main filtration cartridge706includes first main filtration media positioned between a first endplate and a second endplate. The second main filtration cartridge708includes second main filtration media positioned between a third endplate and a fourth endplate. In some arrangements, the third endplate and the second endplate are opposing sides of a single endplate. The second main filtration media may have a different filtering efficiency than the first main filtration media. In certain arrangements, the second main filtration media is a bypass filtration media.

The filter element704includes a bypass valve710. The bypass valve710is positioned within a central opening of the filter element704. As shown by the fluid flow arrows, the bypass valve710is positioned downstream of the filter media in a flow direction. In an alternative arrangement, the bypass valve is positioned upstream of the second main filtration cartridge708. In such an arrangement, the second main filtration cartridge708may be generally sealed (e.g., surrounded by a sealing element) unless the bypass valve710is open. During hot or normal fluid operating conditions (i.e., when the fluid being filtered by the filtration system700is thin enough to flow through the first main filtration cartridge706media), the bypass valve710is closed, and fluid does not pass through the second main filtration cartridge708. The hot or normal fluid operating condition is shown inFIG. 7A. During cold or plugged full-flow operating condition (i.e., during a cold start condition when the fluid is too vicious to efficiently pass through the first main filtration cartridge706media, when the first main filtration cartridge706media is plugged, etc.) the pressure of the fluid forces the bypass valve710to open thereby allowing the fluid to pass through the second main filtration cartridge708. The cold or plugged full-flow operating condition is shown inFIG. 7B. In the cold or plugged full-flow operating condition, the majority of liquid flow takes place through the second main filtration cartridge708and a small portion of the of the liquid flow takes place through the first main filtration cartridge706.

Referring toFIG. 8, a cross-sectional view of pleated filter media800is shown. In some arrangements, filter media800is the filter media used in the first main filtration cartridge706ofFIGS. 7A and 7B. The pleated filter media800includes a full flow multi-layer pleated synthetic media802having an outer layer804and an inner layer806. The inner layer806may have different filtering characteristics than the outer layer804. In some arrangements, the pleated filter media800includes an inner wire-screen support layer808and/or an outer wire-screen support layer810. Filter media800forms a “tight” media that has a higher filtering efficiency than a bypass filter media (e.g., filter media900as discussed below).

Referring toFIG. 9, a cross-sectional view of pleated filter media900is shown. In some arrangements, filter media900is the filter media used in the second main filtration cartridge708ofFIGS. 7A and 7B. Accordingly, the filter media900is bypass filter media. The pleated filter media800includes a pleated single-layer of coarse plain-weave wire mesh902. The filter media900has a lower filtering efficiency than filter media800.

Referring toFIGS. 10A and 10B, various testing data of the filtration system700is shown. The testing parameters are shown inFIG. 10A. The test results based on the parameters ofFIG. 10Aare shown inFIG. 10B. As shown inFIG. 10B, as the bypass valve710opens as the flow rate through the filter element704increases. When the bypass valve710opens, a portion of the fluid being filtered passes through the second main filtration cartridge708, which reduces the slope of the pressure drop rise for increased flow rate of fluid being filtered.

The above-described filtration system100that utilizes the filter element104with the bypass filtration media116ensures that liquid flowing through the filtration system100during bypass mode operation is filtered. This arrangement provides additional protection for internal combustion engines during cold start conditions that trigger the bypass mode operation. Additionally, the arrangement provides enhanced protection for the bypass valve114by reducing the amount of contaminant carried through the bypass valve during bypass mode operation.

Although the above-described filtration system100and filter element104are described in the context of an oil or lubricant filtration system, it should be appreciated that the filtration system100can be applied to other types of filtration system. For example, the filtration system100and filter element104may be applied to hydraulic filtration systems.

It should be noted that any use of the term “example” herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Additionally, features from particular embodiments may be combined with features from other embodiments as would be understood by one of ordinary skill in the art. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various example embodiments without departing from the scope of the present invention.