Systems and methods for securing a sealing member on a filter assembly

A filter assembly comprises a filter housing defining an internal volume, a filter element positioned within the internal volume, and a gasket retainer. An outer edge of the gasket retainer is coupled to a top end of the filter housing, and an inner rim thereof forms a gasket retainer ledge. The filter assembly further comprises a retainer loop comprising a retainer loop main body. A plurality of retainer arms extend axially from the retainer loop main body towards the gasket retainer. Each of the plurality of retainer arms comprise a retainer arm ledge extending radially towards the retainer loop main body and snap-fit to the gasket retainer ledge. A retainer loop sidewall extends from the main body away from the gasket retainer. An outer surface of the retainer loop sidewall defines a curvature. A sealing member is removably positioned around the outer surface of the retainer loop sidewall.

TECHNICAL FIELD

The present disclosure relates generally to filters for use with internal combustion engine systems.

BACKGROUND

Internal combustion engines generally use various fluids during operation. For example, fuel (e.g., diesel, gasoline, natural gas, etc.) is used to run the engine. Air may be mixed with the fuel to produce an air-fuel mixture, which is then used by the engine to run under stoichiometric or lean conditions. Furthermore, one or more lubricants may be provided to the engine to lubricate various parts of the engine (e.g., piston cylinder, crank shaft, bearings, gears, valves, cams, etc.). These fluids may become contaminated with particulate matter (e.g., carbon, dust, metal particles, etc.) which may damage the various parts of the engine if not removed from the fluid.

Some filter assemblies comprise a filter element positioned within a filter housing, such as a shell housing. Such filter assemblies are generally provided as self-contained assemblies structured to be mounted on a filter head or other mounting structure. A sealing member such as an O-ring may be positioned on the filter assembly and structured to form a fluid seal between the filter assembly and the filter head. In a number of conventional filter assemblies, the sealing member is generally positioned loosely around the filter assembly and can easily come off during installation or removal of the filter assembly from the filter head, which may cause leakage of fluid.

SUMMARY

Embodiments described herein relate generally to systems and methods for securing a sealing member on a filter assembly, and in particular, a retainer loop snap-fit on a gasket retainer of a filter assembly and structured to secure the sealing member on an outer curved surface thereof cooperatively with the gasket retainer.

In a set of embodiments, a retainer assembly for a filter assembly comprises a gasket retainer and a retainer loop. An outer edge of the gasket retainer is configured to be coupled to a filter housing top end of a filter housing, and an inner rim of the gasket retainer forms a gasket retainer ledge. The retainer loop comprises a retainer loop main body, a plurality of retainer arms extending axially from the retainer loop main body towards the gasket retainer, each of the plurality of retainer arms comprising a retainer arm ledge extending radially towards the retainer loop main body and snap-fit to the gasket retainer ledge, and a retainer loop sidewall extending from the retainer loop main body away from the gasket retainer. An outer surface of the retainer loop sidewall defines a curvature. A sealing member is removably positioned around the outer surface of the retainer loop sidewall.

In another set of embodiments, a filter assembly comprises a filter housing defining an internal volume. A filter element is positioned within the internal volume. The filter assembly also comprises a gasket retainer. An outer edge of the gasket retainer is coupled to a top end of the filter housing. An inner rim of the gasket retainer forms a gasket retainer ledge. The filter assembly further comprises a retainer loop. The retainer loop comprises a retainer loop main body. A plurality of retainer arms extend axially from the retainer loop main body towards the gasket retainer. Each of the plurality of retainer arms comprises a retainer arm ledge extending radially towards the retainer loop main body and snap-fit to the gasket retainer ledge. A retainer loop sidewall extends from the retainer loop main body away from the gasket retainer. An outer surface of the retainer loop sidewall defines a curvature. A sealing member is removably positioned around the outer surface of the retainer loop sidewall.

In still another set of embodiments, a method for securing a sealing member of a filter assembly comprises providing a gasket retainer, an inner ledge of the gasket retainer forming a gasket retainer ledge. An outer edge of the gasket retainer is coupled to a filter housing top end of a filter housing. A retainer loop is provided, the retainer loop comprising: a retainer loop main body, a plurality of retainer arms extending axially from the retainer loop main body towards the gasket retainer, each of the plurality of retainer arms comprising a retainer arm ledge extending radially towards the retainer loop main body and snap-fit to the gasket retainer ledge, and retainer loop sidewall extending from the retainer loop main body away from the gasket retainer. An outer surface of the retainer loop sidewall defines a curvature. The retainer loop is positioned on the gasket retainer such that the plurality of retainer arms snap-fit onto the gasket retainer ledge. The sealing member is positioned around the outer surface of the retainer loop sidewall.

DETAILED DESCRIPTION

Embodiments described herein relate generally to systems and methods for securing a sealing member on a filter assembly, and in particular, a retainer loop snap-fit on a gasket retainer of a filter assembly and structured to secure the sealing member on an outer curved surface thereof cooperatively with the gasket retainer.

Some filter assemblies comprise a filter element positioned within a filter housing, such as a shell housing. Such filter assemblies may be generally provided as self-contained assemblies structured to be mounted on a filter head or other mounting structure. A sealing member such as an O-ring may be generally positioned on the filter assembly and structured to form a fluid seal between the filter assembly and the filter head. In a number of conventional filter assemblies, the sealing member is generally positioned loosely around the filter assembly and can easily come off during installation or removal of the filter assembly from the filter head, which may cause leakage of fluid.

Embodiments described herein that provide for securing a sealing member of a filter assembly may provide benefits including, for example: (1) positioning the sealing member via a retainer loop comprising a plurality of retainer arms which snap-fit on a gasket retainer, thereby increasing a contact surface area of the retainer arms on the gasket retainer and leading to an increase in a retention force on the sealing member; (2) securing the sealing member cooperatively via the retainer loop and a gasket retainer so as to prevent the sealing member form being dislodged and/or lost which may cause sealing issues (e.g., fluid leakage); (3) centrally locating the sealing member around the retainer loop; (4) providing easier assembly by allowing positioning of the sealing member on the retainer loop after the retainer loop has been coupled to the gasket retainer; and (6) providing both radial and axial sealing of the filter assembly when the filter assembly is coupled to a filter head.

FIG. 1is a side cross-section of a filter assembly100according to an embodiment. The filter assembly100may be used to filter a liquid (e.g., lubricant, fuel, etc.), a gas (e.g., air), air/fuel mixture, or another fluid provided to an engine. The filter assembly100comprises a filter housing102, a filter element110, a gasket retainer130, a retainer loop140, and a sealing member150positioned around the retainer loop140as described in detail herein.

The filter housing102defines a filter housing internal volume103within which the filter element110is positioned. The filter housing102may be formed from a strong and rigid material, for example plastics (e.g., polypropylene, high density polyethylene, polyvinyl chloride, etc.), metals (e.g., aluminum, stainless steel, etc.), polymers (e.g., reinforced rubber, silicone) or any other suitable material. In particular embodiments, the filter housing102may comprise a cylindrical housing having generally a circular cross-section. In other embodiments, the filter housing102may have any suitable cross-sectional shape, for example racetrack, oval, rectangular, polygonal, etc. In particular embodiments, the filter housing102may comprise a shell housing.

The filter housing102includes a filter housing base105which may have a bowl shape, for example to collect any water included in the fluid (e.g., air, fuel, air/fuel mixture or lubricant) being filtered through the filter assembly100. A drain port126may be provided in the filter housing base105. A drain plug127may be coupled to the drain port126. The drain plug127may be selectively removable from the drain port126so as to allow accumulated water to be drained from the filter housing102.

In some embodiments, a sensor port128is also formed in the filter housing base105of the filter housing102. A water-in-filter (WIF) sensor129may be positioned in the sensor port128and connected to a controller (e.g., WIF monitor an engine control unit) via an electrical connector. The WIF sensor129may be configured to sense a level of water accumulated in the filter housing base105. In some embodiments, the WIF sensor129may communicate a water level signal to a controller. The controller may inform a user that a water level in the filter housing102is above a predetermined threshold, so that the user may remove the drain plug127and drain the water from the filter assembly100via the drain port126. In other embodiments, a valve may be positioned in the drain port126. The WIF sensor129may be configured to communicate a valve signal to the valve causing the valve to move into an open position in response to a level of water accumulated in the filter housing base105exceeding a predetermined threshold.

The filter element110is positioned along a longitudinal axis ALof the filter assembly100within the filter housing internal volume103. The filter element110comprises a filter media120. The filter media120includes a porous material having a predetermined pore size and is configured to filter particulate matter from the fluid flowing therethrough. The filter media120or any other filter media described herein may include pleated media, tetrahedral media, fluted filter media, corrugated filter media or variations thereof.

In some embodiments, the filter media120may be caged. For example, the filter element110may also comprise a porous rigid structure (e.g., a wire mesh) positioned around the filter media120, which is structured to prevent damage to the filter media120during insertion of the filter element110into the filter housing internal volume103.

The filter media120may be positioned around a center tube116. In particular embodiments, the center tube116may be included in the filter element110, for example, the filter media120may be wound around or otherwise coupled to the center tube116. The center tube116defines a center tube channel118in fluid communication with a fluid outlet125through which filtered fluid (e.g., filtered air, fuel or air/fuel mixture) is delivered out of the filter housing102. The center tube116may include a plurality of openings117structured to allow the filtered fluid to flow through the filter media120into the center tube channel118, and therefrom to the fluid outlet125.

A first end cap112is coupled to a filter media first end of the filter media120proximal to the filter housing base105. The first end cap112may define a first end cap opening structured to receive a center tube first end of the center tube116. A second end cap114is coupled to a filter media second end of the filter media120opposite the filter media first end proximate a filter housing top end104. The second end cap114may define a second end cap opening structured to receive a center tube second end of the center tube116opposite the center tube first end. The first end cap112and the second end cap114may be formed from any suitable material, for example plastics, metals, rubber, reinforced rubber, polymers, etc.

The first end cap112and the second end cap114may have a cross-section generally corresponding to the cross-section of the filter housing102. In other embodiments, the cross-section of the first end cap112and the second end cap114may be smaller than the cross-section of the filter housing102. The second end cap114may protect the filter media first end of the filter media120from damage as the filter element110is inserted into the filter housing internal volume103and/or maintain a shape (e.g., a cylindrical shape) of the filter media120, so as to facilitate insertion of the filter element110into the filter housing internal volume103. In particular embodiments, the first end cap112and the second end cap114may be fixedly coupled to the filter media first end and the filter media second end, respectively via an adhesive or thermally bonded thereto.

A nut plate170is positioned in the filter housing internal volume103proximate the filter housing top end104. The nut plate170comprises a generally circular member positioned radially around the longitudinal axis ALand having a diameter or cross-section corresponding to diameter or cross-section of the filter housing102. The nut plate170comprises a nut plate outer portion171positioned proximate to a sidewall of the filter housing102. In some embodiments, threads may be defined on an edge of the nut plate outer portion171of the nut plate170. The threads may be configured to mate with mating threads defined on an inner surface of the sidewall of the filter housing102proximate to the filter housing top end104. In other embodiments, the edge of the nut plate outer portion171may be welded to the inner surface of the filter housing102. In still other embodiments, the nut plate170may be coupled to (e.g., welded to or monolithically formed with) the gasket retainer130included in the filter assembly100which is coupled to the filter housing top end104of the filter housing102, and described in further detail herein.

A plurality of openings172are defined in the nut plate outer portion171. The plurality of openings172may be configured to allow the fluid (e.g., air, fuel or air/fuel mixture) to be communicated therethrough into the filter housing internal volume103around the filter media120. The fluid flows through the filter media120to the center tube channel118and is thereby filtered. The nut plate170also comprises a nut plate inner portion174. The nut plate inner portion174is positioned on the filter element110and may be configured to secure the filter element110in the filter housing102.

Expanding further, the filter element110may be positioned on a biasing member124(e.g., a helical spring, a coil spring, a Belleville spring, a leaf spring or any other suitable biasing member) positioned on the filter housing base105. Furthermore, an interfacial sealing member122may be positioned on or coupled to the second end cap114. The interfacial sealing member122may be formed from a soft polymeric material, for example, rubber or polymers. In particular embodiments, the interfacial sealing member122may be monolithically formed with the second end cap114(e.g., molded therewith).

As shown inFIG. 1, the nut plate inner portion174is structured to contact the interfacial sealing member122as the nut plate170is inserted into the filter housing internal volume103. The biasing member124exerts a biasing force on the filter element110and pushes the filter element110and thereby, the interfacial sealing member122towards the nut plate170. In this manner, the interfacial sealing member122is pressed against the nut plate inner portion174so as to form a fluid tight seal therewith and prevent unfiltered fluid from entering the center tube channel118.

A nut plate conduit176extends axially from an inner rim of the nut plate inner portion174away from the filter element110. The nut plate conduit176is configured to receive an inlet conduit162of a filter head160to which the filter assembly100may be removably coupled, and configured to allow filtered fluid to be communicated from the fluid outlet125out of the filter assembly100into the inlet conduit162. The filter head160may include, for example, a receiving structure of a system (e.g., an engine or a vehicle) structured to allow mounting of the filter assembly100thereto. The filter head160is configured to communicate unfiltered fluid (e.g., air, fuel or air/fuel mixture) to the filter assembly100and receive filtered fluid therefrom (e.g., via the inlet conduit162). A plurality of threads177may be defined on an inner surface of the nut plate conduit176and configured to mate with mating threads defined on an outer surface of the inlet conduit162of the filter head160. This may allow coupling of the filter assembly100to the filter head160.

The gasket retainer130and the retainer loop140are configured to cooperatively secure a sealing member150to the filter assembly100. The sealing member150may comprise, for example, an O-ring, a gasket, or any other sealing member. The sealing member150may be formed from any suitable flexible material (e.g., rubber, polymers, etc.). In particular embodiments, the sealing member150comprises an O-ring having a circular cross-section.

As shown inFIG. 1, the sealing member150is positioned between a filter head inner-sidewall164of the filter head160, the retainer loop140and the gasket retainer130, and is configured to provide an axial and radial fluid seal between the retainer loop140, the gasket retainer130and the filter head inner sidewall164so as to prevent leakage of the fluid (e.g., air, fuel or air/fuel mixture) being inserted into the filter assembly100from the filter head160and/or flow of an external fluid (e.g., air) from outside the filter assembly100, into the filter assembly100. In particular embodiments, an additional axial fluid sealing member may be positioned between the filter head160and a top surface of the sealing member150distal from the gasket retainer130.

Referring also now toFIGS. 2A-5, the gasket retainer130comprises a generally ring shaped gasket retainer main body132. In other embodiments, the gasket retainer main body132may have any other suitable cross-section, for example, oval, racetrack, square, rectangular, polygonal, asymmetrical, etc. An outer edge134of the gasket retainer130extends radially outwards from the gasket retainer main body132and is coupled to the filter housing top end104of the filter housing102. For example, as shown inFIGS. 1, 4 and 5, the outer edge134may be rolled with the filter housing top end104or otherwise crimped to the filter housing top end104so as to couple the outer edge134of the gasket retainer130to the filter housing top end104. In other embodiments, the outer edge134may be welded, bonded (e.g., fusion bonded, heat bonded, etc.), bolted, screwed, snap-fit, or otherwise coupled to the filter housing top end104using any other suitable coupling mechanism. In particular embodiments, the gasket retainer130may be coupled to the nut plate170or monolithically formed therewith. For example, an outer nut plate sidewall may extend axially from an outer rim of the nut plate outer portion171away from the filter element110, and be shaped to form the gasket retainer130. An inner rim of the gasket retainer130extends inwards from the gasket retainer main body132and is structured to form a gasket retainer ledge136.

The retainer loop140is configured to snap-fit to the gasket retainer ledge136. The retainer loop140may be formed from any suitable material, for example, plastics, metals, rubber, polymers, etc. As shown inFIGS. 2A-5, the retainer loop140comprises a ring shaped retainer loop main body142(best shown inFIGS. 2A and 3A). In other embodiments, the retainer loop main body142may have any other suitable cross-section corresponding to a cross-section of the gasket retainer main body132, for example, oval, square, rectangular, polygonal, asymmetrical, etc. A plurality of retainer arms144extend axially from the retainer loop main body142towards the gasket retainer130, and may generally be L-shaped. Each of the plurality of retainer arms144comprises a retainer arm ledge145extending radially towards the retainer loop main body142from a bottom end of the plurality of retainer arms144proximate to the gasket retainer ledge136. Each of the retainer arm ledges145are structured to snap-fit to the gasket retainer ledge136, for example, when the sealing member150is positioned around the retainer loop140, as described in further detail herein.

A retainer loop sidewall146extends axially from an outer rim of the retainer loop main body142away from the gasket retainer130. An outer surface147of the retainer loop sidewall146defines a curvature. The sealing member150is removably positioned around the outer surface147of the retainer loop sidewall146. The curvature of the outer surface147may correspond to a curvature of the sealing member150.

FIG. 4is a side cross-section of a top portion of the filter assembly100ofFIG. 1showing the retainer loop140and the gasket retainer130in a first configuration in which the sealing member150is removed from the outer surface147. The plurality of retainer arms144may have a length such that removing of the sealing member150from the filter assembly100may cause a first gap g1to exist between each of the retainer arm ledges145and a bottom surface of the gasket retainer ledge136. Furthermore, a second gap g2may also exist between the retainer loop main body142and a top surface of the gasket retainer ledge136. This may allow the retainer loop140to be free to move axially and rotate relative to the gasket retainer130. Free movement of the retainer loop140in the first configuration may indicate to a user that the sealing member150is missing from the filter assembly100, thereby preventing the user from erroneously installing the filter assembly100on a filter head (e.g., the filter head160) without the sealing member150positioned thereon.

FIG. 5is a side cross-section of the top portion of the filter assembly100showing the retainer loop140and the gasket retainer130in a second configuration in which the sealing member150is positioned around the outer surface147of the retainer loop sidewall146. As shown inFIG. 5, positioning of the sealing member150on the outer surface147of the retainer loop sidewall146causes a first portion of the sealing member150to be in contact with the gasket retainer130. Furthermore, a second portion of the sealing member150contacts the outer surface147of the retainer loop sidewall146. The sealing member150exerts a force on each of the gasket retainer130and the retainer loop140(i.e., the outer surface147of the retainer loop sidewall146) in directions shown by the arrows F. For example, positioning of the sealing member150around the outer surface147may cause the sealing member150to be slightly compressed (e.g., up to 10% of a diameter of the sealing member150), thereby causing the sealing member150to exert the force on the outer surface147of the retainer loop sidewall146and the gasket retainer130.

The force causes the retainer loop140to move upwards relative to the gasket retainer130. Each of the plurality of retainer arms144may be structured to have a predetermined length such that the upward movement causes the retainer arm ledges145to contact the bottom surface of the gasket retainer ledge136and no gap remains between the retainer arm ledges145and the gasket retainer ledge136. In other words, the retainer arm ledges145engage the gasket retainer ledge136in the second configuration so as to snap-fit the retainer arms144to the gasket retainer ledge136. Furthermore, a third gap g3exists between the retainer loop main body142and the top surface of the gasket retainer ledge136, which is larger than the second gap g2.

In this manner, the sealing member150is secured between the outer surface147of the retainer loop sidewall146of the retainer loop140, and the gasket retainer130, as well as centered around the longitudinal axis ALof the filter assembly100. The retainer loop140may exert an equal and opposite force on the sealing member150, for example, due to the retainer arm ledge145engaging the gasket retainer ledge136and preventing upward motion of the retainer loop140relative to the gasket retainer130. Moreover, a number and/or spacing of the plurality of retainer arms144may be configured to provide a uniform force on the sealing member150.

The force exerted by the sealing member150on the retainer loop140and engagement of the gasket retainer ledge136by the retainer arm ledge145causes the retainer loop140to be immovable relative to the gasket retainer130when the sealing member150is positioned between the retainer loop140and the gasket retainer130. For example, friction between the outer surface147of the retainer loop sidewall146and the sealing member150, the sealing member150and the gasket retainer130, and the retainer arm ledge145and the gasket retainer ledge136may immobilize the retainer loop140relative to the gasket retainer130.

FIG. 6is schematic flow diagram of a method600for securing a sealing member (e.g., the sealing member150) on a filter assembly (e.g., the filter assembly100), according to an embodiment. The method600comprises providing a gasket retainer, at602. An inner rim of the gasket retainer forms a gasket retainer ledge. For example, the gasket retainer may comprise the gasket retainer130with an inner rim thereof forming the gasket retainer ledge136.

At604, an outer edge of the gasket retainer is coupled to a top end of a filter housing. For example, the outer edge134of the gasket retainer130is coupled to the filter housing top end104of the filter housing102(e.g., crimped, welded, bonded, bolted, screwed or otherwise coupled thereto using any suitable coupling mechanism). At606, a retainer loop (e.g., the retainer loop140) is provided. The retainer loop (e.g., the retainer loop140) comprises a retainer loop main body (e.g., the retainer loop main body142). A plurality of retainer arms (e.g., the plurality of retainer arms144) extend axially from an inner rim of the retainer loop main body (e.g., the retainer loop main body142). A retainer loop sidewall (e.g., the retainer loop sidewall146) extends axially from an outer rim of the retainer loop main body away from plurality of retainer arms. An outer surface (e.g., the outer surface147) of the retainer loop sidewall (e.g., the retainer loop sidewall146) defines a curvature. The curvature may correspond to a curvature of an outer surface of a sealing member (e.g., the sealing member150).

At608, the retainer loop is positioned on the gasket retainer such that the plurality of retainer arms snap-fit onto the gasket retainer ledge. For example, the retainer loop140is positioned on the gasket retainer130such that each of the retainer arm ledges145of the plurality of retainer arms144engage and snap-fit to the gasket retainer ledge136. Furthermore, the retainer loop may be free to move axially and rotate relative to the gasket retainer after operation608, as previously described herein with respect toFIG. 4.

At610, a sealing member is positioned around the outer surface of the retainer loop sidewall. For example, the sealing member150is positioned around the outer surface147of the retainer loop sidewall146such that the sealing member150is secured between the outer surface147of the retainer loop sidewall146and the gasket retainer130, as previously described herein with respect toFIG. 5. Moreover, the retainer loop140may be immovable relative to the gasket retainer130after operation610, as previously described herein.

FIG. 7is a schematic flow diagram of an example method700for replacing a used filter assembly mounted on a filter head (e.g., the filter head160). The method700comprises uncoupling a used filter assembly from the filter head, at702. For example, a conventional filter assembly which may have a sealing member positioned loosely therearound is removed from the filter head160.

At704, a filter assembly (e.g., the filter assembly100) is provided. The filter assembly comprises a filter housing (e.g., the filter housing102). An outer edge of a gasket retainer (e.g., the outer edge134of the gasket retainer130) is coupled to a top end of the filter housing (e.g., the filter housing top end104of the filter housing102, as previously described herein). A retainer loop (e.g., the retainer loop140) is snap-fit on a gasket retainer ledge (e.g., the gasket retainer ledge136) of the gasket retainer. For example, the plurality of retainer arms144of the retainer loop140are snap-fit on the gasket retainer ledge136of the gasket retainer130, as previously described herein. Furthermore, a sealing member (e.g., the sealing member150) is positioned around an outer surface (e.g., the outer surface147) of a retainer loop sidewall (e.g., the retainer loop sidewall146) of the retainer loop (e.g., the retainer loop140). For example, the sealing member150is positioned around the outer surface147of the retainer loop sidewall146and secured between the retainer loop140and the gasket retainer130as previously described herein.

At706, the filter assembly is mounted on the filter head. For example, the filter assembly100is mounted on the filter head160such that the sealing member150is disposed between the filter head160, the gasket retainer130and the retainer loop140, and fluidly seals the filter assembly100to the filter head160.

It should be noted that the term “example” as used 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).