Filter block mounted fuel processor apparatus

A fuel processor device is described which is particularly adapted for replacing existing fuel filters of diesel powered machines and fuel consuming devices. The fuel processor designs described have inlet and outlet passages within their upper surface and include a lower plate assembly which provides a mounting location for various elements such as water sensors, drain valves, temperature sensors and heaters which are provided in accordance with the user's needs. The lower plate assembly may be mounted directly to a housing by a through bolt or matching threads or may be made integral with the fuel processor housing. The fuel processor device may include an integral throwaway filter element or the element may be integrated with the fuel processor housing. Various control means may be employed in connection with the fuel processor disclosed wherein the automatic drain water or other accumulated impurities from the lower portion of the fuel processor housing. Additionally, heaters and heater control elements can be installed to aid in fuel water separation and prevent fuel waxing. Since these fuel processors are adapted to be mounted to existing mounting provisions, the requirement of a remotely mounted fuel processor is avoided and therefore the provision of additional fuel lines and fittings is eliminated.

BACKGROUND AND SUMMARY OF THE INVENTION 
This invention relates to a fuel processor device and particularly, to such 
a device suitable for use in connection with existing fuel filter mounting 
provisions of internal combustion engines and other fuel consuming 
devices. 
In the past, when diesel fuel and other hydrocarbon fuels were plentiful 
and comparatively inexpensive, there were relatively few problems with the 
quality of fuel. Refineries, distributors, and retailers were careful to 
keep water out of fuel and they usually did not pump out the heavy 
settlings from the bottom of the storage tanks. In more recent times, 
however, fuel suppliers have been providing fuel with increased 
proportions of water and other contaminants. Also, in the past, kerosene 
and other fuels with lower paraffin formation (cloud) and pour points were 
blended with diesel fuel for cold weather use. Fuel allocations due to 
government regulations, fuel stock availability, refinery capacity and 
other factors have now made it almost impossible to continue this 
practice. The result of these developments has been a tendency toward 
lower quality diesel fuel containing substantially more impurities such as 
water, waxes, paraffins, heavier compounds and particulate matters which 
are very disruptive to the proper operation of fuel oil using devices. 
In order to overcome the above-mentioned fuel quality problems, operators 
of diesel equipment are incorporating fuel conditioning devices to serve 
as water separators and/or impurity filters. Several of such devices are 
described by my issued U.S. Pat. Nos. 4,368,716; 4,428,351; 4,395,996; 
4,421,090 and by my copending U.S. patent applications Ser. Nos. 463,041 
and 573,292. These patents and applications are hereby incorporated by 
reference. The devices constructed according to the teachings of these 
patents and copending applications provide excellent water separation and 
filtration performance, These devices are essentially stand-alone units 
which are mounted remotely from the engine or associated fuel consuming 
apparatus. Such remote mounting requires a mounting location, the use of 
mounting hardware and fuel conduit connection provisions. 
Many motor vehicle engines and other fuel consuming devices have filter 
head assemblies to which a particulate filter is mounted. Existing filter 
assemblies are generally of two types. One type is the so-called spin-on 
filter assembly which employs an integral filter element inside a 
throw-away canister which is threaded onto a boss on the filter head 
assembly. Another type of filter is the cartridge type fuel filter which 
employs an outer canister having an internal replaceable filter element. 
The cartridge type fuel filter device is normally held in position on the 
filter head assembly by using a through bolt which engages a threaded bore 
in the filter head assembly. 
In view of the foregoing, it is an object of this invention to provide a 
fuel processing apparatus which may be interchanged for, and mounted 
directly to, conventional fuel filter mounting structures. By this 
approach, a fuel processor which is simple to install, inexpensive, and 
effective is provided. It is a further object of this invention to provide 
such a fuel processor device which may indicate the presence of water 
within the processor device and/or may automatically cause such water or 
other impurities to be drained from the fuel processor apparatus as 
required. 
In accordance with this invention, a number of embodiments of fuel 
processor devices are provided which can be attached directly to filter 
head assemblies to replace existing conventional or spin-on type fuel 
filters. In accordance with one embodiment of this invention, a filter 
housing is provided having a removable lower assembly which provides for a 
drain and water sensor. A heater and thermostat assembly may also be 
included or omitted from the lower assembly as desired. This assembly may 
also include an automatic drain to remove water or other impurities from 
the lower portion of the filter housing when the level therein accumulates 
to a predetermined level. Other embodiments according to this invention 
describe various means for attaching the fuel processor components within 
the lower portion of the processor housing, and various approaches toward 
fixing a fuel filter media element within the processor assembly. 
Additional benefits and advantages of the present invention will become 
apparent to those skilled in the art to which this invention relates from 
the subsequent description of the preferred embodiments and the appended 
claims, taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION 
FIGS. 1 and 2 depict existing conventional fuel filters, each of which are 
mounted to filter mounting block 10. FIG. 1 shows a spin-on type fuel 
filter 12. This filter includes an integral filter element and canister 17 
which is mounted to filter mounting block 10 through engagement between 
threaded bore 14 and threaded boss 16. Sealing element 18 positioned 
around the periphery of filter 12, prevents fuel leakage. Spin-on type 
filter 12 includes a plurality of fuel inlet passages 20 and central 
outlet passage 22. Filter 12 is also shown equipped with a manually 
operated drain valve 24 which permits the user to periodically release 
quantities of water or other contaminants which may collect in the lower 
portion of filter 12. 
Another type of conventional fuel filter, shown by FIG. 2, is the so-called 
cartridge or two piece type filter assembly 26. Cartridge fuel filter 26 
differs from spin-on filter 12 in that the internal filter media element 
28 is replaceable, whereas housing 30 is reusable. Mounting of cartridge 
fuel filter 26 is achieved by inserting through bolt 32 into a bore within 
housing 30 and threadingly engaging a threaded bore within filter mounting 
block 10. This filter type also includes sealing element 34 positioned at 
the junction between filter mounting block 10 and housing 30. 
Now with reference to FIGS. 3 and 4, a fuel processor device according to 
this invention is described which is adapted for mounting to filter 
mounting block 10. Fuel processor 36 according to this first embodiment is 
particularly adapted for use with vehicles or other fuel consuming devices 
which are designed to accept a spin-on type fuel filter assembly 12 as 
described in connection with FIG. 1. Fuel processor 36 includes housing 38 
which is mounted by threading bore 14 onto threaded boss 16. The details 
of filter block 10 are best shown with reference to FIG. 4. Filter block 
10, which may be an existing structure or may be an installed component, 
includes filter inlet passage 40 and filter outlet passage 42. Mounting 
block 10 may include a priming pump, as generally indicated by reference 
character 37 which pressurizes the inlet passages to force fuel into 
filter outlet passage 42. Filter inlet passage 40 forms an annular 
passageway thereby supplying fuel to each of inlet passages 54. A portion 
of filter outlet passage 42 is formed by a bore within threaded boss 16. 
Fuel processor 36 is adapted to be mounted to filter mounting block 10 of 
the type usable for a spin-on type filter. Fuel processor 36 includes 
housing 38 which has an enclosed upper end with a plurality of inlet 
passages 54 and a centrally disposed outlet port 44. The lower opened end 
of housing 38 is enclosed by plate 46 and is sealed against housing 38 by 
seals 48 and 50. Disposed internally within housing 38 is filter media 
element 52 which is compressed between ring seals 55 and 56. Ring 56 is 
attached to stanpipe 58 which includes an internal passageway in 
communication with outlet port 44 and includes a plurality of radially 
spaced ports 62. Stanpipe 58 is attached to upper plate 60 of fuel 
processor 36. The lower extending end of stanpipe 58 includes an 
internally threaded bore 64 which enables threaded through bolt 66 to 
engage therewith. Filter media element 52 is retained in sealing 
engagement with ring seals 55 and 56 through compression of coil spring 68 
which is placed around through bolt 66. Alternately, spring 68 can be 
replaced with any suitable tensioning or mounting device. Washer 70 is 
located at the contact surface between coil spring 68 and seal ring 55 to 
uniformly compress the seal. 
According to a principal aspect of this invention, filter media element 52 
is disposed substantially within the upper internal portion of housing 38. 
The lower portion forms a region for the collection of water and/or heavy 
contaminants. A number of fuel processor components may be mounted to 
lower plate 46. Such components may be devices which do one or more of the 
following; provide an indication of the presence of water or other 
contaminants, automatically drain contaminants, sense the temperature of 
the collected contaminants, and heat the fuel. In its simplest form, fuel 
processor lower plate 46 would include only water sensor 74 and manually 
operated drain valve 76. This configuration would preferably provide the 
operator with a warning indicator that a quantity of water or other 
contaminants has collected in the lower portion of housing 38, therefore 
requiring manual actuation of drain valve 76. 
In a more sophisticated configuration for fuel processor 36, a signal from 
water sensor 74 could be used to actuate an automatic drain valve (or a 
pump when processor 36 is used on the negative pressure side of a fuel 
system) such that water or other contaminants are automatically drained 
once they collect above a predetermined level within housing 38. Such a 
configuration would further preferably include temperature sensor 80 which 
would prevent the automatic drain valve from operating when the water or 
other contaminant temperature is below a predetermined temperature, 
thereby avoiding problems of operation of the drain valve when ice 
crystals are present which could lead to damage or improper operation of 
the drain valve. Fuel processor 36 as shown by FIGS. 3 and 4 further 
includes electric heating element 82 which is provided in the lower 
chamber area and is bent in an inverted U-shaped form having its lower 
ends in communication with bottom plate 46 (through electrical connections 
84). The upper end of heating element 82 is positioned close to gap 86 
which is formed by the lower bottom portion of filter media element 52. As 
is best shown in FIG. 4, the bight portion 88 of heater element 82 is 
slightly spaced from the wall of housing 38 and annular gap 86. 
When heat energy is supplied to heater element 82, it becomes warmed 
quickly and fuel in the vicinity of the heating element is also warmed. 
Therefore, if wax crystals are formed which prevent fuel flow through 
filter media element 52, the heat generated by heating element 82 causes a 
"window" to be formed at gap 86 which presents a flow path for fuel 
through the filter media element. This "window" is maintained until the 
fuel within the fuel processing apparatus, the fuel within the fuel 
supply, and the engine itself can reach steady state temperatures above 
the waxing point of the fuel. When fuel in the lower portion of housing 38 
is warmed, it, of course, flows upwardly through annular gap 86. Such 
warming of the entire fuel processor apparatus 36 is enhanced in 
accordance with this invention since filter mounting block 10 is typically 
located on, or in close proximity with, an engine or other heat source and 
therefore receives radiant heat from the assembly. It is also desirable 
that the energy to heating element 82 be controlled by, as an example, an 
automatic control device which receives a signal from temperature sensor 
80 and therefore supplies heat energy to element 82 only when necessary. 
Various approaches toward providing automatic control of fuel processor 
devices which are equally applicable to the inventions described herein 
are detailed in copending U.S. patent application Ser. No. 463,041 
assigned to the assignee of this invention. 
Other heat sources could be used and could be of any basic type which 
provides the heat required to maintain a "window" within gap 86 when the 
temperature drops below the fuel's cloud or wax point. Heating element 82 
is positioned to concentrate heat onto filter element 52 in such a manner 
to take advantage of the laws of thermodynamics and physics to minimize 
caloric input requirements. The heater can be of any type and can be 
self-regulated, or regulated by an internal or external thermostat or 
temperature sensor. Heater energy may be furnished electrically or by 
using any other source of heat such as water, fuel, oil, exhaust, air, 
radiation, or other available source of energy. The heater configuration 
can be any which meets the requirements dictated by the flow rate of fuel 
and usage conditions. 
In operation, fuel is caused to travel through filter mounting block inlet 
passage 40 into inlet passages 54 to the area within housing 38 
surrounding filter media element 52. Thereafter, water and heavy 
particulate matter collects within the lower portion of housing 38. After 
passing through filter media element 52, the fuel enters ports 62 and 
through outlet passageway 42. 
FIGS. 5, 6, and 7 illustrate fuel processor device 90 according to a second 
embodiment of this invention. This embodiment differs from that described 
with reference to FIGS. 3 and 4 in that it is particularly adaptable for 
use in replacing cartridge fuel filter 26 illustrated by FIG. 2. Housing 
92 includes a lower plate structure which is integral with the housing. 
Attachment of housing 92 is achieved by providing through bolt 94 having 
sufficient length to engage the threaded bore within filter mounting block 
10. Sealing of housing 92 against mounting block 10 is provided by seal 
93. Internally, fuel processor 90 varies from that described by FIG. 4 in 
that stanpipe 58 is eliminated and filter media element 96 seals directly 
against filter block 10. Filter element 96 is held in sealing engagement 
with the filter block by compression of coil spring 98 against washer 100 
and ring seal 102. Fuel processor 90 is shown having temperature sensor 
104, drain valve 106, water sensor 108 and heater 110. As previously 
explained, fewer elements may be installed within the fuel processor, 
depending on the mode of operation desired. 
In conjunction with this embodiment and with particular reference to FIGS. 
6, 7 and 8, an additional improvement is shown. This improvement comprises 
the addition of baffle 166 which is provided to prevent incoming fuel from 
directly contacting filter media element 96 prior to its flow into the 
lower portion of fuel processor housing 92. By preventing such direct 
contact, particulate matter and water contained within the incoming fuel 
is kept from contaminating the filter element. Instead, the incoming fuel 
is directed into the lower portion of housing 92 where water and heavy 
particulates are removed from the fuel prior to its flow through filter 
element 96. Baffle 166 is generally cup-shaped having a central port 174 
and having an outer cylindrical surface characterized in that it 
preferably has portions lying on cylindrical surfaces of differing radial 
dimensions. The side surfaces of baffle 166 would preferably be slightly 
inclined in order to provide a draft angle, thereby facilitating 
production by injection molding processes. Baffle 166 extends downwardly 
to a point below the lower surface of filter element 96. As shown 
particularly by FIG. 7, a plurality of indented portions 167 and a 
plurality of radially extending portions 172 are provided. Now with 
particular reference to FIG. 6, the flow of fuel through fuel processor 90 
is described. Fuel flowing into fuel processor 90 is directed along the 
outside surface of baffle 166 and within channels 168 formed by radially 
indented portions 167. Such flow is indicated by downwardly directed 
arrows in FIGS. 6 and 7. Once fuel has been directed into the lower 
portion of housing 92, heavy particulate matter and water is separated 
therefrom. Thereafter, fuel flowing upwardly toward filter media element 
96 is directed along the inter surface of baffle 166 within channels 176 
formed by radially extending portions 172. 
Baffle 166 may be provided as a separate component as shown by FIG. 7 or 
may be integrated into a fuel processor housing or filter structure. 
Additionally, numerous other forms of baffle 166 can be provided which 
perform the above-described function. For example, baffle 166 may have a 
true cylindrical surface without the inwardly or outwardly directed 
extending portions described above provided that annular clearances for 
fuel flow exist both around the outside and within the baffle. Also, as 
shown by the partial pictorial view of FIG. 8, a large number of inwardly 
and outwardly extending portions could be provided, giving the baffle a 
corrugated appearance. 
By providing baffle 166 in conjunction with heating element 110, direct 
contact between cold incoming fuel and the filter media element is 
prevented. Therefore, only warmed fuel directly contacts the filter 
element thereby aiding in the prevention of a solid accumulation of cold 
fuel and water globules from developing on the outer surface of the media 
element. In addition to the above-described benefits, baffle 166 enhances 
the water separating characteristics of the associated fuel processor by 
presenting a large surface area which acts to coalesce water suspended 
within the fuel. Moreover, baffle 166 improves the thermal efficiency of 
the fuel processor by separating the cold incoming fuel from the warmed 
fuel. 
Baffle 166 is explained and depicted in conjunction with one embodiment of 
a fuel processor device for illustrative purposes only. Baffle 166 is 
equally suitable for any of the remaining embodiments described as part of 
this specification. Moreover, baffle 166 is suitable for use with any type 
of filter in which it is desirable to prevent direct contact between 
incoming fluid and the filter media element. 
FIGS. 9 and 10 illustrate a third embodiment according to this invention 
wherein fuel processor 112 is shown. This embodiment varies from that 
described by FIGS. 5, 6 and 7 in that coil spring 98 for resiliently 
biasing filter media element 96 in sealing contact with filter mounting 
block 10, is eliminated. For this embodiment, an internally disposed 
annular rib 114 is provided within housing 116 which engages a downwardly 
projecting flange 117 of filter element 118 to bias it against filter 
block 10. This embodiment is also suitable for replacement of a cartridge 
type fuel filter apparatus described by FIG. 2. Like the previous 
embodiments, fuel processor 112 preferably includes; temperature sensor 
120, drain valve 122, heater 124 and through bolt 126. 
FIGS. 11 and 12 illustrate fuel processor 128 according to a fourth 
embodiment of this invention wherein housing 130 and filter media element 
132 are integrated such that both are replaced when the filter element 
becomes contaminated. An upper plate 134 forms a threaded bore for 
engagement with threaded boss 16. Stanpipe 136 provides a means for 
fastening lower plate 138 against seal 142 to housing 130 using through 
bolt 140. Other means for attaching lower plate 138 to housing 130 could 
be provided, for example, by theading engagement therebetween. As 
illustrated by FIGS. 11 and 12, fuel processor 128 also preferably 
includes; temperature sensor 144, drain valve 146, water sensor 148 and 
heater 150. 
FIG. 13 illustrates a fifth embodiment of a fuel processor 152 which 
differs from the previous embodiments in that electric heating element 154 
is attached to an intermediate annular ring 156 which is positioned 
between lower plate 158 and housing 160 (shown cut away in FIG. 13). This 
enables fuel processor device 152 to be readily adapted between operating 
conditions wherein a heating device is desirable and those wherein it is 
unnecessary. In the latter situation, annular ring 156 would simply be 
provided as a spacer without including heating element 154. Annular ring 
156 also provides a convenient mounting location for a temperature sensor 
(not shown). Lower plate 158 preferably carries water sensor 162 and drain 
valve 164. 
While the above description constitutes the preferred embodiments of the 
present invention, it will be appreciated that the invention is 
susceptible to modification, variation and change without departing from 
the proper scope and fair meaning of the accompanying claims.