FILTER ASSEMBLY AND RELIEF VALVE OF SAME

A filter assembly comprises a housing open at one end, a filter element therein, and a plate at the open end enclosing the filter element within the housing. The filter assembly further includes a fluid flow control assembly disposed between an end of the filter element and the plate. The fluid flow control assembly includes a check valve and a relief valve seat upon which the check valve abuts to prevent flow of fluid through a by-pass passage. The check valve is held in a sealed position against the relief valve seat by a biasing member retained by the relief valve seat. The force of the biasing member is overcome when pressure in the fluid acting upon the check valve reaches or exceeds a certain level, causing the check valve to move away from the relief valve seat, and permitting the fluid to flow through the relief valve assembly to an outlet opening of the filter assembly, bypassing the filter element of the filter assembly.

BACKGROUND

1. Field of the Disclosure

The present invention relates generally to a fluid filter assembly and, more particularly, to a fluid filter assembly having a relief valve.

2. Background of the Disclosure

Filter assemblies generally include a housing having an open end, a filter element received in the housing, an base plate closing the open end and having inlet and outlet openings therein, and a valve for cooperating with the inlet openings to allow oil to flow into the filter through the inlet openings, but prevent flow of oil in a reverse direction. Prior art filters have included a combination valve having two portions, the first portion for closing the inlet openings to block the flow of oil back out of the inlet openings when the oil is not being circulated and the second portion for opening a bypass opening when the filter media is clogged for returning oil to the engine to keep the engine lubricated even though the filter element is clogged. Such a construction is disclosed in Stanhope et al. U.S. Pat. No. 7,175,761.

The present disclosure improves upon current valves and overcomes disadvantages and deficiencies of such prior art constructions.

SUMMARY

In an illustrative embodiment, a filter assembly comprises a housing open at one end and holding a filter element therein and a plate closing the open end of the housing and enclosing the filter element within the housing. The filter assembly further includes a fluid flow control assembly disposed between an end of the filter element and the plate. The fluid flow control assembly includes a check valve and a relief valve assembly, the relief valve assembly including a relief valve seat upon which the check valve seals to prevent flow of fluid through a by-pass passage of the fluid flow control assembly. The check valve is held in a sealed position against the relief valve seat by a biasing member retained in place by the relief valve seat. The force of the biasing member is overcome when pressure in the fluid acting upon the check valve reaches or exceeds a certain level, causing the check valve to move away from the relief valve seat against the bias of the biasing member, and permitting the fluid to flow through the relief valve assembly to an outlet opening of the filter assembly, bypassing the filter element of the filter assembly.

In any of the embodiments herein, the relief valve assembly may comprise a valve seat with a seat portion and a centering portion. The seat portion may extend generally perpendicular to a longitudinal axis of the filter assembly when the relief valve assembly is inserted into the filter assembly. The valve seat may be configured to extend through an aperture of the check valve with an end point of the check valve abutting an outer surface of the valve seat. The check valve may include a horizontal portion that terminates at the end point, the horizontal portion extending across a portion of the valve seat to block flow of fluid through an aperture in the relief valve assembly.

In any illustrative embodiment, the valve seat may include a check valve sealing ring within the seat portion. The check valve sealing ring includes an upper surface upon which the check valve rests when sealed against the seat portion to seal the aperture of the relief valve assembly. The check valve may be maintained in the sealed position against the check valve sealing ring by a bias force applied to the top of the check valve above the check valve sealing ring, where the bias force can only be overcome by application of a predetermined force from fluid flowing in a by-pass passageway of the valve seat upon the check valve.

In any illustrative embodiment, the relief valve assembly may comprise a biasing member that biases the check valve into sealing arrangement with the check valve sealing ring, wherein the biasing member is held in place by one or more stop surfaces of the valve seat. The biasing member may be a spring or other similar mechanism that is held between the stop surfaces and a top surface of the check valve to maintain the check valve in a closed position. An optional washer may extend between a bottom surface of the biasing member and the top surface of the check valve, such that the optional washer is capable of transferring pressure from the biasing member to the check valve.

In any illustrative embodiment, the valve seat may further include a cartridge sealing ring that is annularly outward of the check valve sealing ring and that includes a top surface configured to permit a portion of the check valve to abut against. A bypass gap may extend between the cartridge sealing ring and the check valve sealing ring for fluid to flow through when the bypass path is not blocked by the check valve. The check valve is normally configured to extend over the bypass gap to prevent fluid flow therethrough, but the check valve is lifted away from the bypass gap when pressure in the fluid meets or exceeds a predetermined level.

In illustrative embodiments, the valve seat includes a centering portion that is substantially perpendicular to the seat portion and is configured to extend generally along the longitudinal axis of the filter assembly. The centering portion includes one or more annular walls that are configured to be partially received within a central core opening of the filter assembly to permit the valve seat to be properly centered therewith. The centering portion further includes one or more by-pass apertures that extend between the annular walls, the by-pass apertures fluidly connected to the flow of fluid passing through the by-pass gap in the seat portion of the valve seat. The by-pass apertures are configured to direct fluid flow to the outlet opening of the filter assembly when fluid flows through the by-pass gap, permitting such fluid to by-pass the filter element of the filter assembly.

In illustrative embodiments, the valve seat may further include a tapping plate or base plate sealing ring that substantially defines a bottom of the valve seat. The base plate sealing ring is configured to abut against a portion of a base plate of the filter assembly when the base plate is inserted into the filter housing. In certain embodiments, the base plate sealing ring is compressed against a shoulder portion of the base plate that extends into the housing, the shoulder portion including one or more of the inlet openings for fluid to flow into the filter assembly. The base plate sealing ring may include one or more alignment features that can align with one or more portions of the base plate to permit proper alignment of the fluid flow control assembly between the base plate. The fluid flow control assembly may be retained against the base plate without a snap or lock fit engagement.

In any illustrative embodiment, the valve seat may be configured as a two (or more) piece valve seat component that is assembled together as the relief valve assembly is assembled. In any illustrative embodiment, for instance, the check valve sealing ring that is formed as a separate component from the cartridge sealing ring. In other instances, the seat portion may be formed as a separate component from the centering portion of the valve seat. Other forms of separating the components of the valve seat are envisioned herein.

These and other features of the present disclosure are more full described with reference to the detailed description and drawings herein.

DETAILED DESCRIPTION

The present disclosure is directed to a filter assembly including a fluid flow control assembly. While the present disclosure may be embodied in many different forms, one specific embodiment is discussed herein with the understanding that the present disclosure is to be considered only as an exemplification of the principles of the disclosure, and it is not intended to limit the disclosure to the embodiment illustrated.

Referring toFIGS. 3 and 8, a filter assembly20is depicted as having a generally cup-shaped cylindrical shell or housing22that is open at a first or lower open end24and closed at a second or upper, opposite end26. A filter, for example, in the form of a filter component or element28that includes filter media mounted on a core30, is disposed within the housing22, wherein the filter element28includes a first or lower end32positioned adjacent the first end24of the housing and a second or upper end34adjacent the second end26of the housing22. The core30may define an opening31that fluid flows into after it has passed through the filter element28, and the opening31may extend about a longitudinal axis82of the filter assembly20so that the opening31is substantially positioned within the center of the housing22. In various embodiments, a lid38may be coupled to the lower open end24of the housing22to substantially enclose the filter assembly20. While a particular filter is disclosed herein, one skilled in the art will understand that the principles of the present disclosure may be applied to any suitable filter assembly having any suitable filter.

In various embodiments of the filter assembly20, a threaded base plate or tapping plate36is provided to be connected at the lower open end24of the housing22. The base plate36may be configured between the lid38and the filter element28within the housing22. An annular, resilient gasket25may be received and retained in a recess39in the lid38for providing a seal between the filter assembly20and an engine block (not shown) to which the filter assembly20is secured in normal use. Optionally, any other suitable additional or alternative seal may be used. A biasing element40, for example, a spring, may be provided between the upper end34of the filter element28and an interior44of the housing22for biasing the filter element28toward the first end24of the housing22. In illustrative embodiments, the biasing element40biases the filter element28toward the base plate36to apply pressure on the base plate36. The biasing element40may be replaced with any suitable element(s) that bias the filter toward the first end24of the housing22or may be omitted.

The filter element28may include any suitable filter media45comprised of, for example, pleated filter material composed of cellulose with some polyester, although other forms of filter media are envisioned herein. The core30, which may be molded from any appropriate material, for example, a glass filled plastic, such as, Nylon, is perforated so as to permit fluid flow therethrough in use. The filter element28may include a first face46suitable to receive and permit the flow of fluid through the filter element, and a second face48suitable to permit flow of fluid from the filter media, with the second face48being secured to the core30, as seen inFIG. 3. The filter media45may be formed from a sheet of pleated material joined along the facing ends by a suitable adhesive to form an annular sleeve on the core30. End caps50,52may be disposed at the bottom and top, respectively, of the filter element28. The end caps50,52may be fabricated from a suitable composite material, for example, a cellulose/polyester composite. In various embodiments, the end caps50and52are configure to prevent the flow of fluid into the filter media45and may further direct the flow of fluid within the housing22. In an illustrative embodiment, the end caps50,52are bonded to the filter media45, for example, by ultrasonic welding, to form a seal between the ends of the filter media45and the end caps50,52to prevent fluid flow between these elements in use. The end caps50,52may alternatively be bonded to the filter media in any other suitable manner. In various embodiments, the end caps50and52may be a non-rigid material, such as cellulose fiber or polyester.

In various embodiments, the end or base plate36may include various designs or configurations. For instance, the base plate36may be a double-draw design (as illustrated inFIG. 3), or it may be an inverted type of base plate36. Other types of base plates36include a flat design. The present disclosure is directed for use in a filter assembly20that incorporates substantially any type of base plate36design. In an exemplary embodiment, the base plate36is configured to include a raised portion or shoulder110that extends inward into the housing22and towards the filter element28when the base plate36is secured in the housing22. The raised portion110includes a top surface112that can abut against components retained in the housing22, as further described herein. In various embodiments, the raised portion110includes one or more flow apertures66to permit flow of fluid into the filter assembly20.

The filter element28and housing22of the filter assembly20may be similar to the filter element28and housing22disclosed in U.S. Pat. No. 7,175,761, the disclosure of which is hereby incorporated by reference in its entirety. In other illustrative embodiments, the principles of the present disclosure may be applied to any suitable filter assembly having any suitable housing and/or any suitable filter element.

Referring toFIGS. 3-4B, an embodiment of a fluid flow control assembly54retained within the filter housing22is depicted. The fluid flow control assembly54includes a relief valve seat assembly56and a check valve58, as will be described herein. The fluid flow control assembly54is retained adjacent the lower end32of the filter element28and a top or inner side62of the base plate36. In various embodiments, the fluid flow control assembly54abuts against or contacts the raised portion110of the base plate36, and may further rest or abut against the top surface112of the raised portion110. In illustrative embodiments, the fluid flow control assembly54is configured to control flow of fluid that is entering the filter assembly20prior to the fluid being filtered through the filter element28. An outlet opening80is provided centrally within the base plate36, defined by a rim37of the base plate37, to permit fluid to flow out of the filter assembly20and the fluid flow control assembly54may be configured to be adjacent to the outlet opening80. As seen inFIG. 3, the outlet opening80may be centrally disposed about the longitudinal axis82of the filter assembly20. While the outlet opening80is depicted as being circular in cross-section, the outlet opening80may have any other suitable configuration depending on the application for the filter assembly20. Still optionally, the outlet opening80may be oriented in any suitable manner. The fluid flow control assembly54may be retained adjacent the outlet opening80such that the fluid flow control assembly54does not block or restrict flow of fluid as it exits through the outlet opening80.

As illustrated inFIGS. 4A-6B, the check valve58of the fluid flow control assembly54is configured for controlling flow through a first inlet opening or openings66in the base plate36. As illustrated, the openings66may extend through the raised portion110of the base plate36, although other embodiments are envisioned herein. The check valve58is illustratively annular and includes a generally horizontal segment90that extends from an end point71and an angled segment92extending from the generally horizontal segment90and disposed at an angle with respect to the generally horizontal segment90, thereby forming a bend94. In an illustrative embodiment, the generally horizontal segment90extends from the end point71and the angled segment92extends at the angle with respect to a horizontal plane such that a free end96of the angled segment92is inclined outwardly and downwardly from the generally horizontal segment90. The free end96is configured to abut against the top side62of the base plate36in its natural state. The free end96of the angled segment92may be bulbous or semi-bulbous to elevate the angled segment92and provide a gap between an elastomeric surface of the angled segment92and the base plate36to distribute pressure evenly across the check valve58. Still further, the free end96may have any shape. In various embodiments, the check valve58is annularly disposed around the longitudinal axis82when positioned within the filter assembly20. Still further in various embodiments, the inlet openings66of the base plate36may be positioned below the angled segment92of the check valve58when assembled in the filter assembly20, and the inlet openings66may direct fluid flow against the angled segment92when directing fluid into the filter assembly20. In certain embodiments, the raised portion110of the base plate36may be aligned under a portion of the check valve58, such as the horizontal segment90, and include the inlet openings66that direct flow of fluid toward the angled segment92. The check valve includes a central aperture that may be substantially aligned with the outlet opening80of the base plate36and the longitudinal axis82of the filter assembly20.

The check valve58may be made of rubber, plastic, an elastomeric material, or any other suitable material. The check valve58may be made of Nitrile, Silicone rubber, or any other suitable material. In various embodiments, the materials for the check valve58should be suitable for use with engine oil at up to 300 degrees Fahrenheit for several thousand miles. As is understood by review ofFIGS. 4A-6B, the check valve58, and at least some of its components such as the angled segment92and horizontal segment90, are configured to be deformable or elastic such that a certain pressure of fluid abutting against the check valve58may deform or move such components relative to the rest of the components of the filter assembly20. For instance,FIGS. 4A-4Billustrative show the check valve58in a natural state with no pressure applied thereto,FIGS. 5A-5Billustratively show the check valve58in a first state where pressure of a fluid is applied to the angled segment92(via fluid entering from the openings66) to force the angled segment92upward such that a gap or space extends between the free end96and the base plate36, andFIGS. 6A-6Billustrative show the check valve58in a second state where pressure of a fluid is applied to a portion of the horizontal segment90to force a portion of the horizontal segment90upward against a bias force such that fluid may pass between the horizontal segment90and the relief valve seat assembly56, described below. In various embodiments, certain parts of the check valve58may be deformable independent of other parts of the check valve58. In other embodiments, certain pressures of fluid may deform various parts of the check valve differently, or the parts of the check valve may uniformly deform at a certain pressure.

As illustrated inFIGS. 4A-6B, the relief valve seat assembly56of the fluid flow control assembly54is configured to work in conjunction with the check valve58to direct fluid flowing into the opening66of the base plate36to be directed to the outlet opening80without flowing through the filter element28. For instance, the relief valve seat assembly56and check valve permit fluid to by-pass the filter element28within the filter assembly20when the pressure of the fluid flowing into the filter assembly20is at or above a certain level (e.g. when the pressure of the fluid is high because the filter element28is overly clogged, causing fluid flowing through the filter assembly20to be at a greater pressure).

In illustrative embodiments, the relief valve seat assembly56includes a valve seat60, a biasing member64, and a washer68. As illustrated inFIGS. 4A-6B, the relief valve seat assembly56may also be annular to the longitudinal axis82of the filter assembly20when assembled within the filter assembly20, similar to the check valve58. Specifically, the valve seat60may have a longitudinal axis A that is generally configured to be aligned with the longitudinal axis82of the filter assembly20when the valve seat60is secured therein. The valve seat60, biasing member64, and washer68are configured to be retained in the lower end24of the housing22, and may further be configured to abut against the raised portion110of the base plate36when secured within the housing22. The relief valve seat assembly56may at least partially extend into the opening31formed by the core30of the filter element28. As more fully described herein, the valve seat60provides a seat for a portion of the check valve58to abut against and further retains the biasing member64against the check valve58to bias the check valve58to be seated against a portion of the valve seat60. The biasing member64is configured to move upward in the direction of the longitudinal axis82within the filter assembly20(e.g. within the valve seat60). The relief valve seat assembly56cooperates together with the check valve58to permit fluid to by-pass the filter element28when exiting the outlet opening80. Illustratively, a portion of the relief valve seat assembly56may extend through the center aperture of the check valve58, with an exterior surface of the relief valve seat assembly56abutting against the end71of the horizontal segment90of the check valve58.

As illustrated for example inFIGS. 1-2 and 7, the valve seat60illustratively includes a seat portion70and a centering portion72coupled together at a connector portion73. Both the seat portion70and centering portion72may be annular in nature to the longitudinal axis82when the valve seat60is incorporated into the filter assembly20. The seat portion70may be generally horizontal in direction (that is, perpendicular to the longitudinal axis82) and the centering portion72may be generally vertical in direction (that is, parallel to the longitudinal axis82). In various embodiments, the seat portion70and centering portion72may be formed as a unitary component that is co-molded of the same material. In various embodiments, the seat and centering portions70and72may be made of rubber, plastic, an elastomeric material, or any other suitable material. For instance, the seat and centering portions70and72may be formed of nylon or a silicone-based or silicon-like material, although other materials are also envisioned herein. In illustrative embodiments, one or more components of the valve seat60may be formed of nylon, such as Nylon6, Nylon 6/6 or Nylon12. Any material that may be injection-molded or extruded and can withstand the environment of an oil filter may be used. In illustrative embodiments, the valve seat60may have a diameter DI that is approximately 1.700 inches, although other diameters are envisioned herein.

In various embodiments, the seat portion70of the valve seat60includes a base plate sealing ring74, a cartridge sealing ring76, and a check valve sealing ring78, as illustrated inFIGS. 1-2. The check valve sealing ring78may be adjacent and connected to the connector portion73that connects the seat portion70to the centering portion72and extends annularly outward from the centering portion72. Specifically, the check valve sealing ring78may extend along a plane P1that is generally perpendicular to the longitudinal axis A of the relief valve seat assembly56, as illustrated inFIG. 7. As illustrated inFIGS. 4A-5B, the check valve sealing ring78is configured to provide a sealing surface for the check valve58to seat against when the valve seat60is aligned within the central aperture of the check valve58along the longitudinal axis82of the filter assembly20. Illustratively, a bottom surface59of the check valve58is configured to abut against a top surface79of the check valve sealing ring78to seal the check valve58to the valve seat60to prevent fluid flow therebetween. Such sealing may occur at or near the end point71of the check valve58, although other locations are envisioned herein. In illustrative embodiments, the seat portion70may have a thickness (between top surface79and bottom surface81) that may be between 0.160 inches and 0.210 inches, although other thicknesses are envisioned herein.

In illustrative embodiments, the base plate sealing ring74is configured to extend annularly outward of and below the check valve sealing ring78and be coupled thereto, as illustrated inFIG. 7. A connection wall84may extend downwardly from an outside edge77of the check valve sealing ring78to connect the base plate sealing ring74to the check valve sealing ring78. For instance, the connection wall84may terminate at a bottom edge85of the connection wall84, and the base plate sealing ring74may extend annularly outward of the bottom edge85in a direction that is horizontal to the connection wall84and longitudinal axis A of the relief valve seat assembly56. The base plate sealing ring74may extend along a plane P2that is substantially parallel to the check valve sealing ring78and plane P1, and the base plate sealing ring74may extend below the check valve sealing ring78, as illustrated inFIG. 7to create a horizontal gap between the sealing rings74and78. Accordingly, the planes P1and P2may be spaced apart from each other. The base plate sealing ring74includes a bottom surface81and a top surface83and terminates at an end point87that is opposite to the bottom edge85of the connection wall84.

In illustrative embodiments, the cartridge sealing ring76is configured to extend annularly outward of the check valve sealing ring78, and may further extend annularly outward of the base plate sealing ring74. In certain embodiments, the cartridge sealing ring76is generally aligned with the plane P1of the check valve sealing ring78but is annularly spaced away from the check valve sealing ring78by a first gap G1that can permit fluid to flow between the check valve sealing ring78and the cartridge sealing ring76, as illustrated inFIG. 7. The first gap G1may have a width measurement W1of approximately 0.125 inches or 3.2 mm, although other measurements are envisioned herein. The cartridge sealing ring76may be coupled to the check valve sealing ring78by one or more connection bridges88that extend outwardly from the check valve sealing ring78to retain the cartridge sealing ring76to the rest of the valve seat60. In various embodiments, the connection bridges88may be equally spaced apart around the circumference of the check valve sealing ring78, although other embodiments are envisioned herein. The cartridge sealing ring76may be configured to align longitudinally with a portion of the end cap50of the filter element when the valve seat60is positioned within the housing22of the filter assembly20. In various embodiments, the cartridge sealing ring76provides a supporting engagement between the valve seat60and the end cap50in order to secure the components with respect to each other within the filter assembly20.

In various embodiments, a top surface89of the cartridge sealing ring76is aligned horizontally with the top surface79of the check valve sealing ring78. Accordingly, the check valve sealing ring78and the cartridge sealing ring76are generally parallel to each other and provide two parallel surfaces79and89upon which the bottom surface59of the check valve58can abut against to seal the check valve58to the valve seat60to prevent fluid flow through the gap G1. The cartridge sealing ring76terminates at an end point86. In illustrative embodiments, the end point86may be complimentarily shaped to be received in the bend94of the check valve58when the check valve58is sealed thereto. For instance, the end point86may be rounded in shape, although other forms and shapes are envisioned herein.

As illustrated inFIGS. 1-7, the cartridge sealing ring76is longitudinally spaced away from the base plate sealing ring74to form a second gap G2therebetween. The second gap G2may have a width measurement W2of between approximately 0.060 and 0.150 inches (or 3.8 mm), although other measurements are envisioned herein. The second gap G2is an opening below the check valve58through which fluid flowing into the openings66of the base plate36can flow after entering the filter assembly20. The second gap G2is connected to the first gap G1such that a flow passageway P extends between the gaps G1and G2that fluid can flow through. In illustrative embodiments, the second gap G2is upstream of the angled portion92of the check valve58, as illustrated inFIGS. 4A-6B. Accordingly, when fluid is flowing through the passageway P and exits the gap G1, the fluid takes a bypass path B that bypasses the filter element28. Further, such fluid will enter the second gap G2before subjecting the angled portion92of the check valve58to pressure from the fluid, reducing unnecessary wear and tear on the check valve58.

In illustrative embodiments, the centering portion72of the valve seat60includes one or more annular walls42that extend upward from the connector portion73and are annular to the longitudinal axis A of the valve seat60. The annular walls42may illustratively be substantially perpendicular to the seat portion70, but other embodiments are envisioned herein. As illustrated, for example, inFIG. 7, the annular walls42may be slightly angled with respect to the longitudinal axis A to form an angle that is less than 90 degrees to the seat portion70. The annular walls42include an outside surface41from which the connector portion73extends to connect to the seat portion70. In various embodiments, the annular walls42of the centering portion72extend through the central aperture of the check valve58, and the outside surface41of the annular walls42may abut against the end point71of the horizontal segment90of the check valve58. In illustrative embodiments, the annular walls42may have a length that may be between 0.500 inches and 1.000 inches, although other lengths are envisioned herein.

An outflow aperture100extends along the longitudinal axis A of the valve seat60. The outflow aperture100extends within the circumference of the annular walls42of the centering portion72and further extends through the seat portion70to provide a flow path for fluid flowing to the outlet opening80of the filter assembly20. Accordingly, fluid that has been filtered through the filter element28and flows into the opening31, or fluid that has by-passed the filter element28via the check valve58and relief valve seat assembly56, is directed to pass through the flow aperture100of the valve seat60to the outlet opening80.

The annular walls42of the valve seat60are spaced apart to form one or more bypass apertures102. The bypass apertures102are configured to permit fluid to flow into the outflow aperture100from the gap G1. In various embodiments, and as illustrated inFIGS. 1 and 2, the bypass apertures102may be spaced equally around the circumference of the valve seat60. In illustrative embodiments, the bypass apertures102may be positioned to at least partially be aligned longitudinally above one or more gaps G1between the check valve sealing ring78and the cartridge sealing ring76of the seat portion70of the valve seat60. In various embodiments, the bypass apertures102extend into the connector portion73between the seat and centering portions70and72of the relief valve, and may further extend into a portion of the check valve sealing ring78, as illustrated inFIG. 1. In such a configuration, fluid flowing through the gap G1between the check valve sealing ring78and the cartridge sealing ring76may flow substantially horizontally into the bypass apertures102when the check valve58is not sealed against the check valve sealing ring78.

The centering portion72further includes one or more outwardly-protruding tangs44that are coupled to a top end of the annular walls42. The tangs44may be sized and shaped in various embodiments. In an illustrative embodiment, the tangs44are configured to extend annularly outwardly from the outside surface41of the annular walls42and include a stop surface43that is substantially perpendicular to the outside surface41of the annular walls42, as illustrated inFIG. 7. In certain configurations, the stop surface43of the tang44, the outside surface41of the annular walls42, and the top surface79of the check valve sealing ring78form a retainment gap47therebetween. The retainment gap47may retain the biasing member64, as described herein. In illustrative embodiments, the tangs44may have a length that may be between 0.125 inches and 0.200 inches, although other lengths are envisioned herein.

In illustrative embodiments, the valve seat60of the relief valve seat assembly56may be composed of two or more separate structures that make up the components of the valve seat60. The components of the valve seat60may be separated in various ways, which will now be described herein, and the coupled together to form the valve seat (for instance, before or during manufacturing or assembly of the filter assembly20). Specifically, alternative embodiments of a two-piece valve seat260/360/460that may be incorporated into the relief valve seat assembly56will be described herein; however, similar reference numerals will be used to identify and describe similar structures as described above regarding the valve seat60. Separation of the structures of the two-piece valve seat260may provide manufacturing efficiencies and reduction of costs for production of the valve seat, for example, as compared to a unitary relief valve seat structure. While components of a two-piece relief valve seat are described herein, such components may be further separated into a larger number of pieces and be considered within the scope of this disclosure.

A first alternative two-piece valve seat260for incorporation into the relief valve seat assembly56is illustrated inFIGS. 10-12. As illustrated, the two-piece valve seat260illustratively includes a seating portion270and a separate centering portion272that can be coupled to the seating portion270via, for example, a snap retainment. Alternatively, the seating portion270may be retained upon the centering portion272by resting upon an annular bottom ledge274, described below, that extends radially outward from the centering portion272.

Both the seating portion270and centering portion272may be annular in nature to the longitudinal axis82when the two-piece valve seat260is incorporated into the filter assembly20. The seating portion270may be generally horizontal in direction (that is, perpendicular to the longitudinal axis82) and the centering portion272may be aligned to be generally vertical in direction (that is, parallel to the longitudinal axis82). In various embodiments, the seating and centering portions270and272may be made of rubber, plastic, an elastomeric material, or any other suitable material. For instance, the seating and centering portions270and272may be formed of nylon or a silicone-based or silicon-like material, although other materials are also envisioned herein. In illustrative embodiments, one or more components of the two-piece valve seat260may be formed of nylon, such as Nylon6, Nylon 6/6 or Nylon12. Any material that may be injection-molded or extruded and can withstand the environment of an oil filter may be used.

In various embodiments, the seating portion270of the two-piece valve seat260includes a cartridge sealing ring276, a check valve sealing ring278, and one or more connection bridges288extending between the cartridge sealing ring276and the check valve sealing ring278, as illustrated inFIGS. 10-12. The seating portion270includes a top surface262, a bottom surface264, an inner surface266, and an outer surface268. A portion of the check valve sealing ring278defines the inner surface266, with the inner surface266forming the inner periphery of the seating portion270. A portion of the cartridge sealing ring276defines the outer surface268, with the outer surface268forming the outer periphery of the seating portion270. In various embodiments, the inner surface266is configured to be positioned adjacent a portion of the centering portion272when the seating portion270is assembled with the centering portion272.

In illustrative embodiments, the check valve sealing ring278may extend along a plane that is generally perpendicular to the longitudinal axis A of the relief valve seat assembly56. As understood from the description above, the check valve sealing ring278is configured to provide a sealing surface for the check valve58to seat against when the two-piece valve seat260is aligned within the central aperture of the check valve58along the longitudinal axis82of the filter assembly20. Illustratively, a bottom surface59of the check valve58is configured to abut against a top surface279of the check valve sealing ring278to seal the check valve58to the two-piece valve seat260to prevent fluid flow therebetween. Such sealing may occur at or near the end point71of the check valve58, although other locations are envisioned herein.

In illustrative embodiments, the cartridge sealing ring276is configured to extend annularly outward of the check valve sealing ring278. In certain embodiments, the cartridge sealing ring276is generally aligned with the plane of the check valve sealing ring278but is annularly spaced away from the check valve sealing ring278by a first gap G1that can permit fluid to flow between the check valve sealing ring278and the cartridge sealing ring276, as illustrated inFIG. 10. As noted, the cartridge sealing ring276may be coupled to the check valve sealing ring278by one or more connection bridges288that extend outwardly from the check valve sealing ring278to retain the cartridge sealing ring276to the check valve sealing ring278. In various embodiments, the connection bridges288may be equally spaced apart around the circumference of the check valve sealing ring278, although other embodiments are envisioned herein. Illustratively, there may be 8 equally spaced apart connection bridges288in the two-piece valve seat260.

In various embodiments, a top surface289of the cartridge sealing ring276is aligned horizontally with the top surface279of the check valve sealing ring278. Accordingly, the check valve sealing ring278and the cartridge sealing ring276are generally parallel to each other and provide two parallel surfaces279and289upon which the bottom surface59of the check valve58can abut against to seal the check valve58to the two-piece valve seat260to prevent fluid flow through the gap G1. The cartridge sealing ring276terminates at an end point286. In illustrative embodiments, the end point286may be complimentarily shaped to be received in the bend94of the check valve58when the check valve58is sealed thereto. For instance, the end point286may be rounded in shape, although other forms and shapes are envisioned herein.

As illustrated inFIGS. 10-12, the cartridge sealing ring276of the seating portion270is longitudinally spaced away from the base plate sealing ring274of the centering portion272to form a second gap G2therebetween. The second gap G2is an opening below the check valve58through which fluid flowing into the openings66of the base plate36can flow after entering the filter assembly20. The second gap G2is connected to the first gap G1such that a flow passageway P extends between the gaps G1and G2that fluid can flow through. In illustrative embodiments, the second gap G2is upstream of the angled portion92of the check valve58. Accordingly, when fluid is flowing through the passageway P and exits the gap G1, the fluid takes a bypass path B that bypasses the filter element28. Further, such fluid will enter the second gap G2before subjecting the angled portion92of the check valve58to pressure from the fluid, reducing unnecessary wear and tear on the check valve58.

In illustrative embodiments, the centering portion272of the two-piece valve seat260includes an annular bottom ledge274that functions as a base plate sealing ring. The base plate sealing ring274is configured to extend annularly outward of and below seating portion270, and in particular outward and below the check valve sealing ring278, as illustrated inFIG. 10. The base plate sealing ring274may extend outward from an outside surface241of the centering portion272at a point273and be configured to extend in a substantially perpendicular direction from the alignment of the centering portion272and the longitudinal axis A of the relief valve seat assembly56. The base plate sealing ring274may extend along a second plane that is substantially parallel to the plane of the check valve sealing ring278, but the base plate sealing ring274may extend below the check valve sealing ring278, to create a horizontal gap between the base plate sealing ring74and the check valve sealing ring278. The base plate sealing ring274includes a bottom surface281and a top surface283and terminates at an end point287that is opposite to the point273from where the base plate sealing ring274extends from the outside surface241of the centering portion272. In various embodiments, the cartridge sealing ring276may extend further annularly outward of the base plate sealing ring274when the centering portion272is coupled to the seating portion270.

In illustrative embodiments, the centering portion272of the two-piece valve seat260further includes one or more annular walls242that extend upward from the base plate sealing ring274and are annular to the longitudinal axis A of the two-piece valve seat260. The annular walls242may illustratively be substantially perpendicular to the base plate sealing ring274, but other embodiments are envisioned herein. In an illustrative embodiment, the annular walls242may include or more ribs205that provide structural support for the centering portion272during manufacturing and/or assembly within the filter assembly20.

As illustrated, for example, inFIGS. 10 and 12, at least a portion of the annular walls242may be slightly angled with respect to the longitudinal axis A to form an angle that is less than 90 degrees to the base plate sealing ring274in order to, for example, provide structural support or assistance for positioning of the centering portion272within the filter assembly20. The annular walls242include the outside surface241from which the base plate sealing ring274extend. In various embodiments, the annular walls242of the centering portion272extend through the central aperture of the check valve58, and the outside surface241of the annular walls242may abut against the end point71of the horizontal segment90of the check valve58. In illustrative embodiments, the annular walls242may have a length that may be between 0.500 inches and 1.000 inches, although other lengths are envisioned herein.

An outflow aperture200extends along the longitudinal axis A of the two-piece valve seat260. The outflow aperture200extends within the circumference of the annular walls242of the centering portion272to provide a flow path for fluid flowing to the outlet opening80of the filter assembly20. Accordingly, fluid that has been filtered through the filter element28and flows into the opening31, or fluid that has by-passed the filter element28via the check valve58and relief valve seat assembly56, is directed to pass through the outflow aperture200of the two-piece valve seat260to the outlet opening80.

The annular walls242of the two-piece valve seat260are spaced apart to form one or more bypass apertures202. The bypass apertures202are configured to permit fluid to flow into the outflow aperture200from the gap G1. In various embodiments, and as illustrated inFIGS. 10-12, the bypass apertures202may be spaced equally around the circumference of the two-piece valve seat260. In illustrative embodiments, the bypass apertures202may be positioned to at least partially be aligned longitudinally above one or more gaps G1between the check valve sealing ring278and the cartridge sealing ring276of the seating portion270of the two-piece valve seat260. In various embodiments, the bypass apertures202extend to the connection point273for the base plate sealing ring274, as illustrated inFIG. 12. In such a configuration, fluid flowing through the gap G1between the check valve sealing ring278and the cartridge sealing ring276may flow substantially horizontally into the bypass apertures202when the check valve58is not sealed against the check valve sealing ring278.

The centering portion272further includes one or more outwardly-protruding tangs244that are coupled to a top end of the annular walls242. The tangs244may be sized and shaped in various embodiments. In an illustrative embodiment, the tangs244are configured to extend annularly outwardly from the outside surface241of the annular walls242and include a stop surface243that is substantially perpendicular to the outside surface241of the annular walls242, as illustrated inFIG. 12. In certain configurations, the stop surface243of the tang244, the outside surface241of the annular walls242, and the top surface279of the check valve sealing ring278form a retainment gap247therebetween. The retainment gap247may retain the biasing member64, as described herein. In illustrative embodiments, the tangs244may have a length that may be between 0.125 inches and 0.200 inches, although other lengths are envisioned herein.

In illustrative embodiments, the connection bridges288of the seating portion270are configured to extend below the cartridge sealing ring276and check valve sealing ring278along the longitudinal axis82. Accordingly, the connection bridges288define the bottom surface264of the seating portion270. In illustrative embodiments, the bottom surface264is configured to abut or rest upon the top surface283of the base plate sealing ring274when the seating portion270is coupled together with the centering portion272to form the two-piece valve seat260. Similarly, the inner surface266of the seating portion270may be configured to abut against the outside surface241of the centering portion272when the seating portion270is coupled together with the centering portion272.

As noted, the two-piece valve seat260may be assembled via a snap-lock method, wherein one or more of the components are snapped together to be retained within the relief valve seat assembly56. Similarly, the components of the relief valve seat assembly56, and the fluid flow control assembly54, may be snapped together to be retained together. Accordingly, the present disclosure encompasses a fluid flow control assembly54that requires no seaming, welding, melting or applied glue to be assembled. Assembly can happen prior to installation of the fluid flow control assembly54within the housing22.

A second alternative two-piece valve seat360for incorporation into the relief valve seat assembly56is illustrated inFIGS. 13-15. As illustrated, the two-piece valve seat360illustratively includes a cartridge seating portion370and a centering-and-valve-sealing portion372that can be coupled to the cartridge seating portion370via, for example, a snap retainment. Alternatively, the cartridge seating portion370may be retained upon the centering-and-valve-sealing portion372by resting upon an annular bottom ledge374, described below, that extends radially outward from the centering-and-valve-sealing portion372.

Both the cartridge seating portion370and centering-and-valve-sealing portion372may be annular in nature to the longitudinal axis82when the two-piece valve seat360is incorporated into the filter assembly20. The cartridge seating portion370may be generally horizontal in direction (that is, perpendicular to the longitudinal axis82) and the centering-and-valve-sealing portion372may be aligned to be generally vertical in direction (that is, parallel to the longitudinal axis82). In various embodiments, the two portions370and372may be made of rubber, plastic, an elastomeric material, or any other suitable material. For instance, the portions370and372may be formed of nylon or a silicone-based or silicon-like material, although other materials are also envisioned herein. In illustrative embodiments, one or more components of the two-piece valve seat360may be formed of nylon, such as Nylon6, Nylon 6/6 or Nylon12. Any material that may be injection-molded or extruded and can withstand the environment of an oil filter may be used.

In various embodiments, the cartridge seating portion370of the two-piece valve seat360includes a cartridge sealing ring376and one or more connection bridges388extending radially inward from the cartridge sealing ring376, as illustrated inFIGS. 13-15. The cartridge seating portion370includes a top surface362, a bottom surface364, an inner surface366, and an outer surface368. The one or more connection bridges388each include an inner surface365that defines the inner surface366of the cartridge seating portion370. An end point386of the cartridge sealing ring376defines the outer surface368, with the outer surface368forming the outer periphery of the cartridge seating portion370. In various embodiments, the inner surface366is configured to be positioned adjacent a portion of the centering-and-valve-sealing portion372when the cartridge seating portion370is assembled with the centering-and-valve-sealing portion372, as described below.

In illustrative embodiments, the centering-and-valve-sealing portion372of the two-piece valve seat360includes an annular bottom ledge374and a check valve sealing ring378, as illustrated inFIG. 15. The annular bottom ledge374functions as a base plate sealing ring374. The base plate sealing ring374is configured to extend annularly outward of and below a portion of cartridge seating portion370when assembled together, as illustrated inFIG. 13. The base plate sealing ring374may extend outward from an exterior surface341of the centering-and-valve-sealing portion372at an end point373of the exterior surface341and be configured to extend in a substantially perpendicular direction from the alignment of the centering-and-valve-sealing portion372and the longitudinal axis A of the relief valve seat assembly56. The base plate sealing ring374includes a bottom surface381and a top surface383and terminates at an end point387that is opposite to the point373from where the base plate sealing ring374extends from the exterior surface341of the centering-and-valve-sealing portion372.

As illustrated inFIG. 15, the check valve sealing ring378of the centering-and-valve-sealing portion372is positioned adjacent to and above the base plate sealing ring374. The check valve sealing ring also extends radially outward of the exterior surface341of the centering-and-valve-sealing portion372. The check valve sealing ring378includes a top surface379that extends in a plane that a substantially perpendicular direction from the exterior surface341. The check valve sealing ring378further includes an outer circumference surface380that extends substantially parallel to the exterior surface341. The base plate sealing ring374extends further in a radial direction away from the longitudinal axis82than the check valve sealing ring378, as illustrated. The length or width of the top surface379and outer circumference surface380can vary within the scope of disclosure. An illustrative embodiment of the length of the top surface379may be anywhere between 0.05 inches and 0.10 inches.

In illustrative embodiments, the cartridge sealing ring376of the cartridge seating portion370is configured to extend annularly outward of the check valve sealing ring378of the centering-and-valve-sealing portion372when assembled together. In certain embodiments, the top surface362of the cartridge sealing ring376is generally aligned along the plane of the top surface379of the check valve sealing ring378when assembled together. However, when the cartridge seating portion370is coupled to the centering-and-valve-sealing portion372, the cartridge sealing ring376is annularly spaced away from the check valve sealing ring378by a first gap G1that can permit fluid to flow between the check valve sealing ring378and the cartridge sealing ring376, as illustrated inFIG. 13. According, when coupled together, the outer circumference surface380of the check valve sealing ring378of the centering-and-valve-sealing portion372may abut against the inner surface365of the one or more connection bridges388that extend inwardly from the cartridge sealing ring376. In various embodiments, the connection bridges388may be equally spaced apart around the circumference of the cartridge seating portion370, although other embodiments are envisioned herein. Illustratively, there may be eight equally spaced apart connection bridges388in the two-piece valve seat360.

As noted, in various embodiments, the top surface362of the cartridge sealing ring376is aligned horizontally with the top surface379of the check valve sealing ring378when the cartridge seating portion370is coupled to the centering-and-valve-sealing portion372. Accordingly, the check valve sealing ring378and the cartridge sealing ring376are generally parallel to each other and provide two parallel surfaces379and362upon which the bottom surface59of the check valve58can abut against to seal the check valve58to the two-piece valve seat360to prevent fluid flow through the gap G1. The cartridge sealing ring376terminates at an end point386. In illustrative embodiments, the end point386may be complimentarily shaped to be received in the bend94of the check valve58when the check valve58is sealed thereto. For instance, the end point386may be rounded in shape, although other forms and shapes are envisioned herein.

As illustrated inFIGS. 13-15, the cartridge sealing ring376of the cartridge seating portion370is configured to be longitudinally spaced away from the base plate sealing ring374to form a second gap G2therebetween when the cartridge seating portion370is coupled to the centering-and-valve-sealing portion372. The second gap G2is an opening below the check valve58through which fluid flowing into the openings66of the base plate36can flow after entering the filter assembly20. The second gap G2is connected to the first gap G1such that a flow passageway P extends between the gaps G1and G2that fluid can flow through. In illustrative embodiments, the second gap G2is upstream of the angled portion92of the check valve58. Accordingly, when fluid is flowing through the passageway P and exits the gap G1, the fluid takes a bypass path B that bypasses the filter element28. Further, such fluid will enter the second gap G2before subjecting the angled portion92of the check valve58to pressure from the fluid, reducing unnecessary wear and tear on the check valve58.

In various embodiments, the cartridge sealing ring376may extend further annularly outward of the base plate sealing ring374when the centering-and-valve-sealing portion372is coupled to the cartridge seating portion370. The base plate sealing ring374may extend along a second plane that is substantially parallel to the plane of the check valve sealing ring378and cartridge sealing ring376, but the base plate sealing ring374may extend below the check valve sealing ring378and cartridge sealing ring376to create a horizontal gap between the base plate sealing ring74and the check valve sealing ring378.

In illustrative embodiments, the centering-and-valve-sealing portion372of the two-piece valve seat360further includes one or more annular walls342that extend upward from the base plate sealing ring374and are annular to the longitudinal axis A of the two-piece valve seat360. The annular walls342may illustratively be substantially perpendicular to the base plate sealing ring374, but other embodiments are envisioned herein. The annular walls342may define the exterior surface341from which the base plate sealing ring374and the check valve sealing ring378extend.

As illustrated, for example, inFIGS. 13 and 15, at least a portion of the annular walls342may be slightly angled with respect to the longitudinal axis A to form an angle that is less than 90 degrees to the base plate sealing ring374in order to, for example, provide structural support or assistance for positioning of the centering-and-valve-sealing portion372within the filter assembly20. In various embodiments, the annular walls342of the centering-and-valve-sealing portion372extend through the central aperture of the check valve58, and the exterior surface341of the annular walls342may abut against the end point71of the horizontal segment90of the check valve58. In illustrative embodiments, the annular walls342may have a length that may be between 0.500 inches and 1.000 inches, although other lengths are envisioned herein.

An outflow aperture300extends along the longitudinal axis A of the two-piece valve seat360. The outflow aperture300extends within the circumference of the annular walls342of the centering-and-valve-sealing portion372to provide a flow path for fluid flowing to the outlet opening80of the filter assembly20. Accordingly, fluid that has been filtered through the filter element28and flows into the opening31, or fluid that has by-passed the filter element28via the check valve58and relief valve seat assembly56, is directed to pass through the outflow aperture300of the two-piece valve seat360to the outlet opening80.

The annular walls342of the two-piece valve seat360are spaced apart to form one or more bypass apertures302. The bypass apertures302are configured to permit fluid to flow into the outflow aperture300from the gap G1. In various embodiments, and as illustrated inFIGS. 13-15, the bypass apertures302may be spaced equally around the circumference of the two-piece valve seat360. In illustrative embodiments, the bypass apertures302may be positioned to at least partially be aligned longitudinally above one or more gaps G1between the check valve sealing ring378and the cartridge sealing ring376of the cartridge seating portion370of the two-piece valve seat360. In such a configuration, fluid flowing through the gap G1between the check valve sealing ring378and the cartridge sealing ring376may flow substantially horizontally into the bypass apertures302when the check valve58is not sealed against the check valve sealing ring378. In other illustrative embodiments, the bypass apertures302may be positioned adjacent to or above one or more connection bridges388in the two-piece valve seat360.

The centering-and-valve-sealing portion372further includes one or more outwardly-protruding tangs344that are coupled to a top end of the annular walls342. The tangs344may be sized and shaped in various embodiments. In an illustrative embodiment, the tangs344are configured to extend annularly outwardly from the exterior surface341of the annular walls342and include a stop surface343that is substantially perpendicular to the exterior surface341of the annular walls342, as illustrated inFIG. 15. In certain configurations, the stop surface343of the tang344, the exterior surface341of the annular walls342, and the top surface379of the check valve sealing ring378form a retainment gap347therebetween. The retainment gap347may retain the biasing member64, as described herein. In illustrative embodiments, the tangs344may have a length that may be between 0.125 inches and 0.300 inches, although other lengths are envisioned herein.

In illustrative embodiments, the connection bridges388of the cartridge seating portion370are configured to be positioned below the cartridge sealing ring376and check valve sealing ring378along the longitudinal axis82. The connection bridges388may define the bottom surface364of the cartridge seating portion370. In illustrative embodiments, the bottom surface364is configured to abut or rest upon the top surface383of the base plate sealing ring374when the seating portion370is coupled together with the centering-and-valve-sealing portion372to form the two-piece valve seat360. Similarly, the inner surface366of the cartridge seating portion370may be configured to abut against the outer circumference surface380of the check valve sealing ring378when the seating portion370is coupled together with the centering-and-valve-sealing portion372.

As noted, the two-piece valve seat360may be assembled via a snap-lock method, wherein one or more of the components are snapped together to be retained within the relief valve seat assembly56. Similarly, the components of the relief valve seat assembly56, and the fluid flow control assembly54, may be snapped together to be retained together. Accordingly, the present disclosure encompasses a fluid flow control assembly54that requires no seaming, welding, melting or applied glue to be assembled. Assembly can happen prior to installation of the fluid flow control assembly54within the housing22.

A third alternative two-piece valve seat460for incorporation into the relief valve seat assembly56is illustrated inFIGS. 16-18. As illustrated, the two-piece valve seat460illustratively includes a cartridge seating portion470and a centering-and-valve-sealing portion472that can be coupled to the cartridge seating portion470via, for example, a snap retainment. Alternatively, the cartridge seating portion470may be retained upon the centering-and-valve-sealing portion472by resting on a portion of the centering-and-valve-sealing portion472, described below.

Both the cartridge seating portion470and centering-and-valve-sealing portion472may be annular in nature to the longitudinal axis82when the two-piece valve seat460is incorporated into the filter assembly20. The cartridge seating portion470may be generally horizontal in direction (that is, perpendicular to the longitudinal axis82) and the centering-and-valve-sealing portion472may be aligned to be generally vertical in direction (that is, parallel to the longitudinal axis82). In various embodiments, the two portions470and472may be made of rubber, plastic, an elastomeric material, or any other suitable material. For instance, the portions470and472may be formed of nylon or a silicone-based or silicon-like material, although other materials are also envisioned herein. In illustrative embodiments, one or more components of the two-piece valve seat460may be formed of nylon, such as Nylon6, Nylon 6/6 or Nylon12. Any material that may be injection-molded or extruded and can withstand the environment of an oil filter may be used.

In various embodiments, the cartridge seating portion470of the two-piece valve seat460includes a cartridge sealing ring476, as illustrated inFIGS. 13-15. The cartridge seating portion470includes a top surface462, a bottom surface464, an inner surface466, and an outer surface468. The outer surface468extends to an end point486, with the outer surface468forming the outer periphery of the cartridge seating portion470. In various embodiments, the inner surface466is configured to be positioned adjacent a portion of the centering-and-valve-sealing portion472when the cartridge seating portion470is assembled with the centering-and-valve-sealing portion472, as described below.

In illustrative embodiments, the centering-and-valve-sealing portion472of the two-piece valve seat460includes an annular bottom ledge474, a check valve sealing ring478, and one or more connection bridges488, as illustrated inFIG. 18. The annular bottom ledge474functions as a base plate sealing ring474. The base plate sealing ring474is configured to extend annularly outward of and below a portion of cartridge seating portion470when assembled together, as illustrated inFIG. 16. The base plate sealing ring474may extend outward from an exterior surface441of the centering-and-valve-sealing portion472at an end point473of the exterior surface441and be configured to extend in a substantially perpendicular direction from the alignment of the centering-and-valve-sealing portion472and the longitudinal axis A of the relief valve seat assembly56. The base plate sealing ring474includes a bottom surface481and a top surface483and terminates at an end point487that is opposite to the point473from where the base plate sealing ring474extends from the exterior surface441of the centering-and-valve-sealing portion472.

As illustrated inFIG. 18, the check valve sealing ring478of the centering-and-valve-sealing portion472is positioned adjacent to and above the base plate sealing ring474. The check valve sealing ring also extends radially outward of the exterior surface441of the centering-and-valve-sealing portion472. The check valve sealing ring478includes a top surface479that extends in a plane that a substantially perpendicular direction from the exterior surface441. The check valve sealing ring478further includes an outer circumference surface480that extends substantially parallel to the exterior surface441. The base plate sealing ring474extends further in a radial direction away from the longitudinal axis82than the check valve sealing ring478, as illustrated. The length or width of the top surface479and outer circumference surface480can vary within the scope of disclosure. An illustrative embodiment of the length of the top surface479may be anywhere between 0.05 inches and 0.10 inches.

The one or more connection bridges488of the centering-and-valve-sealing portion472are configured to extend radially outward from the outer circumference surface480of the check valve sealing ring478, as illustrated inFIG. 18. In various embodiments, the connection bridges488include at least a top surface490, an exterior surface491, and a ledge492. The ledge492formed by a vertical surface494and a horizontal surface496that are substantially perpendicular to each other. As illustrated inFIG. 18, the ledge492may be positioned adjacent the exterior surface491of the connection bridge488, and may be formed to receive a portion of the cartridge sealing ring476when the cartridge seating portion470is coupled to the centering-and-valve-sealing portion472. The ledge492may accordingly act as a seat to receive the cartridge sealing ring476and facilitate proper alignment between the components of the two-piece valve seat460. According, when coupled together, the inner surface466of the cartridge sealing ring476may abut against the horizontal surface496and/or vertical surface494of the ledges492of the one or more connection bridges488that extend outwardly from the check valve sealing ring478. The exterior surface491of the connection bridges488may be positioned to be unitary with the end point487of the base plate sealing ring474. In various embodiments, the connection bridges488may be equally spaced apart around the circumference of the cartridge seating portion470, although other embodiments are envisioned herein. Illustratively, there may be eight equally spaced apart connection bridges488in the two-piece valve seat460.

In illustrative embodiments, the cartridge sealing ring476of the cartridge seating portion470is configured to extend annularly outward of the check valve sealing ring478of the centering-and-valve-sealing portion472when assembled together. In certain embodiments, the top surface462of the cartridge sealing ring476is generally aligned along the plane of the top surface479of the check valve sealing ring478when assembled together. However, when the cartridge seating portion470is coupled to the centering-and-valve-sealing portion472, the cartridge sealing ring476is annularly spaced away from the check valve sealing ring478by a first gap G1that can permit fluid to flow between the check valve sealing ring478and the cartridge sealing ring476, as illustrated inFIG. 16.

As noted, in various embodiments, the top surface462of the cartridge sealing ring476is aligned horizontally with the top surface479of the check valve sealing ring478when the cartridge seating portion470is coupled to the centering-and-valve-sealing portion472. Accordingly, the check valve sealing ring478and the cartridge sealing ring476are generally parallel to each other and provide two parallel surfaces479and462upon which the bottom surface59of the check valve58can abut against to seal the check valve58to the two-piece valve seat460to prevent fluid flow through the gap G1. The cartridge sealing ring476terminates at an end point486. In illustrative embodiments, the end point486may be complimentarily shaped to be received in the bend94of the check valve58when the check valve58is sealed thereto. For instance, the end point486may be rounded in shape, although other forms and shapes are envisioned herein.

As illustrated inFIGS. 16-18, the cartridge sealing ring476of the cartridge seating portion470is configured to be longitudinally spaced away from the base plate sealing ring474to form a second gap G2therebetween when the cartridge seating portion470is coupled to the centering-and-valve-sealing portion472. The second gap G2is an opening below the check valve58through which fluid flowing into the openings66of the base plate36can flow after entering the filter assembly20. The second gap G2is connected to the first gap G1such that a flow passageway P extends between the gaps G1and G2that fluid can flow through. In illustrative embodiments, the second gap G2is upstream of the angled portion92of the check valve58. Accordingly, when fluid is flowing through the passageway P and exits the gap G1, the fluid takes a bypass path B that bypasses the filter element28. Further, such fluid will enter the second gap G2before subjecting the angled portion92of the check valve58to pressure from the fluid, reducing unnecessary wear and tear on the check valve58.

In various embodiments, the cartridge sealing ring476may extend further annularly outward of the base plate sealing ring474when the centering-and-valve-sealing portion472is coupled to the cartridge seating portion470. The base plate sealing ring474may extend along a second plane that is substantially parallel to the plane of the check valve sealing ring478and cartridge sealing ring476, but the base plate sealing ring474may extend below the check valve sealing ring478and cartridge sealing ring476to create a horizontal gap between the base plate sealing ring74and the check valve sealing ring478.

In illustrative embodiments, the centering-and-valve-sealing portion472of the two-piece valve seat460further includes one or more annular walls442that extend upward from the base plate sealing ring474and are annular to the longitudinal axis A of the two-piece valve seat460. The annular walls442may illustratively be substantially perpendicular to the base plate sealing ring474, but other embodiments are envisioned herein. The annular walls442may define the exterior surface441from which the base plate sealing ring474and the check valve sealing ring478extend.

As illustrated, for example, inFIGS. 16 and 18, at least a portion of the annular walls442may be slightly angled with respect to the longitudinal axis A to form an angle that is less than 90 degrees to the base plate sealing ring474in order to, for example, provide structural support or assistance for positioning of the centering-and-valve-sealing portion472within the filter assembly20. In various embodiments, the annular walls442of the centering-and-valve-sealing portion472extend through the central aperture of the check valve58, and the exterior surface441of the annular walls442may abut against the end point71of the horizontal segment90of the check valve58. In illustrative embodiments, the annular walls442may have a length that may be between 0.500 inches and 1.000 inches, although other lengths are envisioned herein.

An outflow aperture400extends along the longitudinal axis A of the two-piece valve seat460. The outflow aperture400extends within the circumference of the annular walls442of the centering-and-valve-sealing portion472to provide a flow path for fluid flowing to the outlet opening80of the filter assembly20. Accordingly, fluid that has been filtered through the filter element28and flows into the opening31, or fluid that has by-passed the filter element28via the check valve58and relief valve seat assembly56, is directed to pass through the outflow aperture400of the two-piece valve seat460to the outlet opening80.

The annular walls442of the two-piece valve seat460are spaced apart to form one or more bypass apertures402. The bypass apertures402are configured to permit fluid to flow into the outflow aperture400from the gap G1. In various embodiments, and as illustrated inFIGS. 16-18, the bypass apertures402may be spaced equally around the circumference of the two-piece valve seat460. In illustrative embodiments, the bypass apertures402may be positioned to at least partially be aligned longitudinally above one or more gaps G1between the check valve sealing ring478and the cartridge sealing ring476of the cartridge seating portion470of the two-piece valve seat460. In such a configuration, fluid flowing through the gap G1between the check valve sealing ring478and the cartridge sealing ring476may flow substantially horizontally into the bypass apertures402when the check valve58is not sealed against the check valve sealing ring478. In other illustrative embodiments, the bypass apertures402may be positioned adjacent to or above one or more connection bridges488in the two-piece valve seat460.

The centering-and-valve-sealing portion472further includes one or more outwardly-protruding tangs444that are coupled to a top end of the annular walls442. The tangs444may be sized and shaped in various embodiments. In an illustrative embodiment, the tangs444are configured to extend annularly outwardly from the exterior surface441of the annular walls442and include a stop surface443that is substantially perpendicular to the exterior surface441of the annular walls442, as illustrated inFIG. 18. In certain configurations, the stop surface443of the tang444, the exterior surface441of the annular walls442, and the top surface479of the check valve sealing ring478form a retainment gap447therebetween. The retainment gap447may retain the biasing member64, as described herein. In illustrative embodiments, the tangs444may have a length that may be between 0.125 inches and 0.400 inches, although other lengths are envisioned herein.

In illustrative embodiments, the connection bridges488of the cartridge seating portion470are configured to be positioned below the cartridge sealing ring476along the longitudinal axis82. In illustrative embodiments, the connection bridges488are configured to extend upward from the top surface483of the base plate sealing ring474. In further illustrative embodiments, the top surface490of the connection bridges488may be aligned with or unitary with the top surface479of the check valve sealing ring478.

As noted, the two-piece valve seat460may be assembled via a snap-lock method, wherein one or more of the components are snapped together to be retained within the relief valve seat assembly56. Similarly, the components of the relief valve seat assembly56, and the fluid flow control assembly54, may be snapped together to be retained together. Accordingly, the present disclosure encompasses a fluid flow control assembly54that requires no seaming, welding, melting or applied glue to be assembled. Assembly can happen prior to installation of the fluid flow control assembly54within the housing22.

Remaining components of the fluid flow control assembly54will be now described by referencing a unitary valve seat60described above. However, such descriptions are equally applicable to the two-piece valve seats260/360/460described above.

The biasing member64of the relief valve seat assembly56is configured to bias the fluid flow control assembly54in a position that prevents flow of fluid through the bypass path B and into the flow aperture100of the valve seat60, thereby preventing fluid from by-passing the filter element28under normal operating conditions. Specifically, the biasing member64is naturally biased to engage with or place a downward pressure D on a top surface91of the horizontal segment90of the check valve58to seal the check valve58over the check valve sealing ring78and gap G1. As described further in detail below, the end cap50of the filter element28is also configured to abut against the top surface91of the horizontal segment90of the check valve58over the cartridge sealing ring76. Accordingly, the gap G1that extends between the check valve sealing ring78and the cartridge sealing ring76is sealed by the check valve58, preventing flow of fluid through the gap G1under normal conditions. Accordingly, pressure from fluid flowing in the passage P under normal operations may not overcome the downward pressure D of the biasing member64. However, if the pressure of fluid flowing into the passage P of the valve seat60exceeds a certain amount, the pressure of the fluid will overcome the downward pressure D of the biasing member64, forcing the check valve58above the check valve sealing ring78to move upward and causing the biasing member64to be compressed upward against the stop surface43of the tangs44, as illustrated inFIGS. 6A-6B.

The annular washer68of the relief valve seat assembly56is configured to be annular in nature and includes a bottom wall57and two spaced apart side walls55and53. The bottom wall57and spaced apart side walls55and53form a receiving aperture69in the annular washer68that can receive a portion of the biasing member64as illustrated inFIGS. 4A-6Bto retain the biasing member64in a fixed position. In particular, the annular washer68may retain the biasing member64in a position that is longitudinally above the check valve58, and the annular washer68and biasing member64may be aligned above the check valve sealing ring78of the valve seat60to apply the downward force D on a portion of the check valve58that abuts against or contacts the check valve sealing ring78to maintain the check valve58in a sealed position above the gap G1, as illustrated.

In various embodiments, the biasing member64may be a spring or other similar biasing mechanism that is retained within the retainment gap47of the valve seat60, although other forms of applying a downward pressure onto the top surface91of the horizontal segment90of the check valve58are envisioned herein. In various embodiments, a top surface63of the biasing member64engages with the stop surface43of one or more tangs44of the centering portion72of the valve seat60. Accordingly, the stop surface43provides stabilization to the biasing member64to be retained within the retainment gap47and to permit the biasing member64to apply the downward pressure D onto the check valve58. In various embodiments, a bottom surface65of the biasing member64abuts against or contacts the top surface91of the check valve58to apply the downward pressure D. In other embodiments, as illustrated inFIGS. 1-8, a portion of the biasing member64may be retained by the annular washer68, and force from the biasing member64is transferred onto the top surface79of the check valve58via the annular washer68. Other embodiments of transferring the downward pressure D to the check valve58are envisioned herein.

In various embodiments the bottom surface65of the biasing member64and/or the top surface63of the biasing member64may include a flat or planar segment67that is configured to abut against the check valve58and/or the annular washer68. The flat segment67along the circumference of the annular biasing member64may exist in a single plane such that the biasing member64applies the downward force D consistently to substantially the entire circumference of the check valve58.

In illustrative embodiments, the valve seat60may further include one or more alignment ribs104that extend below the base plate sealing ring74. The alignment ribs104may be positioned to be equally spaced apart around the circumference of the valve seat60, although other locations are envisioned herein. The alignment ribs104are configured to extend below the plane P2of the base plate sealing ring74and configured to engage with a portion of the base plate36to assist with aligning the fluid flow control assembly54in a proper position within the filter assembly20when the base plate36is secured to the rest of the filter assembly20. For example, in an illustrative embodiment, the base plate36may include a double draw design that features one or more draw-down grooves106that form an opening108to the interior cavity of the filter assembly20. The alignment ribs104may be formed and positioned to extend into the opening108of the draw-down grooves106of the base plate36in order to align the fluid flow control assembly54appropriately with regard to the base plate36, and thereby the rest of the filter assembly20, when the base plate36is secured to the filter assembly20. In various embodiments, the draw-down grooves106may be annually inward of the raised portion110of the base plate36. Accordingly, the alignment ribs104may be positioned to be annularly inward of the engagement between the bottom of the valve seat60and the base plate36when the valve seat60abuts against or contacts the top surface112of the raised portion110.

The relief valve seat assembly56may be manufactured in any suitable manner. In one embodiment, the valve seat60, biasing member64, and washer68may be formed separately and then assembled together. In another embodiment, the biasing member64and/or the washer68may at least partially be inserted into a mold and rubber and/or another suitable material may be injected into the mold to create the valve seat60. In this manner, when the injected material sets, the biasing member64and/or the washer68will be at least partially embedded within the valve seat60. Other forms of manufacturing the relief valve seat assembly56are envisioned herein.

The assembly and operation of the filter assembly20and the fluid flow control assembly54will now be described. The filter element28is assembled with the annular filter media45on the core30and the end caps50,52secured in place. Assembly of the filter element28may occur prior to assembly of the filter assembly20, for example, the filter element28may be purchased from a third party. The spring40or other biasing means, if used, is first inserted into the open end of the housing22until it seats against the closed end26of the housing22. The filter element28is positioned in the housing22abutting the spring40. The spring40is configured to keep the filter element28positioned away from the end26of the housing.

The fluid flow control assembly54may be assembled via a snap-lock method, wherein one or more of the components of the fluid flow control assembly54are snapped together to be retained in the fluid flow control assembly54. Accordingly, the present disclosure encompasses a fluid flow control assembly54that requires no seaming, welding, melting or applied glue to be assembled. Assembly can happen prior to installation of the fluid flow control assembly54within the housing22.

In an illustrative embodiment, the fluid flow control assembly54can be assembled by coupling the check valve58to the valve seat60by, for instance, positioning the annular walls42of the valve seat60within the center aperture of the check valve58and securing the check valve58against the check valve sealing ring78of the seat portion70of the valve seat60. The annular washer68and biasing member64may then be inserted over the annular walls42to be received within the retainment gap47of the valve seat60along the outside surface41of the annular walls42. The biasing member64may be snap fit against the stop surface43of the tangs44of the valve seat60to place a downward biasing force onto the annular washer68and the check valve58, thereby holding the components of the fluid flow control assembly54in place.

Once assembled, the fluid flow control assembly54may be placed into the housing22after the filter element28. The annular walls42of the valve seat60will be received within the flow opening31formed in the core30to position the fluid flow control assembly54in an appropriate position relative to the rest of the components. This automatic positioning of the fluid flow control assembly54advantageously provides a simple and easy way to align the components together for assembly. Further, by such positioning, a portion of the top surface91of the check valve58will abut against the bottom end cap50of the filter element28. This abutment will, among other things, prevent the fluid flow control assembly54from being misaligned within the filter assembly20or positioned in an undesired place. This alignment will also help seal undesired fluid flow between the fluid flow control assembly54and the core30of the filter element28. The base plate36is inserted to close the open end of the housing22, and a lid38is inserted over the base plate36to secure all of the components together within the housing22. The configuration of the fluid flow control assembly54further provides correct positioning of the base plate36relative to the fluid flow control assembly54without additional securement between those components. For example, the fluid flow control assembly54may be spaced apart from, or lack contact with, the rim37of the outlet opening80. Further, the alignment ribs104that extend toward the base plate36may provide some automatic positioning of the base plate36relative to the fluid flow control assembly54and vice versa. An outer rim29of the lid38is rolled, for example, with the open end of the housing22to form a seal (FIG. 3). Optionally, any other suitable seal may be formed between the lid38and the housing22.

The components are assembled together such that the opening31formed by the core30of the filter element28is generally aligned along the longitudinal axis82of the filter assembly20, and the longitudinal axis A of the valve seat60is substantially aligned with the longitudinal axis82. Accordingly, the outflow aperture100of the valve seat60will be aligned with the outlet opening80of the base plate36, permitting fluid to flow out of the filter assembly20.

The components are configured to permit ease of assembling, and may be used for a variety of sizes and shapes of a filter assembly20. In light of the automatic positioning that occurs by the proposed design, the fluid flow control assembly54is not required to be directly or tightly secured to the filter element28(e.g. to the core30or the end cap50), and is further not required to be tightly secured to the base plate36. Such a design provides and advantage in that no tight connection (e.g. snap-lock or similar connection) is required between the fluid flow control assembly54and any individual component. Instead, the configuration permits the fluid flow control assembly54to be maintained in a proper position by its alignment features and by the pressure applied to the fluid flow control assembly54from the components of the filter assembly20, such as the filter element28(which is biased downward by the spring40) and the base plate36.

Illustratively, positioning of the base plate36in the housing22partially compresses the spring40, whereby, when the parts are assembled, a spring force is applied to the top of the filter element28urging the filter element28toward the fluid flow control assembly54and the base plate36. If the spring40is used, the spring force will help to clamp the fluid flow control assembly54between the filter element28and the base plate36, and to restrict flow between the filter element28and the base plate36(and vice versa) to be via the fluid flow control assembly54. The core30may engage the annular walls42of the valve seat60and the end cap50may also engage and bear upon the generally horizontal segment90of the check valve58, sealing it against the cartridge sealing ring76and the check valve sealing ring78of the valve seat60.

In operation, the filter assembly20is spun onto a stud on the engine block (not shown), which engages threads (not shown) in the central outlet opening80in the base plate36, and is secured in place. The gasket25coupled to the lid38will engage the engine block and preclude fluid flow between the engine block and the filter assembly20. While a particular gasket and lid are described and illustrated, any suitable gasket and lid configurations may be utilized with the principles of the present application.

When the engine is started, fluid, usually oil, will enter the filter assembly20through the inlet openings66. Under normal operations, slight pressure from the entering oil will be applied to the check valve58, for example, on the bottom side of the angled segment92. As illustrated inFIGS. 5A-5B, this slight pressure will cause the angled segment92to bend upward at the bend94in the check valve58, causing the free end96of the angled segment92to move away from engagement with the top surface62of the base plate36. Oil will thereafter flow under a normal flow path N past the check valve58. For example, oil will flow through the inlet openings66, around the free end96of the check valve58and the end cap50of the filter element28, through the first face46of the filter media of the filter element28, through the second face48of the filter element28and past the core30of the filter element, into the opening31, through the flow aperture100of the valve seat60, and then to the outlet opening80of the base plate36to be discharged for return to the engine. When the engine is turned off, the pressure will decrease, causing the angled segment92of the check valve58to close against the base plate36again, closing access by the inlet openings66and preventing return of oil in the filter assembly20to the engine.

As the filter media clogs during normal operation, oil will flow into the passage P of the seat portion70of the valve seat60and hit against the horizontal segment90of the check valve58the extends across the gap G1. A differential pressure will build across the horizontal segment90of the check valve58, applying an upward force onto the horizontal segment90. Upon attainment of a predetermined pressure, for example, on the order of between about 6 and about 36 psid at 0.1 gpm with 18 cSt oil in an illustrative embodiment (although other predetermined pressures are envisioned herein), the horizontal segment90of the check valve above the check valve sealing ring78will overcome the downward pressure D of the biasing member64of the valve seat60, causing the end point71of the horizontal segment90of the check valve58to move upward and to open flow of oil through the gap G1, as illustrated inFIGS. 6A-6B. At this point, oil will flow through the bypass flow path B. For example, oil may flow into the openings66, through the passage P and the gap G1, into the bypass apertures102of the centering portion72of the valve seat60, into the outflow aperture100of the valve seat60, and into the outlet opening80of the base plate36to exit the filter assembly20back to the engine, thereby bypassing the filter media of the filter element28. In other words, during periods of time when high differential pressure exists across the filter media, due to cold thick oil or high contaminant loading of the filter media, for example, the oil will travel through the passage P and open the horizontal segment90of the check valve58across the gap G1of the valve seat60to permit oil to bypass the filter media via the bypass path B and exit the filter assembly20through the central outlet opening80for return to the engine.

In various embodiments, a portion of the horizontal segment90of the check valve58spaced away from the end point71is retained in a fixed position relative to the end point71during the by-pass operation, causing the end point71of the horizontal segment90to pivot upward when the pressure increases past a predetermined threshold. As illustrated, for instance, inFIGS. 4A-6B, the end cap50of the filter element28may abut against the horizontal segment90of the check valve58that is aligned over the cartridge sealing ring76. Force from the spring40of the filter assembly20, as well as compression force from the base plate36and lid38, may retain the end cap against the horizontal segment90at this point, creating a pivot area for the rest of the horizontal segment90to move in relation to when the oil pressure has exceed the threshold to cause the upward force of the horizontal segment90to overcome the downward force D of the biasing member64. In such a manner, oil is prevented from re-entering a flow path toward the filter element28and is directed to passing through the valve seat60under the bypass process.

During operation, the biasing member64provides the desired amount of predetermined resistance to moving the horizontal segment90of the check valve58upward to permit passage of oil through the gap G1at the end of the path P. More particularly, the biasing member64is designed with a particular resistance value (based on, for instance, a spring rate, tensile strength, hardness, modulus of elasticity, thickness, number of arms, distance between arms, and other spring properties), wherein the resistance value is overcome upon attainment of the predetermined pressure in the housing (for example, between about 6 and about 36 psid at 0.1 gpm with 18 cSt oil). The predetermined pressure, and thus the necessary resistance valve of the biasing member64may be different for different filter assemblies and/or applications. The biasing member64is easily customizable for these different applications and provides a more precise resistance value, thereby providing more control over the flow of fluid through path P and through the gap G1into the bypass apertures102.

In any of the embodiments herein, a resistance or load on the biasing member64when assembled in the filter assembly20may be determined by multiplying a surface area of the horizontal segment90of the check valve58that is exposed to a differential pressure across it, times a predetermined relief valve opening pressure. For example, if an area under the horizontal segment90over the gap G1is approximately 1 square inch and a predetermined valve opening pressure is 20 pounds per square inch (psi), the spring load of the biasing member64could be 20 pounds.

FIG. 9illustrates exemplary flow curves of flow rate to flow restriction in exemplary embodiment of the fluid flow control assembly54having different spring loads. In particular,FIG. 9illustrates the change in flow restriction across different flow rates for different spring loads (lb-F) when using standard conventional oil (5w30) having a set viscosity (50+/−5 cST (mm2/s)). As illustrated, the flow restriction (PSID, pounds per square inch differential) of the fluid flow control assembly may be increased or decreased at the same flow rates noted (i.e. the curve moves up or down the flow restriction axis) by selecting a spring with different lb-F load at its load height. The higher the average spring load, the higher the flow restriction will be at a given flow rate. Other means of altering the flow curve are envisioned herein.

While directional terminology, such as upper, lower, top, bottom, etc. is used throughout the present application, such terminology is not intended to limit the disclosure. Such terminology is only used for purposes of describing the various features and components in relation to one another. While certain illustrative embodiments have been described in detail in the figures and the foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. There are a plurality of advantages of the present disclosure arising from the various features of the apparatus, systems, and methods described herein. It will be noted that alternative embodiments of the apparatus, systems, and methods of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the apparatus, systems, and methods that incorporate one or more of the features of the present disclosure.