Fuel filter

Abstract: A fuel filter assembly employs a base (12) which mounts a dispo­ sable filter element cartridge (14). The cartridge (14) includes a dual stage filter system wherein fuel flows axially to a primary filter element for removing particulate matter and coalescing water droplets and axially to a secondary filter stage which functions as a water barrier. The filtered fuel flows axially and exits through an outlet passage in the base (12). Water may be collected in a sump. The cartridge (14) is retained on the base (12) by a collar (62) which engages against a roll seam structure of the cartridge (14).

Description: Background of the Invention This invention relates generally to devices for filtering and separating liquids. More particularly, the present invention relates to a fuel filter assembly for removing foreign particles and separating water from fuel of the fuel supply system of an internal combustion engine according to the introductory clause of claim 1. The absence of high standards of quality control in diesel fuel supplies dictates that an effective fuel filter be incorporated into the fuel supply system for a diesel engine. It is not uncommon for diesel fuel to have significant quantities of abrasive particles and water. The abrasive particles present the potential for permanent damage to components of the fuel injection pump. The abrasive particles can also adversely effect the performance of the pump by destroying the ability of the fuel injection pump to precisely meter and deliver fuel at high pressures. The presence of water in the diesel fuel supply can cause rusting of engine components, and during freezing conditions, can result in interruption of the fuel injection system and/or seizure of moving components. Diesel fuel also contains a waxy constituent which precipitates as wax crystals when the fuel temperature drops below a characteristic "cloud point". In cold weather conditions, the precipitating wax crystals can rapidly plug a fuel filter and thereby cut off fuel delivery to the internal combustion engine. A number of conventional fuel filters perform the dual function of removing particulate material from the diesel fuel and separating water from the fuel. In addition, conventional fuel filter units or fuel conditioners frequently employ heaters to prevent wax crystal formation. Commonly, the fuel filters employ a disposable filter cartridge which is replaced at pre-established intervals of filter usage. US-A-4,491,120 assigned to the assignee of the present invention, discloses a fuel conditioner to which the present invention relates. A disposable filter/water separator cartridge is releasably secured to a base. A multi-stage filter assembly within the cartridge includes filtering and coalescing media and separates an upper portion of the chamber from a lower portion which functions as a water collection sump. A heater mounted in the base warms the fuel before the fuel enters the cartridge. The fuel conditioner also features sensing devices in the base to indicate the presence of a predetermined quantity of water in the sump and the occurrence of a plugged filter condition. A priming pump is also manually operable to restore the fuel conditioner to operational condition after the cartridge replacement. FR-A-1 321 845 discloses a fuel filter assembly as mentioned in the first paragraph of this specification. This previously known fuel filter assembly has the disadvantage of being of very complicated structures. For replacing the two separate filter elements, obviously the whole assembly has to be taken apart. Therefore, much time and experience is required for replacing the filter cartridges, which replacing will be correspondingly costly. An object of the invention is to provide a new and improved fuel filter adaptable for use in filtering the fuel supplied to a diesel engine which is of simple construction. Another object of the invention is to provide a new and improved fuel filter of efficient low cost construction which provides an effective and efficient means for filtering particulate matter from the fuel and for removing water from the fuel. A further object of the invention is to provide a new and improved fuel filter having a disposable cartridge element incorporating a dual stage filter assembly. Summary of the Invention These objects are solved by the features of the characterizing part of claim 1. Further advantageous embodiments are given in the subclaims. Briefly stated, the invention in a preferred form is a fuel filter assembly which includes a base and a disposable filter cartridge mountable to the base. The base includes a fuel inlet passage, a fuel outlet passage, a central first conduit which interiorly defines a first axial passage communicating with the inlet passage, and a second conduit which surrounds the first conduit and defines a second axial passage which communicates with the outlet passage. The base also forms a sump which collects water separated from the fuel. The cartridge comprises a container-like housing. A primary filter unit enclosed in the housing comprises a pleated primary filter element defining a first chamber which communicates with the first axial passage and a second chamber surrounding the first chamber. A secondary filter element extends exteriorly from the housing. The base and secondary filter element cooperate to define a third chamber and an inner fourth chamber. The fourth chamber is surrounded by the third chamber. The fourth chamber communicates with the second axial passage. The first and second axial passages are preferably coaxial. The housing also includes a first endcap and a first sealing grommet surrounding an opening for fluidly sealing the endcap with the first conduit. A second endcap axially spaced from the first endcap mounts a second sealing means for fluidly sealing the second endcap to the second conduit. The secondary filter element is disposed between the first and second endcaps. The first endcap also has a plurality of angularly spaced apertures which provide fluid communication between the second and third chambers. A heating unit comprising a heat rod extending axially in the first conduit is employed for heating fuel. The secondary filter element is impervious to the passage of water. The primary filter element contains water coalescing properties which result in the formation of water droplets in the second chamber. The inlet passage has an inlet port and the outlet passage has an outlet port. The ports are located at diametrically opposed locations of the base. The sump has a pair of sump sections with the inlet and outlet passages being disposed between the sump sections. A water level sensor is disposed in the sump. A drain cock is also disposed in the sump for draining collected water from the filter assembly. A fuel filter cartridge in accordance with the invention includes a container which forms a housing. A continuous fan-shaped, pleated primary filter element is disposed in the housing. The primary filter element has water coalescing properties and defines a central inner region on one side of the element and an outer region on the opposite side of the element. An endcap connects at one end of the housing and encloses the primary element. The endcap defines a central opening. A sealing grommet is mounted in the opening for fluidly sealing a conduit which is received through the opening. A secondary filter element disposed axially from the primary filter element is located exteriorly of the housing. The secondary filter element is impervious to the passage of water and defines a central inner region. A second endcap encloses an axial end of the secondary filter element. The endcap defines a central opening which is coaxial with the first opening. A sealing grommet is received in the second opening for fluidly sealing a second conduit which is received through the second opening. The first endcap has a plurality of angularly spaced apertures. Both the first and second filter elements have a fan-shaped pleated configuration. The first endcap comprises a plate which is bent to form a first shoulder which engages peripheral edge proportions of the first element and a second shoulder of smaller diameter which engages peripheral edge proportions of the second element. The first endcap connects with the container housing along a circumferential roll seam. A sealing ring is disposed between the first endcap and an upper shoulder of the base. A retaining collar is threaded to the base and axially engages the top of the roll seam to secure the cartridge to the base and to load the sealing ring. Other objects and advantages of the invention will become apparent from the drawings and the specification. Brief Description Of The Drawings Figure 1 is an exploded view of a fuel filter assembly in accordance with the present invention; Figure 2 is a sectional view of the assembled fuel filter assembly of Figure 1; Figure 3 is a top plan view of the base portion of the fuel filter assembly of Figure 2, said base portion being rotated 90° to the orientation of Figure 2; Figure 4 is a cross-sectional view of the base portion taken along the line 4-4 of Figure 3; Figure 5 is a sectional view of the cartridge portion of the fuel filter assembly of Figure 1; Figure 6 is a sectional view of the filter cartridge taken along the line 6-6 of Figure 5; Figure 7 is a sectional view of the filter cartridge taken along the line 7-7 of Figure 5; Figure 8 is an enlarged fragmentary sectional view of the fuel filter assembly of Figure 1; Figure 9 is an enlarged fragmentary sectional view of a second embodiment of a fuel filter assembly in accordance with the present invention; and Figure 10 is an enlarged fragmentary sectional view of a third embodiment of a fuel filter assembly in accordance with the present invention. Detailed Description Of The Invention With reference to the drawings wherein like numerals represent like parts throughout the several figures, a fuel filter assembly in accordance with the present invention is generally designated by the numeral 10. Fuel filter assembly 10 comprises a base 12 and a disposable filter cartridge 14. The fuel filter assembly is especially adapted for incorporation into the fuel supply system of an internal combustion engine (not illustrated) such as a diesel engine for removing particulate matter from the fuel and for separating water from the fuel. In addition, the fuel filter assembly 10 includes a heater for heating the fuel during cold conditions to prevent the precipitation of wax crystals from the fuel. The base 12 rests on a header endcap 20 which has an opening through which an electric fuel heater 22 is inserted. Electric fuel heater 22 includes an integral endcap bolt 24 and an opening 26 which leads to an internal chamber 28. A heating rod 32 projects axially from the fuel heater bolt 24. The fuel heater contains an intermediate threaded surface 34 which threads into a complementary threaded portion of the base 12 for mounting the base to the header endcap 20. Seal rings 36 and 38 are mounted in annular grooves of the header endcap for sealing the base with the endcap. Base 12 is a quasi-cup-like member which includes an interior diametral shoulder 40. The shoulder 40 separates the lower portion of the base into a pair of sumps 42 and 44 for collecting water which is separated from the fuel by the filter assembly. A transverse passage 43 through shoulder 40 connects sumps 42 and 44. A central stepped bore 46 extends axially through the shoulder. The bore 46 has a threaded opening at the lower interior portion for threading with the heater element 22. A sleeve 48 having an intermediate integral locating ring 51 is closely partially received in a reduced segment of the bore 46. The diameter of the sleeve is greater than the diameter of the heating rod 32 of the heater element and extends in coaxial relationship with rod 32 so as to radially enclose the heating rod 32. The upper segment of the bore 46 has an enlarged diameter. A second sleeve 50 is closely received in the enlarged bore portion in concentric relationship with sleeve 48. Sleeve 50 has an intermediate integral locating ring 53 and has a reduced axial length in comparison to that of sleeve 48. The sleeve 50 and its locating ring 53 provide a variable clearance between the base 12 and the cartridge which allows for tolerance buildup. An annular axial passage 49 is formed between sleeves 48 and 50. Sleeves 48 and 50 function as axial fluid conduits. A fuel inlet passage 52 includes a threaded female connector 54. The fuel inlet passage extends radially and axially in the shoulder and opens through an annular recess 56 in the endcap 20. A fuel outlet passage 58 extends radially in general alignment with fuel inlet passage 52. An enlarged annulus surrounding the inner sleeve 48 in axial communication with passage 49 (defined between sleeves 48 and 50) leads to the outlet passage 58. The fuel outlet passage includes a threaded female connection 59 for connecting with an outlet fuel line. A threaded surface at the upper peripheral portion of the base is configured for threaded engagement with a retaining collar 62 for securing the disposable filter cartridge 14 to the base 12. An upper circumferential lip 64 of the base receives an O-ring 65 which is engaged by the underside of the cartridge 14. A drain cock 66 and a water sensor 68 are threaded into the side of the base for interior communication with sump 42. The water level sensor 68 electrically communicates with the compartment of the vehicle for indicating that the water level has reached a pre-established level so that the water can be manually drained from the sumps by rotatably loosening the drain cock 66. With additional reference to Figure 5, the disposable filter cartridge 14 comprises a can-like container 70 which is configured to have an upper peripheral recessed indentation 72. A primary stage filter element 74 having a continuous fan-shaped pleated form is received in the container. The filter element 74 axially extends slightly below the bottom of the side wall of the container. The primary filter element thus defines an interior central axial chamber 76 and quasi-annular outer chamber 78. The primary filter element is affixed with resin binders or other water coalescers so that as the fuel passes from the passage 76 through the filter element 74 to chamber 78, the water coalesces to form water droplets in the coalescing chamber 78. A primary stage endcap 80 encloses the primary filter element. The endcap 80 is rolled and fastened against the bottom edge portions of the container to form a circumferential roll seam 81 having an upper retaining shoulder 83. The endcap 80 is also folded so as to have an inner annular retaining shoulder 82 which engages the lower portion of the filter element 74 for locating the element. The endcap 80 also defines at an inner underside location an annular retaining shoulder 84 which is generally coaxial with shoulder 82 and has a smaller diameter than shoulder 82. A central circular opening 86 through the endcap receives an elastomeric sealing element 88 which is dimensioned to fluidly seal against sleeve 48 upon mounting the filter cartridge to the base. The axially spaced edge portions of the primary filter element 74 are secured to the upper underside of the container and the upper surface of the endcap 80 by adhesive such as "Plastisol" adhesive. An upper annular platform formed by the endcap at the bottom of the coalescing chamber 78 includes a plurality of angularly spaced apertures 90. The coalesced water droplets drop through the apertures 90 from chamber 78 and are collected in the sumps 42 and 44 as will be described hereinafter. A secondary filter element 92 having a continuous fan-shaped, pleated configuration extends from the underside surface of endcap 80. The upper peripheral edges of the filter element 92 retainably abut against shoulder 84 of the endcap 80. A secondary stage endcap 94 encloses the axial end of the filter element 92. Endcap 94 includes a peripheral flange which is upturned so as to retainably engage the peripheral edges of the filter element. A circular opening 96 through the central portion of the endcap receives an elastomeric sealing grommet 98. Sealing grommet 98 is dimensioned and positioned for fluidly sealing against the outer sleeve 50 when the filter cartridge is mounted on the base. Adhesive such as "Plastisol" adhesive is applied to the end portions of filter element 92 for securing the filter element to endcaps 80 and 94. The exterior surfaces of the secondary filter element 92 function as a water barrier which prevents water passage to the central chamber 95 defined between endcaps 80 and 94. Secondary filter element 92 may be comprised of a porous substance which is saturated with silicon so as to form the exterior water barrier. In the unmounted state such as illustrated in Figures 1 and 5, a substantial portion of the exterior surface of filter element 92 is exposed at the underside of the container 70. The top cover of container 70 also includes a circular opening through which a valve body 100 is inserted. The valve body 100 is sealed to the container with adhesive. A releasable air vent valve 102 is positionable in the valve body. The air vent valve functions to controllably release air from the interior of the fuel filter. The air vent valve 102 may be removed from the valve body 100 and reinserted into the valve body of a new cartridge upon replacement of a spent cartridge. In practice, the disposable filter cartridge 14 is mounted to the base 12 by forcing the cartridge over the sleeves 48 and 50 of the base so that the elastomeric grommets 88 and 98 diametrically seal against the respective sleeves 48 and 50. With additional reference to Figure 8, the underside of endcap 80 engages an elastomeric O-ring 65 which is positioned against lip 64 of the base. The retaining collar 62 is then threaded to the base and axially engageable against the roll seam shoulder 83 of the container 70 to compressively load the O-ring 65 and secure the cartridge in a fluid tight relationship with the base. The roll seam 81 has a multi-layer configuration which imposes a rigid structure at the endcap/container interface. The O-ring 65 is located in close proximity to the roll seam 81 at a cartridge location having a high degree of structural integrity. A substantial compressive force may thus be exerted against the O-ring through the endcap 80 without jeopardizing the structural or functional integrity of the cartridge. The only cartridge sealing element which is compressively loaded is O-ring 65. Grommets 88 and 98 essentially function as diametrical seal elements and are not compressively loaded. Consequently, the cartridge is axially "floatable" to a limited degree relative to sleeves 48 and 50 to compensate for any build-up that may be present. The heavy arrows of Figure 8 illustrate the floating type mounting relative to locating ring 53. The lip 64 is preferably inclined (from the inner to outer portions) at a downward angle so that the axial compressive load functions additionally to center the cartridge on the base. The inclined lip configuration also tends to force the O-ring sealing interface radially away from the apertures 90 to insure unobstructed fluid communication therethrough. The fuel filter assembly may be suitably mounted to the vehicle by means of a bracket 104 having cooperative shoulders which receive a clamp ring 106. A bolt (not illustrated) extends between aligned openings of the clamp ring and an opening in the bracket for securing the clamp ring to the bracket. The clamp ring 106 surrounds and clampingly engages a recessed neck 108 of the base for securing the base in position. The flow path of fuel through the filter assembly is illustrated by the arrows in Figure 2. In operation, fuel is supplied to the inlet passage 52 for traversal through annulus 56 and opening 26 to the heat chamber 28. The fuel then flows axially through sleeve 48 in close proximity to heat rod 32 so that the fuel may be heated if required. The fuel continues axially upwardly (in the direction of the arrows in Figure 2) into the primary chamber 76 for outward traversal through the primary filter element 74. The filter element 74 functions to remove particulate matter from the fuel. The particulate matter is entrapped on the upstream side of the primary filter element 74. The fuel passes into the coalescing chamber 78 wherein water coalesces as droplets from the fuel and passes along with the fuel through apertures 90. The water continues downwardly for collection in the sumps 40 and 42. The secondary stage filter is a water barrier which prevents the entry of water into the secondary stage chamber 94. The filtered fuel then passes through secondary stage element 92 to the interior chamber 95 for generally axial traversal through passage 49 between sleeves 48 and 50 (as illustrated by the arrows in Figure 2). The filtered fuel then flows generally radially out the outlet passage 58 for delivery to the fuel injection pump and/or engine. The foregoing fuel filter assembly 10 provides an efficient means for filtering particulate matter from the fuel, for removing water from the fuel and for heating the fuel if required to a sufficient temperature to prevent the precipitation of wax crystals. Furthermore, the filter cartridge 14 is disposable so that when the effectiveness of the filter cartridge is expended, a new cartridge may be mounted in place as required. The retaining collar 62 is threadably loosened, the releasable air vent 102 is removed from the cartridge element, and a new cartridge is suitably secured in position. It should be appreciated that for some applications the installed fuel filter assembly may be inverted, i.e., the cartridge mounted below the base as best illustrated in Figures 9 and 10. With reference to Figure 9, the fuel filter assembly 10a also principally differs from fuel filter assembly 10 in that the primary and secondary filter elements 74a and 92a essentially function as a dual stage fuel filter without additionally employing an effective provision for removing water from the fuel. Components of fuel filter assembly 10a which correspond to those previously described are designated generally by the numerals corresponding to the components of fuel filter assembly 10 followed by the letter "a". The fuel enters the fuel filter assembly 10a through fuel inlet passage 52a and exits the filter through outlet passage 58a. The general flow path of the fuel through the filter assembly is generally designated by the arrows of Figure 9. The fuel flow path is essentially directionally inverted in comparison to the path of Figure 2. Fuel filter assembly 10b illustrated in Figure 10 is an inverted fuel filter (as compared to Figures 1 - 5) which also functions as a water separator. The container 70b of the cartridge portion surrounding the primary filter element 74b is elongated to provide a chamber or sump 120 which is below the primary filter element. A lower endcap 122 is also mounted over the lower axial end of the filter element 74b. The primary filter element 74b has water coalescing properties so that water droplets form at the outlet side of the filter element and fall to the bottom of the sump 120 (as schematically illustrated in Figure 20). A drain cock 124 is mounted at the bottom of the sump for draining the collected water from the filter. The container 70b may be manufactured from a transparent or translucent material to permit visual inspection of the water level. The general fuel flow path through filter assembly 10b is generally designated by the arrows in Figure 10.

Claims: A fuel filter assembly (10) comprising: base means comprising a base (12) having a fuel inlet passage (52), fuel outlet passage (58), central first conduit means (48) for interiorly defining a first axial passage communicable with said inlet passage; disposable filter cartridge means (14) mountable to said base means for removing particulate matter from fuel, said disposable cartridge means comprising: housing means comprising a container; first filter means (74) enclosed in said housing means defining a first chamber (76) communicating with said first axial passage and a second chamber (78) surrounding said first chamber; and second filter means disposed axially from said first filter means (74) comprising a second filter element (92) and defining a central inner region, characterized in that the base (12) is forming a lip (64) and comprises second conduit means (50) surrounding said first conduit means for defining a second axial passage (49) communicating with said central inner region and with said outlet passage (58), that the housing means comprises endcap means enclosing an end portion of a filter means connected to said container along a circumferential seam forming a retaining shoulder (83); and that retainer means are provided comprising a collar (62) threadably engageable with said base means (12) and axially engageable against said seam shoulder (83) for retaining said cartridge means (14) to said lip (64) of said base means (12). The fuel filter assembly of claim 1, characterized in that said first (48) and second (50) axial passages are coaxial. The fuel filter assembly of claim 1, characterized in that it comprises sealing means (65) engaging sealable between said lip (64) and said endcap means for fluidly sealing said cartridge means (14) to said base means (12). The fuel filter assembly of claim 3, characterized in that said sealing means (65) is located in close proximity to said seam and is compressively loaded by threadably tightening said retainer means against said seam. The fuel filter assembly of claim 3, characterized in that said lip (64) is inclined at an oblique angle to the central axis through said first conduit means (48). The fuel filter assembly of claim 1, characterized in that said second filter element (92) is generally impervious to the passage of water therethrough. The fuel filter assembly of claim 3, characterized in that it comprises sump means (42,44) for collecting separated water. The fuel filter assembly of claim 3, characterized in that said container has an outer end opposite said seam and said container further forms a sump (120) axially disposed between said first filter element (74) and said outer end. The fuel filter assembly of claim 1, characterized in that said housing is manufactured from a material which permits visual inspection of water collected in said sump. The fuel filter assembly of claim 3, characterized in that said sealing means (65) comprises an O-ring which is compressively loaded by threadably tightening said collar (62) against said base means (12). The fuel filter assembly of claim 1, characterized in that said retaining shoulder (83) means extends circumferentially around the housing.

Inventors: JANIK LEON P, MAXWELL CRAIG M, JANIK, LEON P., MAXWELL, CRAIG M.
Applicants: STANADYNE AUTOMOTIVE CORP, STANADYNE AUTOMOTIVE CORP.
Application year: 1990
Main classification: B01D36
IPC codes: B01D17, B01D36, B01D35, F02M37, B01D29, B01D27