Abstract:
One embodiment is a filter assembly wherein the shape of the filter is a non-circular geometry. Other embodiments include unique apparatus, devices, systems, and methods to remove contaminates from a flow of fuel while at the same time providing a unique filter and filter assembly geometry. Further embodiments, forms, objects, features, advantages, aspects, and benefits of the present application shall become apparent from the detailed description and figures included herewith.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to filter elements and more particularly, to noncircular replaceable filter elements and systems including the same. 
       BACKGROUND 
       [0002]    Fuel filters are found in almost all modern internal combustion engines in one form or another. A fuel filter is a filter that is placed at some point in the fuel line and is designed to remove unwanted contaminates or particulates from the supply of fuel. If these contaminates are not removed before the fuel enters the engine, they can cause rapid wear and failure of such items as fuel pumps, injectors, and cylinders due to the abrasive action of the particles on high-precision components. Fuel filters also can improve performance of the engine, as the less contaminants in the fuel, the more efficiently it can be burned. In many potential engine system designs space constraints would not allow for a conventional circular filter element. 
       SUMMARY 
       [0003]    One embodiment is a filter assembly wherein the shape of the filter is a non-circular geometry. Other embodiments include unique apparatus, devices, systems, and methods to remove contaminates from a flow of fuel while at the same time providing a unique filter and filter assembly geometry. Further embodiments, forms, objects, features, advantages, aspects, and benefits of the present application shall become apparent from the detailed description and figures included herewith. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0004]      FIG. 1  is a perspective view of an exemplary fuel filter assembly. 
           [0005]      FIG. 2  is a front view of  FIG. 1 . 
           [0006]      FIG. 3  is a side view of  FIG. 1 . 
           [0007]      FIG. 4  is a perspective view of an exemplary fuel filter cartridge. 
           [0008]      FIG. 5  is an alternate perspective view of  FIG. 4 . 
           [0009]      FIG. 6  is a cross-sectional view of  FIG. 4 . 
           [0010]      FIG. 7  is a cross-sectional view of an exemplary filter media. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
         [0012]    With reference to  FIGS. 1-3 , there is illustrated a fuel filter assembly  100  including a housing  102  and a lid  104  removably connected with an upper portion of the housing  100 . Housing  102  includes an upper segment or portion  106 , a central segment or portion  108 , and a lower mounting surface segment or portion  110 . In one embodiment, upper portion  108  of housing  102  has a generally circular cross-section shape and central portion  108  has a generally non-circular cross-section shape. The lower mounting surface portion  110  of housing  102  has ends that include partially circular shaped recessed portions  112  which provide space for fluid connections to be connected with filter assembly  100 . 
         [0013]    The upper portion  106  of housing  102  includes a shelf portion  114  that is defined at a point where the upper portion  106  of housing  102  transitions into central portion  108  of housing  102 . As illustrated, shelf portion  114  of housing  102  extends outwardly from the non-circular central portion  108  of housing  102  a predetermined distance. The shelf portion  114  includes a fuel inlet port  116  and a fuel outlet port  118 . In the illustrated example, fuel inlet port  116  and fuel outlet port  118  are located at opposite sides of shelf portion  114  of housing  102 . 
         [0014]    Fuel inlet port  116  and fuel outlet port  118  are positioned substantially parallel in relation to a vertical axis of housing  102 . The non-circular cross-sectional shape of central portion  108  of housing  102  provides extra space under upper portion  106  of housing  102 . This extra space is used for fluid connection ports  116 ,  118 . A fuel supply line  120  is connected with fuel inlet port  116  in a vertical direction or orientation in relation to the vertical axis of the housing  102 . Fuel supply line  120  is used to supply fuel or fluid to filter assembly  100 . Fuel enters filter assembly  100  through fuel supply line  120  where it is filtered by filter assembly  100 , and the filtered fuel then exits filter assembly  100  through fuel outlet port  118 . 
         [0015]    In one embodiment, a fuel regulator valve  122  is connected with fuel outlet port  118 . Fuel regulator valve  122  is designed to open at a predetermined pressure level, for example 60 PSI, so that fuel will only exit filter assembly  100  through fuel outlet port  118  once a predetermined amount of pressure exists in filter assembly  100 . Fuel regulator valve  122  is connected with a fuel or fluid return line  124 . Although not illustrated, return line  124  may be in fluid communication with a fuel tank or reservoir or an engine. As with fuel supply line  120 , fuel regulator valve  122  and fuel return line  124  are connected with fuel outlet port  118  in a vertical direction or orientation in relation to the vertical axis of housing  102 . 
         [0016]    The exemplary non-circular cross-section shape of the central portion  108  of housing  102  provides extra space under upper portion  106  of housing  102  thereby allowing fluid connections to be connected to filter assembly  100  in a vertical direction. This provides vertical access to fluid lines which allows filter assembly  100  to be positioned in locations having tight tolerances or minimal space. As illustrated, fuel or fluid connections  120 ,  124  run vertically down filter assembly  100  through partially circular shaped recessed portions  112  of ends of lower mounting surface portion  110  of housing  102 . 
         [0017]    The non-circular cross-sectional configuration of central portion  108  of housing  102  is further illustrated in  FIGS. 2 and 3 . A front view of filter assembly  100  is depicted in  FIG. 2  and a side view of filter assembly  100  is depicted in  FIG. 3 . Upper portion  106  of housing  102  is configured having a generally circular cross-sectional configuration or shape. Central portion  108  of housing  102  is configured having a generally non-circular cross-sectional configuration or shape. In the illustrated example, central portion  108  has a generally oval or elliptical cross-sectional configuration or shape. 
         [0018]    Referring collectively to  FIGS. 4 and 5 , filter assembly  100  includes a replaceable filter cartridge  200  that is positioned within an interior portion of housing  102 . Filter cartridge  200  includes a top endplate  202 , a filter media  204 , and a lower endplate  206 . Top endplate  202  has a generally circular configuration or shape and has a lower surface  208  that is connected with an upper end  210  of filter media  204 . The diameter of circular shaped top end plate  202  is larger than the overall cross-sectional size of filter media  204  such that peripheral edge  212  of top end plate  202  extends beyond the outer edges or periphery of filter media  204 . 
         [0019]    Filter media  204  has a generally oval or elliptical cross-sectional configuration or shape that generally matches the configuration or shape of central portion  108  of housing  102 . In one form, filter media  204  comprises a meltblown media, an air-laid media, a wet-laid media or a synthetic blend of one or more of the media types. Lower end plate  206  has a generally oval or elliptical cross-sectional configuration. Lower end  214  of filter media  204  is connected with an upper surface of lower end plate  206 . Lower end plate  206  also includes aperture  216  located at approximately the center of lower end plate  206 . Seal  218  is positioned around aperture  216 . As set forth in greater detail below, filter cartridge  200  can be removably positioned in a fluid chamber defined by the interior of housing  102 . 
         [0020]    Referring to  FIG. 6 , a cross-sectional view of filter assembly  100  is illustrated. Upper portion  106  of housing  102  defines first fluid chamber  300  and central portion  108  of housing  102  defines second fluid chamber  302 . First fluid chamber  300  is generally cylindrical or circular in shape and transitions into second fluid chamber  302 , which has a generally non-circular shape or configuration. First and second fluid chambers  300 ,  302  house filter cartridge  200 . Filter media  204  of filter cartridge  200  is spaced apart from internal wall  303  of upper portion  106  and central portion  108  of housing  102  a desired distance. 
         [0021]    Lower mounting surface portion  110  of housing  102  and lower end plate  206  of filter cartridge  200  define a third fluid chamber  304 , which is illustrated as having a generally non-circular shape. In the illustrated example, a smooth transition is illustrated between third fluid chamber  304  and second fluid chamber  302 . As such, third fluid chamber  304  generally has the same shape as second fluid chamber  302 . However, in alternative forms, third fluid chamber  304  may take many different forms or shapes such as, for example, oval, elliptical, circular, square, rectangular and so forth. In some fluid applications, such as diesel fuel for example, third fluid chamber  304  provides a location in which water that is removed from the fuel may be collected. A small space or gap  305  is located between the outer edge of lower end plate  206  and internal wall  303  of central portion  108  of housing  102  that allows water to travel to third fluid chamber  304 . Although not illustrated, a lower end of lower mounting surface portion  110  may include a valve that allows a user to drain water that has been removed from the fuel from third fluid chamber  304 . 
         [0022]    A lower surface  306  of the lower mounting surface portion  110  of housing  102  includes a connection member  308 . As illustrated, the connection member  308  protrudes upwardly a predetermined distance from lower surface  306  of lower mounting surface portion  110 . Connection member  308  is circular in shape in the illustrated example, but may be formed having other shapes in alternative forms. Lower mounting surface portion  110  includes at least one aperture  310  running through the outer edges of a mounting segment or portion  312  of lower mounting surface portion  110 . Aperture  310  allows filter assembly  100  to be connected with a vehicle by a bolt or another equivalent connection device. 
         [0023]    Filter assembly  100  also includes a center post  314  that protrudes upwardly along a vertical axis from connection member  308 . In the illustrated form, center post  314  protrudes up through second fluid chamber  302  defined by central portion  108  of housing  102  and into first fluid chamber  300  defined by upper portion  106  of housing  102 . Center post  314  includes hollow interior  316  and at least one aperture  318  located on upper portion  320  of center post  314 . Aperture  318  allows fluid that has been filtered by filter media  204  to pass into hollow interior  316  of center post  314 . Lower portion  322  of center post  314  includes an externally threaded segment  324  that is used to secure center post  314  to an internally threaded segment  326  of connection member  308 . Lower portion  322  of center post  314  could be secured to connection member  308  using various other connection methods. 
         [0024]    Filter cartridge  200  is fixedly secured in housing  102  by placing aperture  216  of filter cartridge  200  on upper portion  320  of center post  314  and forcing filter cartridge  200  downwardly until seal  218  of lower end plate  206  makes contact with upper portion  328  of connection member  308 . Seal  218  provides a fluid tight seal between lower end plate  206  and center post  314 . As illustrated, lower end plate  206  includes an upwardly extending circular shaped rib  330  that defines aperture  216  of lower end plate  206 . Seal  218  is connected with lower surface  332  of lower end plate  206 , outer surface  334  of the rib  330 , and upper surface  336  of rib  330 . As previously set forth, lower surface  336  of lower end plate  206  and lower surface  306  of lower mounting surface portion  110  define third fluid chamber  304 . In alternative forms, center post  314  may include a connection member that provides a fluid tight seal with lower end plate  206 . 
         [0025]    As further illustrated in  FIG. 6 , the filter cartridge  200  includes a centertube  340 . Centertube  340  runs substantially parallel with filter media  204  and housing  102  along a vertical axis of filter assembly  100 . Centertube  340  includes a plurality of apertures  342  that allow fuel to pass into an internal fluid chamber  344  of filter cartridge  200 . Filtered fluid from internal fluid chamber  344  may then enter hollow interior  316  of center post  314  through apertures  318  in center post  314 . An upper surface of lower end plate  206  is connected with a lower end of centertube  340  and a lower surface of upper end plate  202  is connected with an upper end of centertube  340 . Filter media  204  is wrapped, positioned, or otherwise connected around or with the outside surface of centertube  340 . 
         [0026]    Lid  104  is removably connected with upper portion  106  of housing  102 . Once filter cartridge  200  is placed over center post  314 , lid  104  may then be connected with upper portion  106  of housing  102 . In one form, lid  104  includes an externally threaded segment  346  that screws into an internally threaded segment  348  of upper portion  106  of housing  102 . The externally threaded segment  246  of lid  104  is located on lower portion  350  of lid  104 . The outside diameter of lower portion  350  of lid  104  is somewhat smaller than the inside diameter of upper portion  106  of housing  102 . 
         [0027]    A central portion  352  of lid  104  includes a retaining clip  354  and an upper internal surface  356 . Retaining clip  354  protrudes downwardly a predetermined distance from upper internal surface  356 . As lid  104  is screwed into upper portion  106  of housing  102 , upper end plate  202  of filter cartridge  200  snaps or passes through retaining clip  354 . As lid  104  continues to be screwed into upper portion  106  of housing  102 , upper end plate  202  of filter cartridge  200  eventually makes contact with upper internal surface  356  of lid  104 . Center post  314  and lid  104  thereby cooperate with one another to securely hold filter cartridge  200  within first and second fluid chambers  300 ,  302  defined by housing  102 . In alternative forms, lid  104  may be secured to upper portion  106  of housing  102  using a quarter turn lid (bayonet), a friction fit, or the illustrated threading arrangement could be reversed. 
         [0028]    A seal  358  is positioned within a groove or notch  360  of lid  104  and is used to form a fluid tight seal between an outside edge  362  of lid  104  and an inside edge  364  of upper portion  106  of housing  102 . Referring back to  FIGS. 1-3 , lid  104  includes a dome shaped cap portion  150  that includes a plurality of gripping members  152  protruding upwardly from the dome shaped cap portion  150 . At the top of dome shaped cap portion  150  is a tool attachment member  154 . Gripping members  152  allow an installer to use their hands to begin to tighten lid  104  onto housing  102  and after reaching a certain tightening point, a tool may be placed on tool attachment member  154  to further tighten lid  104  on to an upper edge  156  of upper portion  106  of housing  102 . 
         [0029]    Referring to  FIG. 7 , a top cross-sectional view of a portion of filter media  204  of filter cartridge  200  is illustrated. As depicted, filter media  204  has a predetermined width  204   a  and a predetermined height  204   b . In addition, filter media  204  has a non-circular shape, which is illustrated as being oval or elliptical shaped in this form. In one form, the oval size is such that the ratio of predetermined height  204   b  in relation to predetermined width  204   a  is 0.9 or less. Central portion  108  of housing  102  and center tube  340  have a similar size configuration as well as shape. 
         [0030]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.