Abstract:
A fluid filter providing several degrees of filtering is designed to be receivable in a filter container that is closable by a cover. The filter itself includes both an annular main filter element, through which fluid to be filtered can pass radially to undergo primary filtration, and a supplemental filter element, to which fluid discharged from the main filter element passes to provide supplemental filtration additional to the primary filtration. The main filter element, the supplemental filter element, or both may be oblong or circular in cross section. At least one of a pair of end caps disposed on opposed ends of the main filter element carries the supplemental filter element as well as one end of the main filter element. That end cap may or may not be permanently secured to the one filter element end.

Description:
[0001]    This application claims priority to provisional U.S. Patent application 61/242,622, titled FILTER WITH OVAL OR FLAT-SIDES DESIGN, CCM/CLEANLINES MEDIA GRADE, AND BUBBLE BREAKER, filed Sep. 15, 2009, the entire disclosure of which is incorporated herein. 
         [0002]    Cross-reference is also made to the U.S. Patent application based on provisional U.S. Patent application 61/242,615, titled SPACE REDUCING FILTER WITH OVAL OR ROUND INNER DIAMETER, COALESCER, CCM/CLEANLINESS MEDIA GRADE, AND BUBBLE BREAKER, also filed Sep. 15, 2009. 
     
    
     BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    The present invention concerns a filter, for fuel or other fluids, such as oils or other liquids, or even gases, that is preferably oval or flat-sided in cross-sectional configuration. A design according to this invention permits different functions to be included in an oval, flat-sided, or even round filter design, although an oval design is preferable to a flat design, as it more readily avoids collapse and makes it possible to integrate additional parts for cleanliness, water drainage for the clean side, and so on. 
         [0005]    2. Description of Related Art 
         [0006]    A brief discussion of certain filter systems for automotive or other applications utilizing multiple full flow and bypass filter arrangements is set forth in commonly assigned, co-pending U.S. patent application Ser. No. 12/467,423, filed May 18, 2009, titled Full Flow Liquid Filter with Integral Bypass Filtration. That discussion is partially reiterated here. 
         [0007]    Filter systems for automotive or other applications commonly utilize one of two full flow filter and bypass filter configurations. One such configuration is an arrangement having two separate filtering systems, with a full flow system, which may include more than one filter, depending on flow requirements, and a bypass filter system, which processes only a small percentage of the full fluid volume. In such a configuration, an in-line, series approach is often utilized, with a full flow filter provided downstream of a bypass filter. These systems typically introduce additional costs and components for the automotive assembler and service industry to handle and manage. Vehicle weight is increased as well. U.S. Patent application publication 2008/0078716 to Farmer discloses one such in-line, series approach to filtering. 
         [0008]    Evolutions of this configuration include systems having filters with full flow and bypass media stacked upon each other in the same filter housing. Examples of filters having stacked media include apparatuses disclosed by U.S. Patent application publication 2005/0252838 to Fisher and U.S. Pat. Nos. 5,447,627 to Loafman et al., 6,319,402 to Schwandt et al., and 6,350,379 to Roll et al. 
         [0009]    Further developments have provided increased filtering capacity in the same or smaller footprint, while also offering high efficiency bypass filtration to “polish” the fluid system and provide integral soot filtration, by fitting bypass filters concentrically within full flow filters. U.S. Pat. Nos. 6,666,968 to Smith et al., 6,787,033 to Beard et al., 7,014,761 to Merritt et al., and 7,090,773 to Meddock et al. provide examples of such developments. 
       SUMMARY OF THE INVENTION 
       [0010]    A fluid filter according to the invention is designed to be receivable in a filter container that is closable by a cover. The filter itself includes both an annular main filter element through which fluid to be filtered can pass radially to undergo primary filtration and a supplemental filter element to which fluid discharged from the main filter element passes to provide supplemental filtration additional to the primary filtration. The main filter element, the supplemental filter element, or both may be oblong or circular in cross section. At least one of a pair of end caps disposed on opposed ends of the main filter element carries the supplemental filter element as well as one end of the main filter element. That end cap may or may not be permanently secured to the one filter element end. 
         [0011]    The fluid filter may additionally include a coalescer, which may surround the main filter element exterior, can be used to pre-process fluid to be filtered before that fluid undergoes the primary filtration. A frame, which may be securable to and detachable from the filter container cover, can be provided to mount both the supplemental filter element and the coalescer. 
         [0012]    The supplemental filter can be configure to protrude from one of the end caps on which it is carried into a cavity defined at a downstream side of the main filter element. Optionally, the filter may include an arrangement by which bubbles in the fluid to be filtered are broken up and dissolved. Such a bubble breaker arrangement may be mounted in an appropriate location on one of the end caps. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a schematic perspective view of a typical annular, preferably oval or flat (flattened) filter element. 
           [0014]      FIG. 2  is a schematic perspective view of an annular, preferably flattened filter element according to one embodiment of the invention. 
           [0015]      FIG. 3  is a schematic perspective view of an annular filter element according to another embodiment of the invention. 
           [0016]      FIG. 4  is a schematic perspective view of an annular filter element according to yet another embodiment of the invention. 
           [0017]      FIG. 5A  is a schematic sectional view of a filtering system in which a filter element is glued or otherwise affixed to a filter element container cover. 
           [0018]      FIG. 5B  is a schematic sectional view similar to  FIG. 5A  but of a configuration in which the filter element is not affixed to the filter element container cover so that the filter itself is serviceable. 
           [0019]      FIG. 6A  is a view showing one configuration of the union between the top of the filter element and the cover according to  FIG. 5A . 
           [0020]      FIG. 6B  is a view showing the configuration of the cover according to  FIG. 5B . 
           [0021]      FIG. 7  is an exploded view showing the snap union between the top of a combined coalescer and component cleanliness management (CCM), or cleanliness, medium structure, and a housing cover. 
           [0022]      FIG. 8  is a sectional view of a combined coalescer and CCM medium structure showing a sealing lip. 
           [0023]      FIG. 9  is a sectional view similar to that provided by  FIG. 8  but in which the combined coalescer and CCM medium structure is provided with a bubble breaker. 
           [0024]      FIG. 10  is a external perspective view from above another arrangement that operates similarly to that shown in  FIG. 9 . 
           [0025]      FIG. 11  is an external perspective view from below the arrangement shown in  FIG. 10 . 
           [0026]      FIG. 12  is a cut-away sectional view of the arrangement shown in  FIG. 10  as seen along line  12 - 12 . 
           [0027]      FIG. 13  is an enlarged view of part of the arrangement shown in  FIG. 12 . 
           [0028]      FIG. 14  is a perspective view of the inner jacket and media arrangement of  FIG. 12 . 
           [0029]      FIG. 15  is a view illustrating a snap union I-jacket with a bottom end cap. 
           [0030]      FIG. 16  is a perspective view from above the bubble breaker of  FIG. 10 . 
           [0031]      FIG. 17  is an enlarged, part sectional view along line  17 - 17  of  FIG. 16 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]      FIG. 1  is a schematic perspective view of an oval or flat annular filter element without any “component cleanliness management (CCM),” or supplemental cleanliness medium filter element associated therewith. Fuel or other fluid traverses the filter element shown in  FIG. 1  radially, and, as such, is filtered by the annular main filter element  20 , the material  26  of which may be pleated in typical fashion. In its simplest configuration, the material is glued or bonded in some other way to oval, open-centered or ring-like end caps  22  and  24 , which are disposed at axially opposed open ends of the main filter element  20 . An uppermost open end  28  of the element  20  is visible in  FIG. 1 . The annular main filter element  20  provides fine particle filtration to fluid passing radially through the material  26  in a conventional manner. 
         [0033]      FIG. 2  is a schematic perspective view of an oval or flattened filter F according to a first embodiment of the invention having an annular main filter element  30 . As with the conventional element illustrated in  FIG. 1 , fuel or other fluid traverses the filter element  30  radially, passing through the material  36 , which, again, may be pleated. Oval, open-centered or ring-like end caps  32  and  34  are disposed at axially opposed ends of the main filter element  30 . 
         [0034]    The main filter element  30  includes a pair of open axial ends similar to those present in the conventional configuration shown in  FIG. 1 . The uppermost open end  38  of the filter element  30  is visible in  FIG. 2 . Also visible in  FIG. 2  is the flat outer surface of a supplemental or secondary cleanliness medium filter element  39 , which is disposed at least partly within the open end  38  of the main filter element  30 . Such supplemental cleanliness medium filter elements will hereafter be referred to simply as “supplemental filter elements.” The main filter element  30 , which is the same as the element  20  shown in  FIG. 1 , will not completely filter all particles out of the fluid being filtered. The supplemental filter element  39  has a finer pore size than that of the main filter element  30 , or is otherwise configured to provide filtering beyond that provided by the main filter element  30 , and operates to supply additional filtration of fluid that has already passed through the main filter element. By way of example only, and depending on customer requirements, the main filter element  30  may operate at 86% efficiency, while the supplemental filter element  39  operates at 95% efficiency. The arrangement illustrated in  FIG. 2 , and the arrangements shown in  FIGS. 3-9  as well, may be referred to as “sky” designs, since supplemental cleanliness mediums are disposed at “upper” ends of the combined main filter/cleanliness medium filters and main filter/cleanliness medium filter/coalescer arrangements shown. 
         [0035]      FIG. 3  is a schematic perspective view of another oval or flattened filter F having an annular main filter element  40 . Fuel or another fluid travels relative to the filter element  40  along a path indicated by the various arrows. As in the embodiment shown in  FIG. 2 , this fluid traverses the filter element  40  radially, passing in the direction of an arrow  41  through the material  46 , which, again, may be pleated. Oval, open-centered or ring-like end caps  42  and  44  are disposed at axially opposed ends of the main filter element  40 . 
         [0036]    The main filter F, or, more precisely, the main filter element  40 , includes a pair of open axial ends; an uppermost open end  48  of the filter element  40  is indicated in  FIG. 3 . Also visible in  FIG. 3  is the flat outer surface of a supplemental filter element  49 , which is disposed at least partly within the open end  48  of the main filter element  40 . As in the embodiment shown in  FIG. 2 , the supplemental filter element  49  has a finer pore size than that of the main filter element  40 , or is otherwise configured to provide filtering beyond that provided by the main filter element  40 , and operates to provide additional filtration of fluid that has already passed through the main filter element  40 . 
         [0037]    In this configuration, water-contaminated or dirty fuel received from a fuel tank (not shown) passes in the direction of an arrow  45  through a coalescer  43 . This pre-filtered fuel then passes, as schematically indicated by the arrows  47  and  41 , through the main filter material  46 . The coalescer  43  is formed by an oval or oblong ring extending laterally with respect to a longitudinal axis of the main filter element  40 . The coalescer  43  serves in a known manner to pre-filter or pre-process fuel arriving from the fuel tank by increasing water droplet size, facilitating water repellency of hydrophobic media included in the main filter. Typical coalescers are cellulose based or synthetic. 
         [0038]    Water-contaminated or dirty fuel supplied in the direction of the arrow  45  from the fuel tank is processed sequentially as it travels in the directions indicated by the arrows, passing through the coalescer  43 , the main filter element  40 , and then the supplemental filter element  49  of the overall arrangement. As  FIG. 3  shows, clean, fully processed, filtered fuel exits the overall filter F in the direction of an arrow  50 , and can then be supplied to an engine (not shown). 
         [0039]      FIG. 4  is a schematic perspective view of another oval or flattened filter F with an oval or flattened annular main filter element  60 . The flat surface of a supplemental filter element  69  is visible at one end of the filter F, and a coalescer  63 , formed by a jacket extending parallel to a longitudinal axis of the main filter element  60 , is mounted on the circumferential exterior of the main filter element  60 . A cage or frame  65  may be used to retain the coalescer  63  on the circumferential exterior of the main filter element. The coalescer  63  may be either a single solid element, with the cage or frame  65  disposed around it, or composed of multiple individual coalescer elements received within openings defined by the cage or frame  65 . Again, fuel from a fuel tank, which may initially be water-contaminated or dirty, travels in directions indicated by arrows  66 ,  67 , and  61 , sequentially passing through the coalescer  63 , the main filter element  60 , and the supplemental filter element  69  of the overall arrangement. Clean, fully processed, filtered fuel exits the overall filter F in the direction of an arrow  70 , and can then be supplied to the engine. 
         [0040]      FIG. 5A  is a schematic sectional view of part of a filtering system in which a filter according to the invention, such as the filter F shown in  FIG. 2 ,  FIG. 3 , or  FIG. 4 , is glued or otherwise affixed to the underside of a filter element container cover  80 . The cover  80  is securable to and removable from a container body  82 , and thus serves to close off the container body  82 , in which a filtering process such as that described above in connection with  FIGS. 2-4  occurs. Snaps, threads or other such features may be used to interconnect the cover  80  and the container body  82 . Supply lines  90 , by which water-contaminated, dirty fuel or other fluid may be supplied for filtering, are shown in schematic fashion as opening to the interior of the overall container formed by the cover  80  and the container body  82 . Also illustrated schematically in  FIG. 5A  is a discharge line orifice or connection  92 . It will be understood that fuel or another fluid to be filtered enters the container body  82 , for example through one or more supply lines  90 , passes radially through the main filter element  30 ,  40 , or  60 , passes through the supplemental filter element  39 ,  49 , or  69 , and is discharged from the container  82  through the discharge line orifice or connection  92 . 
         [0041]    The filter F may be affixed in any appropriate manner to the cover  80 ; depending on the material used for the cover  80 , the filter F may be secured to the cover  80  by use of a chemical bonding solution, such as LOCTITE, by polyvinyl chloride (PVC) or polyurethane bonding techniques, by infrared or ultrasonic welding, or by way of appropriate extrusion techniques. When the filter F of the system shown in  FIG. 5A  becomes dirty, the cover  80  and filter F are both removed together and replaced. 
         [0042]      FIG. 5B  is a schematic sectional view similar to  FIG. 5A  but of a configuration in which the filter F is not affixed to the filter element container cover  84 . When the filter F of the system shown in  FIG. 5B  becomes dirty, only the filter F needs to be replaced. The filter element container cover  84  is reusable. 
         [0043]    A more detailed view of one configuration of a union between the top of a filter F and a cover  80  in an arrangement such as that shown in  FIG. 5A  is provided by  FIG. 6A . For the purposes of illustration and this discussion only, it will be presumed that the filter F shown in  FIGS. 5A and 6A  has the configuration of the filter F shown in  FIG. 2 , and thus includes a main filter element  30  and a supplemental filter element  39  disposed at least partly within an open end of the main filter element  30 . The supplemental filter element  39  includes an oval, central area surrounded by an upstanding, recurved, oval mounting flange  90  by which the supplemental filter element  39  is securable within the main filter element open end. The cover  80  shown in  FIG. 6A  has a closed center  98  instead of the discharge line orifice or connection  92  of  FIG. 5A ; the closed center  98  may be removed or punctured or otherwise penetrated to form an orifice for connection to the discharge line. An external thread or flange  96  may be disposed on the circumferential exterior of the cover  80  to cooperate with an internal thread or recess at the open end of the container body  82  in order to retain the cover in place. Other connections between the cover  80  and the open end of the container body  82  are useable. 
         [0044]      FIG. 6B  provides an illustration of a cover  84  in an arrangement in which a main filter element and a frame to which the filter element is secured are detachable. Again, an external thread or flange  96  may be disposed on the circumferential exterior of the cover  84  to cooperate with an internal thread or recess at the open end of the container body in order to retain the cover  84  in place. Again, other connections between the cover  84  and the container body are useable. The arrangement shown in  FIG. 6   b  is also shown in the exploded view provided by  FIG. 7 , which schematically illustrates a plurality of individual supplemental filter elements  109  and a plurality of individual coalescer elements  103  mounted within a frame  110 . The frame  110  shown has a circumferential lip  112 , which is receivable within a groove or recess  116  defined on the inner circumference of a container cover  114  that is similar to the cover  84  shown in  FIG. 6   b . By snapping the lip  112  into the recess  116 , the frame  110 , including elements mounted therein that combine to provide functions of both a supplemental filter and a coalescer, is securable to and interlocks with the cover  114 . The frame  110 , with elements  103  and  109  secured therein, can then be placed over the exterior of the main filter element (not shown in  FIG. 7 ). 
         [0045]    A frame  120 , which is essentially the same as the frame  110  of  FIG. 7 , is schematically shown in  FIG. 8  as attached, by an annular layer  122  of glue, for example, to an end of a conventional main filter element, such as the conventional main filter element  20  shown in  FIG. 1  and described above. By attaching the frame  120 , including individual supplemental filter elements  129  and individual coalescer elements  123 , to the filter element  20 , it is possible to produce an overall filter element having combined main filtering, auxiliary filtering, and coalescing properties.  FIG. 8  also illustrates an annular lip extending around a bottom end of the combined coalescer and cleanliness medium structure to provide a seal between the overall jacket  127  and the housing. More specifically, the frame  120  illustrated in  FIG. 8  has a circumferential lip  128  of plastic surrounding its open end opposite the end receiving the supplemental filter elements  129 . The lip  128  is provided to produce a seal between the external housing (not shown in  FIG. 8 ), within which the jacket  127  formed by the combination of the frame  120  and the elements  123  and  129  is received, and that frame  120 . The lip  128  thus facilitates fluid flow along an appropriate path. 
         [0046]    The jacket  137  illustrated in  FIG. 9  is essentially the same as the jacket  127  shown in  FIG. 8 , except that it has a schematically shown bubble breaker  140  formed or mounted on its end. The bubble breaker  140  is optional, includes an open medium, and may be integrated with the filter to dissolve or reduce sizes of air pockets or bubbles in fluid passing through the filter. Once the bubble breaker  140  has eliminated unwanted air from the fuel or other fluid, “de-bubbled” fuel or fluid is discharged back into the fluid flow. 
         [0047]    The arrangement illustrated in  FIGS. 10-17  is similar to that shown in  FIG. 9 , but differs in terms of placement of the supplemental filter element added to provide the additional filtering discussed above.  FIG. 10  is a external perspective view from above a filter F, and shows a jacket  147 , including an outer frame  150  supporting a coalescer element  152 . A plurality of individual coalescer elements could alternatively be used. The frame  150  shown has a circumferential lip  154  at its lower end. This lip  154  functions in the same way as the lip  128  illustrated in  FIG. 8  to facilitate fluid flow along an appropriate path by cooperation with an external housing (not shown). It will be understood that the extension angle of the lip  154  can be modified to adjust the degree of sealing with the interior of the external housing; as this extension angle is decreased, pressure of the lip against the housing interior decreases, and sealing decreases accordingly. 
         [0048]    Also evident in  FIG. 10  are an upper end cap  156  and a bubble breaker  158  surrounding a discharge line orifice or connection  160 , which is essentially the same as the discharge line orifice or connection  92  represented in  FIG. 5A . The corresponding view from below the filter F provided by  FIG. 11  shows the lowermost part of a main filter element  170 , the central opening of which is closed of by a lower end cap  172 . The lip  154 , forming the terminus of the jacket  147 , is displaced a distance  174  above the bottom of the main filter element  170 . As with other main filter elements described above, the main filter element  170  may be formed of material that is pleated in typical fashion. 
         [0049]    The jacket  147 , the frame  150 , the coalescer element  152 , the circumferential lip  154 , the upper end cap  156 , the bubble breaker  158 , the discharge line orifice or connection  160 , the main filter element  170 , and the lower end cap  172  are all evident in the cut-away sectional view provided by  FIG. 12 . Also evident in  FIG. 12  is an inner frame  176  used to support a supplemental filter element  178 . As with the arrangements described previously, this supplemental filter element  178  serves to provide filtering beyond that provided by the main filter element  170  by way of additional filtration of fluid that has already passed through the main filter element  170 . In the arrangement of  FIG. 12 , however, the additional or supplemental filter element  178  is retained against or adjacent to the radial interior of the main filter element  170  by the inner frame  176 . This is also apparent from the somewhat enlarged view provided by  FIG. 13 . 
         [0050]    The perspective view provided by  FIG. 14  shows the supplemental filter element  178  and the inner frame  176  as separated from the remainder of the arrangement illustrated in  FIG. 10 . It will be understood that the inner frame  176  is united with the lower end cap  172  in an appropriate way such as by snap connections. One such snap connection is shown in  FIG. 15 .  FIG. 15  also shows a portion of the circumferential lip  154  at the lower end of the frame  150 . It will be understood from considering  FIGS. 12 and 16  together that the supplemental filter element  178  protrudes from the lower end cap on which it is carried into the central cavity defined by the annular main filter element  170  at its downstream side. 
         [0051]      FIG. 16  provides a perspective view from above the bubble breaker  158 , while  FIG. 17  is an enlarged, part sectional view of the structure shown in  FIG. 16 . One conceivable way to secure the bubble breaker  158  in place is to first appropriately position the bubble breaker  158  on the upper end cap  156 , for example by way of a protrusion  180  on the cap  156  that cooperates with a slot  182  in the bubble breaker  158  as shown in  FIG. 16 . The bubble breaker  158  can then be pressed into connection with the upper end cap and retained in place over the discharge line connection  160  by cooperating snap elements  184  (visible in  FIG. 17 ) on the bubble breaker and the end cap. 
         [0052]    Air pockets or bubbles entrained in fluid supplied to the interior of a container body, such as the container body  82  shown in  FIG. 5A , tend to rise within the container body interior. Fluid pressure causes the bubbles to proceed into bubble inlets  186 . As the fluid in which the bubbles are entrained passes into the bubble inlets  186 , through filter media  188 , through passages  189 , and back upstream of the main filter element  170 , the bubbles are broken up so that they will not adversely affect an engine or other item to which the fluid passing through the filter is supplied. An o-ring seal  190  facilitating fluid tight connection between the discharge line orifice or connection  160  and a discharge line (not shown) is retained in position by an appropriate groove  192  formed in the upper end cap  156 . An appropriate flange  194  on the bubble breaker  158  can also extend over the seal  190  to assist in proper retention of the seal. 
         [0053]    The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.