Abstract:
A replaceable filter for a liquid filter cartridge system having a valve body and a valve actuator relatively rotatable to control fluid flow through the valve by aligning and unaligning respective fluid inlet passages and fluid outlet passages of the valve body and the valve actuator.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 11/427,795, filed Jun. 30, 2006, which is incorporated herein in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to filters for water and other liquids. 
         [0003]    Filters are widely used to separate impurities and solids from liquids in a variety of applications. For example, filters are used in water lines to provide water in which dissolved minerals and other particles may be removed. Filters are also used in lubrication and fuel lines to remove metals and other solids from the lubricant or fuel. 
         [0004]    Because the filters have a relatively short lifetime, compared to the equipment they are used in association with, such as water dispensers, etc., the filters are arranged to be removed and replaced from time to time. The removal and replacement feature requires that there be an interface between the filter and the remainder of the liquid system which typically requires a seal at the interface, in that generally the liquid moving through the filter is at a pressure elevated above ambient pressure. 
         [0005]    In some systems, removal of the filter creates an opening in the liquid line, requiring replacement of the filter before the system can be used. For example, Great Britain U.S. Pat. No. 1,296,051 discloses a removable filter, that once removed, leaves a disconnected path at a head portion between an inlet and an outlet in the liquid line that requires replacement of the filter before the system can be used. The filter is sealed to the head portion via a sealing ring and a hollow plug which provide sealing interfaces at different planes, and are engaged in a sliding manner between mating surfaces when the filter is attached to the head portion via a bayonet mount arrangement. U.S. Pat. No. 4,764,275 discloses a removable filter, that once removed, leaves a disconnected path at a filter mount between an inlet and an outlet in the liquid line that requires replacement of the filter before the system can be used. The filter is sealed to the filter mount via an O-ring radial seal that slidingly engages a side wall of the filter mount and a gasket that slidingly engages a face of the filter mount, located in a plane different than the side wall of the filter mount. 
         [0006]    In other systems, a valve is provided to close off the liquid line when the filter is removed, also requiring replacement of the filter before the system can be used. For example, U.S. Pat. No. 5,826,854 discloses a removable filter that engages with a rotatable block to rotate the block relative to a valve housing, to align and misalign the inlet and outlet passages. The filter is sealed to the actuator via 2 radial seal O-rings lying in different planes that slidingly seal against an inside side wall of the block as the filter in inserted into the block. 
         [0007]    In still other systems, some type of valve or bypass arrangement is provided so that the system can remain in use, even with the filter removed. For example, U.S. Pat. No. 5,390,701 discloses a removable filter that engages with a rotatable housing member to rotate the housing member relative to a valve body, to align and misalign the inlet and outlet passages, and to align radial bypass passages formed in the housing member to allow the system to remain in use with the filter removed. The filter is sealed to the valve body via an axial seal member that slides against a face of the valve body as the filter is threaded onto the housing member. U.S. Patent Application Publication US2006/0070942 A1 discloses a water purifying apparatus with a removable filter that engages with a rotatable inner case to rotate the inner case relative to an outer case, to align and misalign the inlet and outlet passages, and to align a transverse bypass passage formed on an outer face of the inner case to allow the system to remain in use with the filter removed. The filter is sealed to the inner case via two radial seal O-rings that slide into place relative to the inner case, in different planes, as the filter is engaged with the inner case. 
         [0008]    Sliding sealing surfaces allow for the seals to twist or move or to allow the surfaces or impurities to cause wear of the seal, potentially compromising the integrity of the seal. 
       BRIEF DESCRIPTION 
       [0009]    A replaceable filter for a liquid filter cartridge system has a valve body having a fluid inlet passage and a fluid outlet passage and a valve actuator having a fluid inlet passage and a fluid outlet passage, with the valve body and valve actuator being relatively rotatable to control fluid flow through the valve by aligning and unaligning the respective fluid inlet passages and fluid outlet passages. The replaceable filter comprises a cartridge defining an interior, a filter body located within the interior, a first end provided on the cartridge having an end face, a rotational coupler and a face seal provided on the end face and arranged to abut the valve actuator when the filter is coupled with the valve actuator. The first end has a fluid inlet passage extending through the end face into the interior and a fluid outlet passage extending through the end face into the interior. The rotational coupler is provided on the first end, rotationally coupling the filter with the valve actuator for co-rotation. When the filter is coupled with the valve actuator for co-rotation, the face seal abuts the valve actuator to form a seal between the first end and the valve actuator that fluidly seals the fluid inlet passage and the fluid outlet passage of the first end. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a schematic perspective view of a refrigeration appliance in which the water filter cartridge system embodying the principles of the present invention may be used. 
           [0011]      FIG. 2  is a perspective view of the water filter cartridge system embodying the principles of the present invention shown in isolation. 
           [0012]      FIG. 3  is an exploded perspective view of components of the water filter cartridge system of  FIG. 2 . 
           [0013]      FIG. 4  is a side sectional view of a valve body component used in the water filter cartridge system. 
           [0014]      FIG. 5  is a side sectional view of a valve actuator component used in the water filter cartridge system. 
           [0015]      FIG. 6  is a partial side sectional view of a filter component used in the water filter cartridge system. 
           [0016]      FIG. 7  is a partial side sectional view of a housing component used in the water filter cartridge system. 
           [0017]      FIG. 8  is a side sectional view of an end of the assembled water filter cartridge and housing with the valve shown in the filtering position. 
           [0018]      FIG. 9  is a side sectional view of an end of the assembled water filter cartridge and housing with the valve shown in the bypass/removal position. 
           [0019]      FIG. 10  is an enlarged exploded view of the valve components of the system. 
           [0020]      FIG. 11  is an exploded view of the components of the water filter. 
           [0021]      FIG. 12  is an outside perspective view of the valve body. 
           [0022]      FIG. 13  is an inside perspective view of the valve body. 
           [0023]      FIG. 14  is an outside perspective view of the valve actuator. 
           [0024]      FIG. 15  is an inside perspective view of the valve actuator. 
           [0025]      FIG. 16  is an inside perspective view of the cartridge handle. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0026]    As schematically illustrated in  FIG. 1 , the present invention provides a water filter cartridge system  30 , shown in isolation in  FIG. 2 , which may find particular utility in a water dispensing system  32 , such as found in a refrigeration appliance  34 . The present invention also has utility in other appliances and environments and for filtering liquids other than water. For purposes of disclosing an embodiment of the invention, it will be disclosed in the environment of a water dispensing system  32  in a domestic refrigerator  34  where the water is dispensed at a door  36  of the refrigerator. The water is supplied via a water line  38  plumbed into a building supply, and passes through a cabinet  40  of the refrigerator  34 , and into the refrigerator door  36  at a hinge  42  for the door. The water line  38  in the door  36  is connected to the water filter cartridge system  30 , and then a connecting water line  44  leads up to a water dispenser  46  accessible from an outside of the door. The water filter cartridge system  30  may be accessible for removal and replacement, such as at a stationary ventilation grill  48  positioned below the door  36 . 
         [0027]    As illustrated in more detail in  FIGS. 2-16 , the water filter cartridge system  30  includes a housing  56  which may be permanently attached to the refrigerator  34 , such as via a mounting bracket  57 . The housing  56  may be in the form of a cylinder with a first open end  58 , a second end  60  having a pair of internal flanges  62  ( FIG. 7 ) extending partially around an inner diameter  64  of the housing and a pair of radially outwardly extending ears  66  carrying an inwardly facing pair of tabs  68 . The tabs  68  extend circumferentially a portion of the way around the interior of the housing  56 , for example about 60 degrees each ( FIG. 2 ). The ears  66  extend axially further away from the first end  58  than the position of the internal flanges  62 , such that the inwardly facing pair of tabs  68  are spaced axially from the internal flanges  62 , thereby forming two segments of a circumferential groove  70  between the internal flanges  62  and the inwardly facing pair of tabs  68  along the arcuate length of the tabs. 
         [0028]    The water filter cartridge system  30  also includes a valve body  72  ( FIGS. 4 ,  12  and  13 ) which has an inlet passage  74  and an outlet passage  76  extending therethrough in an axial direction, parallel to one another and laterally spaced from one another. The inlet and outlet passages  74 ,  76  may be formed to receive a connection fitting (not shown), perhaps in the form of a push fit fitting, such as a John Guest™ fitting. For example, an interior wall  78  of the inlet  74  and outlet  76  passages may be formed as a series of steps  80  with seats  82  for receiving the connection fittings. The inlet and outlet passages  74 ,  76  terminate at an inner face  84  ( FIGS. 4 ,  13 ) of the valve body  72 , and at the inner face, the inlet and outlet passages may be provided with a spider  86  to reduce the open area of the inlet and outlet passages at the inner face. 
         [0029]    The valve body  72  may have an outer flange  88  with steps  90  extending radially and circumferentially, the steps comprising a series of alternating radially extending  92  and axially extending  94  walls. The flange  88  may have a pair of opposed radially extending flanges  96  projecting radially from an endmost axially extending wall  98 , each tab extending circumferentially through an arc of about 60 degrees. As best seen in  FIGS. 12 and 13 , adjacent a circumferential end  100  of each of the flanges  96  is a small detent  102  projecting radially from the endmost axially extending wall  98 , and lying in a plane parallel to a plane in which the flanges lie, but spaced away from a free end  104  of the endmost axially extending wall. Projecting radially inwardly from the endmost axially extending wall  98 , and lying against an adjacent one of the radially extending walls  92  may be a small tab  106  ( FIG. 13 ). The inner face  84  may have a groove  108  ( FIG. 4 ) formed therein which surrounds the inlet and outlet passages  74 ,  76 . 
         [0030]    The water filter cartridge system  30  includes a filter  110  ( FIGS. 6 ,  11 ) having a porous filter body  112  that may have a cylindrical shape, a first  114  and second  116  impermeable end cap at each end of the filter body, a surrounding impermeable cartridge  118  and an end cover  120 . The cartridge has an outer diameter  122  sized to fit within the housing  56 . The end caps  114 ,  116  may be permanently attached to a respective end face  124 ,  126  of the filter body  112 , such as by an adhesive material, and each include a lip portion  128 ,  130  which overlies a portion of a side wall  132  of the filter body, to position the end caps correctly on the end faces. The end caps  114 ,  116  assure that water or other liquid entering the filter cartridge  118  will be forced to flow through the side wall  132 , and not short circuit through the end faces  124 ,  126 . An open passage  134  is provided at a central portion of the filter body  112  for filtered liquid. The first end cap  114  has a passage  136  formed therein to allow filtered liquid to flow therethrough. The end cover  120  may be secured to the cartridge  118  in a permanent and non-removable fashion, such as by adhesive, spin welding, fasteners or other well known attachment arrangements. 
         [0031]    The filter cartridge  118  has a first end  138  that has a stepped outer surface  140  forming a shoulder  142  with a pair of opposed tabs  144  extending radially therefrom, spaced from the shoulder. The filter cartridge  118  can be inserted into the open end  58  of the housing  56  and the shoulder  142  is sized to abut against and loosely engage the internal flanges  62  of the housing  56  to prevent the cartridge  118  from passing completely through the housing ( FIG. 8 ). The exploded illustration of  FIG. 3  schematically shows the filter cartridge  118  extending out of the end of the housing  56 , however, the actual geometry of the parts does not allow this to occur. The tabs  144  are sized to pass between adjacent internal flanges  62  of the housing, and then when the filter cartridge  118  is rotated a quarter turn, the tabs  144  will overlie the internal flanges  62  to secure the filter cartridge axially relative to the housing  56  as described later. Leading edges  146  ( FIG. 10 ) of the tabs  144  may be sloped so that the filter cartridge  118  is moved axially further into the housing  56  as the cartridge is rotated, as explained in greater detail below. 
         [0032]    The first end  138  of the filter cartridge  118  has a central outlet passage  148  which includes a cylindrical wall  150  sized to receive a tubular projection  152  of the first end cap  114  which has the passage  136  formed therein. The tubular projection  152  is sealingly joined to the cylindrical wall  150 , such as by an O-ring seal  153 , or other sealing arrangements. 
         [0033]    The first end  138  of the filter cartridge  118  also has a plurality of inlet passages  154  formed therein arranged in a ring surrounding and spaced radially outward of the central outlet passage  148 . The inlet passages  154  lead to a chamber  156  forming the interior of the filter cartridge  118  occupied by the filter body  112 . An end face  158  of the first end  138  of the filter cartridge  118  is provided with a first circular seal gland  160  surrounding the central outlet passage  148 , and positioned radially inward of the ring of inlet passages  154 . An O-ring seal  162  may be positioned in this gland. A second circular seal gland  164  surrounds the ring of inlet passages  154 . An O-ring seal  166  may be positioned in this gland. The end face  158  may be planar such that the first  160  and second  164  seal glands, and the O-ring seals  162 ,  166  lie in the same plane. 
         [0034]    The water filter cartridge system further includes a valve actuator  168  ( FIGS. 5 ,  14 ,  15 ) which is positioned between the first end  138  of the filter cartridge  118  and the valve body  72  when the entire system is assembled. The valve actuator  168  has a first face  170  facing towards the valve body  72  which includes an inlet passage  174  which may be aligned with the inlet passage  74  in the valve body ( FIG. 8 ). A circular seal gland  176  surrounds the actuator inlet passage  174  in the first face  170 . An O-ring seal  178  may be positioned in this gland  176 . The first face  170  of the actuator  168  includes an outlet passage  180  which exits the first face in a position that may be aligned with the outlet passage  76  in the valve body  72 . A circular seal gland  182  surrounds the actuator outlet passage  180  in the first face  170 . An O-ring seal  184  may be positioned in this gland  182 . 
         [0035]    The valve actuator  168  has a second face  186  facing away from the valve body  72  and towards the end face  158  of the filter cartridge. The inlet passage  174  exits at the second face  186  and intersects a circular channel  188  which extends around the second face and aligns with the plurality of inlet passages  154  in the first end  138  of the filter cartridge  118 . The outlet passage  180  of the valve actuator  168  extends through the actuator at an angle and exits the second face  186  at a central location, aligned with the outlet passage in the first end  138  of the filter cartridge  118 . The seals  178 ,  184  are dynamic axial seals in that they effect a seal between the valve actuator  168  and the valve body  72  by means of a sliding motion between the two facing surfaces  154 ,  186 . 
         [0036]    The valve actuator  168  may have an axially extending flange  190  which closely surrounds and receives an outer peripheral edge  192  of the tabs  144  formed on the first end  138  of the filter cartridge  118 . The valve actuator  168  may also have an axially extending circular wall  194  extending from the first face  170  which is received in the circular groove  108  formed in the valve body  72 . The circular wall  194  includes an outwardly facing seal gland  198  formed therein for receiving an O-ring seal  200  which engages with a side wall of the groove  196 , and thus comprises a radial seal. 
         [0037]    The valve actuator  168 , at an edge of the top face  170 , also includes a groove  202   FIG. 14 ) which receives the tab  106  of the valve body  72 . The groove  202  has an angular extent of approximately 90 degrees, so the valve actuator  168  is permitted to rotate only 90 degrees relative to the valve body  72 . The valve actuator  168  has a pair of opposed recesses  204  formed in the axially extending flange  190  which are sized to receive the tabs  144  of the filter cartridge  118 . Rotation of the filter cartridge  118  will therefore cause co-rotation of the valve actuator  168 . 
         [0038]    To assemble the system  30 , the valve actuator  168  is inserted into the end  60  of the housing  56  such that its axially extending flange  190  rests on the inwardly facing flanges  62  of the housing. The valve body  72  is inserted into the end  60  of the housing  56  overlying the valve actuator  168 , the valve body  72 , housing  56 , and valve actuator  168  forming an assembly to define a fluid valve. The valve body  72  is rotated approximately 90 degrees, so that the radially projecting flanges  96  of the valve body engage under the tabs  68  of the housing  56 , thereby holding the valve body, the valve actuator  168  and the housing together as a unit and capturing the valve actuator between the valve body and the housing ( FIGS. 8 ,  9 ). The detents  102  on the valve body  72  engage with endwalls  70  of the inwardly facing tabs  68  on the housing  56  to lock the valve body in the assembled rotational position relative to the housing. 
         [0039]    The assembled filter cartridge  118  is inserted from the first end  58  of the housing  56 , sufficiently into the housing such that the radial tabs  144  of the cartridge are positioned between the inwardly facing flanges  62  of the housing. The radial tabs  144  will be received in the recesses  204  in the valve actuator  168 . The filter cartridge  56  is rotated approximately 90 degrees in a first direction, such as clockwise, the sloped surfaces  146  of the cartridge tabs  144  causing the face  158  of the end  138  of the filter cartridge to move axially towards the second face  186  of the valve actuator  168 , compressing the concentric O-ring seals  162 ,  166  between the filter cartridge and the valve actuator. Since rotation of the filter cartridge  118  also causes co-rotation of the valve actuator  168 , as discussed above, the O-ring seals  162 ,  166 , which comprise axial seals, are only compressed and no sliding between the parts or seals occurs, thereby forming a static face seal (axial seal) which enhances and preserves the seal. In this way, there is no chance for the O-ring seals  162 ,  166  to dislodge from the seal glands  160 ,  164 . Rotation of the cartridge  118  and valve actuator  168  continues until the tab  106  of the valve body  72  strikes an end wall  206  of the groove  202  in the valve actuator, preventing further rotation of the valve actuator relative to the valve body. 
         [0040]    When this rotation assembly occurs, the alignment of the parts is that as shown in  FIG. 8 , with the inlet passage  174  in the valve actuator  168  aligned with the inlet passage  74  in the valve body  72  and the inlet passage  154  of the filter cartridge  118  to permit communication between the inlet passages and define a system inlet passage. The outlet passage  180  in the valve actuator  168  is also aligned with the outlet passage  76  in the valve body  72  and the outlet passage  148  in the filter cartridge  118  to permit communication between the outlet passages and define a system outlet passage. In such an orientation, water, or other liquid, flows in through the valve body inlet passage  74 , through the valve actuator inlet passage  174 , around the distribution channel  188  and into the inlet passages  154  of the filter cartridge  118 . The outer O-ring seal  166  and the inner O-ring seal  162  define the inlet flow path at the interface between the filter cartridge  118  and the valve actuator  168 . The liquid flows into the chamber  156 , past the end cap  114 , and through the side wall  132  of the filter body  112 . The liquid flows into the center passage  134 , now filtered, and through the outlet passage  136  in the end cap  114 , to the outlet passage  148  in the filter cartridge  118 , through the outlet passage  180  in the valve actuator  168 , and out through the outlet passage  76  of the valve body  72 . The inner O-ring seal  162  defines the outlet flow path, on its interior, at the interface between the filter cartridge  118  and the valve actuator  168 . 
         [0041]    When the filter cartridge  118  is to be removed, such as for replacement with another filter cartridge, the filter cartridge is rotated approximately 90 degrees in the opposite direction, such as counter-clockwise, causing the valve actuator  168  to also rotate 90 degrees. This places the valve actuator  168  in the position shown in  FIG. 9 , with the inlet passage  174  and outlet passage  180  of the valve actuator displaced out of alignment relative to the inlet passage  74  and outlet passage  76  of the valve body  72  (and not visible in  FIG. 9 ). This position prevents communication between common passages, that is, between the two inlet passages  74 ,  174  and between the two outlet passages  76 ,  180 . A groove  207  ( FIGS. 5 ,  14 ) in the face  170  of the valve actuator  168  has its ends moved into alignment with the inlet  74  and outlet  76  passages of the valve body  72 , such that liquids flowing into the inlet passage  74  will be diverted into the groove  207  to the outlet passage  76 , automatically bypassing the remainder of the filter system. This groove  207  forms a bypass conduit which will permit the filter cartridge  118  to be removed and replaced, even if a liquid is flowing through the inlet  74  and outlet  76  passages, or will permit continued use of the liquid dispensing system  32  that the filter system  30  is a part of, even if the filter cartridge  118  is not in place. The O-ring  198  carried by the valve actuator  168  assures that any liquid in the space between the first face  170  of the valve actuator and the inner face  84  of the valve body  72  will not leak out of the assembly, and the O-rings  178 ,  184  will assure that no liquid will flow into the inlet  174  or outlet  180  passages in the valve actuator. 
         [0042]    In order to prevent unintentional dislodging of the O-rings  162 ,  166  from the end face  158  of the filter cartridge  118  as it is being removed and replaced, the O-rings may be overmolded onto the end face of the filter cartridge. Alternatively, the O-rings  162 ,  166  may be held onto the filter cartridge  118  by capillary action provided by silicone grease. In any event, the O-rings are to be removed and replaced each time the cartridge  118  is replaced, assuring a proper sealing of the flow paths. Since there is sliding rotational movement between the valve actuator  168  and the valve body  72 , there is a slight chance that the O-rings  178 ,  184  will unseat from their glands  170 ,  182 . The spiders  86  in the inlet  74  and outlet  76  passage openings will prevent the O-rings from extruding into those openings which might otherwise cause leakage. 
         [0043]    To assist in insertion and removal of the filter cartridge  118 , the end cover  120  of the filter  110  may be provided with a projecting element  208 , such as a rectangular shaped element ( FIG. 11 ). A handle  210  ( FIGS. 3 ,  16 ) may be provided to engage, such as at a pocket  211  with the projecting element  208 , and may have an extending arm  212  to give the user greater leverage, and to apply greater torque, when rotating the filter cartridge  118 . The handle  210  may be removed from the projecting element  208 , and attached to the water dispensing unit, such as the grill  48  of the refrigerator  34 , even when the filter cartridge  118  is not in place. Connection arrangements, such as flexible fingers  214  may be provided which will hold the handle  210  in place on the water dispensing unit, and will even allow rotation of the handle relative to the grill  48 , with or without the filter cartridge  118 . 
         [0044]    The present invention has been described utilizing particular embodiments. As will be evident to those skilled in the art, changes and modifications may be made to the disclosed embodiments and yet fall within the scope of the present invention. For example, various components could be utilized separately or independently in some embodiments without using all of the other components in the particular described embodiment. The disclosed embodiment is provided only to illustrate aspects of the present invention and not in any way to limit the scope and coverage of the invention. The scope of the invention is therefore to be limited only by the appended claims. 
         [0045]    As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.