Abstract:
A housing configuration for a liquid filter in which the housing is cup-shaped and is produced by a molding technique. The housing lid or lid is secured to the housing ( 10 ) by a course of threads ( 28 ) which can be produced without forming any undercuts. This is achieved inside an area ( 30 ) around the mold parting plane ( 29 ) by providing recesses ( 31 ) on the course of threads in the horizontal areas. As a result, the thread can be produced directly on the housing by the initial molding technique without any post-molding processing measures, so that manufacturing costs are reduced.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
         [0001]    This application is a continuation of international patent application no. PCT/EP01/04580, filed Apr. 24, 2001 designating the United States of America and published in German as WO 01/85306, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. DE 100 23 427.5, filed May 12, 2000.  
         BACKGROUND OF THE INVENTION  
         [0002]    The invention relates to a liquid filter with a lid, the housing of which is produced using a molding or casting forming technique, and to a method for producing such a liquid filter.  
           [0003]    Liquid filters of the aforementioned type are usually configured with housing components that have a cylindrical basic structure. The lid can be screwed onto the housing by a screw thread. A liquid filter of this type is disclosed, for example, in published German patent application no. DE 196 37 008 A1. In this filter, the screw-on lid is provided with a radial groove into which an O-ring can be inserted to provide a seal relative to the housing component. The lid is screwed together with the housing component and is tightened with a defined torque. This prevents the lid from working itself loose during operation.  
           [0004]    The described components, however, are costly to manufacture since the thread must be produced. At least in the housing component, which is typically made of metal, especially die-cast aluminum, the thread cannot be produced using an original casting technique without post-molding processing.  
         SUMMARY OF THE INVENTION  
         [0005]    Thus, the object of the invention was to provide an improved liquid filter closure arrangement.  
           [0006]    A further object if the invention is to provide a liquid filter with a closure between housing and lid that is cost-effective to produce and reliable in operation.  
           [0007]    Another object of the invention was to provide a liquid filter with a threaded closure between housing and lid that can be produced solely by the original casting or molding without any post-molding processing.  
           [0008]    It is also an object of the invention to provide a method of producing an improved liquid filter according to the invention.  
           [0009]    In accordance with a first aspect of the invention, the objects are achieved by providing a liquid filter with a metal housing produced using an original casting forming technique and in which a filter cartridge is installed through which a liquid flows such that the filter cartridge separates a housing inlet from a housing outlet in a sealing manner, and with a lid which can be installed on and sealingly connected to the housing by rotating it relative thereto, wherein structures which form housing working surfaces are arranged on the housing such that the housing working surfaces communicate with working surfaces on the lid when the lid is installed on the housing, said structures which form housing working surfaces being oriented on the housing in such a way that the structures can be produced without an undercut relative to a removal direction of the housing from a mold in which the housing is cast, said mold having a parting line; wherein the communicating working surfaces of the housing and lid secure the lid to the housing; wherein the structures in the area of the parting line extend precisely in the removal direction from the mold, and wherein the working surfaces on the housing are produced solely by the original casting forming technique.  
           [0010]    In another aspect of the invention, the objects are achieved by providing a method for producing a liquid filter as described above with a housing in which a filter cartridge through which a liquid flows is installed such that the filter cartridge separates a housing inlet from a housing outlet in a sealing manner, said housing being provided with a lid which is sealingly connected to the housing by rotating the lid relative thereto, said method comprising casting the housing with structures thereon having housing working surfaces which engage working surfaces on the lid to secure the lid in sealing connection to the housing, wherein said housing working surfaces are produced solely by said casting.  
           [0011]    The liquid filter according to the invention comprises a housing that is produced using an initial casting or molding forming technique. As used herein, the term “housing” should be understood to include not only a separately configured component but also as a housing part that is integrated into another structure. This is the case, for instance, if the filter is used for the lubricating oil of an internal combustion engine, and the housing is integrated into the engine block. The housing can be sealed by a lid secured to the housing, and the connection between the lid and the housing should form a tight seal, so that the liquid to be filtered cannot escape from the housing. The connection between housing and lid is achieved by rotating the lid relative to the housing.  
           [0012]    The liquid filter of the present invention is characterized in that mutually interacting working surfaces are provided on both the lid and the housing and thereby cause the lid to be secured to the housing. These working surfaces are formed by structures, which at least for the housing are configured without an undercut relative to the direction of removal of the formed parts of the housing from the mold in which they are formed. This makes it possible to produce the structures solely by the original casting, so that chip-producing machining steps can be eliminated. Post-casting processing, in particular, should also be avoided. This makes it possible to use an enormous savings potential in the production of the housing. The accumulation of chips can be completely prevented, so that the housing component does not have to be cleaned at the end. This achieves greater economic efficiency of the entire filter module. At the same time, the geometry of the structures can be freely designed within the limits of the requirement for an undercut-free production, so that the safety aspect can also be taken into account.  
           [0013]    The working surfaces in the lid are arranged in such a way that they can communicate with or engage the working surfaces on the housing. If the working surfaces are arranged on the outside of the housing, those on the lid are arranged on the inside. If the structures forming the working surfaces are provided on the outside of the housing, this can be easily produced using two mold parts for the outside contour of the housing. These mold parts each form 180° of the housing circumference. In the area of the mold parting line, the structures must extend precisely in removal direction from the mold, i.e., perpendicularly to the center axis of the housing.  
           [0014]    Another option is to flatten the area of the parting line to prevent undercuts in the case of thread-like structures. This also prevents the structures themselves, which do not extend up to the parting line, from having a seam that would impair proper functioning of the threads.  
           [0015]    In accordance with one advantageous embodiment of the invention, an axially acting sealing element is used to provide a seal between the lid and the housing. This has the advantage that the effective area of the seal can likewise be located outside the seams that are associated with the production process of the housing. This enhances the sealing effect also if the housing component is produced without any post-processing. The sealing material must merely satisfy average requirements for deformability and sealing capacity.  
           [0016]    To prevent liquid from leaking when the filter lid is screwed on during a filter change, a radially sealing liquid control ring may be used in addition to the actual sealing element between the lid and the housing. Particularly in filter cartridges that are installed at a sloping angle, this liquid control ring prevents liquid from running out during the time when the residual liquid in the housing can flow out through the liquid drain or outlet that is provided in the housing.  
           [0017]    In accordance with a further embodiment of the invention, the structures that form the working surfaces may at least in part be configured perpendicularly to the removal direction of the lid. In a cylindrical housing, this simultaneously means a perpendicular orientation relative to the center axis of the housing. In this vertical area, the holding forces thus also act on the working surfaces between housing and lid perpendicularly to the removal direction. This effectively counteracts any unintended loosening of the lid. This is a significant advantage compared to conventional threaded connections, which can work themselves loose from the housing during operation of the filter through a process called pulsing open. This pulsing open is caused by a pulsating pressure pattern of the liquid to be filtered, which leads to alternating loading and relief of the lid connection.  
           [0018]    A further embodiment of the invention provides that the working surfaces between the lid and the housing simultaneously form a limit stop which limits the installation movement of the lid. This assures a defined installation position of the lid. The limit stop prevents over-rotation of the lid, and if partially horizontal working surfaces are provided as described, it assures that the lid, once installed, remains within this area of the working surfaces.  
           [0019]    Advantageously, the working surfaces can furthermore be provided with a locking or snap connection that locks between the installed lid and the housing. This provides feedback to the mechanic as he installs the lid so that he knows when the lid is properly installed. Furthermore, the snap connection can counteract any loosening of the lid by resisting the removal of the lid. When changing the filter, the mechanic must overcome this resistance. The locking connection can be realized, for instance, by forming the working surfaces with a zigzag profile, which engages when the lid is screwed on.  
           [0020]    In accordance with a further embodiment of the invention, the structures forming the working surfaces ensure a forced guidance of the lid, which requires rotation through an angle greater than 180°. As a result, more time is required to remove the lid, so that the residual liquid remaining in the housing has enough time to drain off. This prevents the residual liquid from reaching the environment during a filter change. Furthermore, a largely liquid-free filter element can more easily be replaced by the mechanic. The configuration of the structures forming the working surfaces is advantageously thread-like. This forces the rotary motion to remove the lid. The structures of one part thus form gaps that resemble thread turns, in which the structures of the other part can move. After a defined rotation, the lid can be removed in the direction of the center axis of the housing.  
           [0021]    One method for producing the described liquid filter provides that the working surfaces on the housing for producing the sealing connection of the lid be produced solely by the initial or original casting or molding forming technique. This achieves the aforementioned advantages.  
           [0022]    According to another embodiment of the method, the working surfaces on the lid also can be solely produced using an initial or original casting or molding forming technique. In this case it is advantageous if the structures are arranged on the outside of the housing and are given a thread-like configuration. These structures are easy to manufacture since the mold parts can be readily removed toward the outside. The structures on the inside of the lid can be formed by short segments or knobs that can be readily produced using a core, which for removal is rotated through a predetermined angle. Thus, the lid can also be easily produced with a few different mold parts. As an alternative, a disintegrating core may be used, which can be incrementally removed from the injection-molded lid. Through geometric simplification, it is possible to manage with few core parts.  
           [0023]    These and other features of preferred embodiments of the invention, in addition to being set forth in the claims, are also disclosed in the specification and/or the drawings, and the individual features each may be implemented in embodiments of the invention either alone or in the form of subcombinations of two or more features and can be applied to other fields of use and may constitute advantageous, separately protectable constructions for which protection is also claimed. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]    The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawing figures in which:  
         [0025]    [0025]FIG. 1 is a cross sectional view through a liquid filter according to the invention with a screw-on lid;  
         [0026]    [0026]FIG. 2 is a cross section of the lid of the liquid filter of FIG. 1;  
         [0027]    [0027]FIG. 3 is a sectional view taken along line  3 - 3  of FIG. 2;  
         [0028]    [0028]FIG. 4 is a perspective view of the upper part of the housing of FIG. 1, and  
         [0029]    [0029]FIG. 5 is an enhanced detail view of the surface of the lateral housing area according to FIG. 4. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0030]    [0030]FIG. 1 is a cross section through a liquid filter for the lubricating oil of an internal combustion engine. This filter comprises a housing  10 , which is sealed by a lid  11 . A filter cartridge  12  through which the oil flows from the outside toward the inside is installed in the housing. The flow of the liquid within the housing is indicated by arrows. The liquid flows from an inlet  13  through the filter cartridge to an outlet  14  configured as a connection piece  15  onto which the filter cartridge is placed.  
         [0031]    The filter cartridge  12  is held and sealed by the screwed-on lid  11 . An axially and radially effective seal  16  configured as a molded sealing element seals the lid relative to the housing. In addition, an O-ring is installed as an oil control ring  17  in the gap between housing  10  and lid  11 . The lid is fixed to the housing by structures  18 . These structures are formed on both the housing and the lid and have a thread-like configuration. These structures will now be described in greater detail with reference to the following detail drawing.  
         [0032]    [0032]FIG. 2 shows the lid  11  according to FIG. 1 by itself. Structures  18  in lid  11  form working surfaces  19 , which interact with the structures in the housing and thereby fix and reliably seal the lid on the housing. Structures  18  in the lid comprise a thread segment  20  and a snap projection  21 . The snap projection and the thread segment form a gap  22  in which the structures of the housing extend, so that the thread segment  20  and the snap projection  21  ensure a fork-like guidance around structures  9  in the housing. The snap projection additionally has the purpose of producing a lock between lid  11  and housing  10  when the lid is installed.  
         [0033]    [0033]FIG. 3 shows the section taken along line  3 - 3  in FIG. 2. The snap projection  21  is formed on a resilient tongue  23 , which can elastically spring back when the snap projection locks into a recess  24  provided on housing  10 . Recess  24  simultaneously forms a limit stop  25 , which limits the rotational movement of lid  11  during installation. Recess  24  and snap projection  21  thus form a snap connection  26  in which limit stop  25  is integrated.  
         [0034]    [0034]FIG. 4 is a perspective view of the upper part of the housing. It shows a groove  27  for receiving the oil control ring  17  (not shown) and the previously described recess  24  with limit stop  25 . Recess  24  together with a thread turn  28  forms the structures  18  on housing  10 . To configure the thread turn without an undercut, a mold parting plane  29  must be taken into account. The two outer parts of the mold (not shown) are moved perpendicularly to the parting plane away from the cast housing. To avoid undercuts, the structures, at least in an area  30  that is adjacent to parting plane  29 , must extend perpendicularly thereto. Such a horizontal course may be seen in the upper part of thread turn  28 . In the lower part, a break  31  of thread turn  28  is provided, which merges into area  30  and thereby cuts out a portion of the thread.  
         [0035]    Within an installation zone  32 , the thread turn has an additional horizontal area, which is unimportant for an undercut-free production of the housing, but when the lid is installed interacts with the likewise horizontal thread segment  20 . This occurs via an working surface  33  that communicates directly with the working surface  19  of the lid. The horizontal orientation of these working surfaces prevents the pressure acting on the lid from being converted into a loosening torque for the lid. This prevents the lid from pulsing open in the previously described manner due to the pulsating pressure loads. As a result, the holding force of the snap connection  26  is sufficient to reliably prevent the lid from working itself loose. In addition, the clamped seal  16 , which is in contact with the housing and the lid, produces resistance against the loosening of the lid.  
         [0036]    [0036]FIG. 5 illustrates the interaction of structures  18  in the lid (black) and the structure on the housing (white) in an enhanced detail view of the lateral area of housing  10 . The mold parting plane  29 , which is perpendicular to the enhanced detail view, is drawn as a reference. Thread section  20   a - d  and snap projection  21   a - d  are depicted in different positions during the removal of the lid. Arrows indicate the removal direction. To represent the removal process coherently, the enhanced detail view is expanded in one direction by broken lines. The structures depicted there correspond to those at the opposite end of the enhanced detail view. At the far left, the lid is shown in the installed state with thread segment  20   a  located in the installation zone  32   r  of thread turn  28   r.  The snap projection  21   a  is fixed within recess  24   r.    
         [0037]    By rotating the lid, the lid in position b is lifted from the axial seal. This occurs because snap projection  21   b  is forcibly guided at the beginning of thread turn  28   l.  This causes thread segment  20   b  to already be pushed into the gap between thread turns  28   r  and  28   l.  In this manner, the break  31   r  in thread turn  28   l  is bridged, so that the lid cannot slide back through this break into its installed position.  
         [0038]    By rotating the lid further, the lid is further lifted as shown in position c. Clearly visible here, in particular, is the fork-like guidance of the lid by thread segment  20   c  and snap projection  21   c,  in the corresponding gap  22   c  of which thread turn  28   l  is forcibly guided. This forced guidance ends with the end of thread turn  28   l  in position d of the lid where snap projection  21   d  can be axially lifted at the end of thread turn  28   l.  The lid can thereby be removed from housing  10 .  
         [0039]    Thread turns  28   r  and  28   l  are identical and are arranged offset on the lid by 180°. Two thread segments and snap projections that are also offset by 180° are likewise provided on the lid. However, only one of the thread segments and snap projections is depicted in FIG. 5 to ensure better clarity. The thread segments and snap projections in positions a, b, c and d represent the same component, which is merely depicted in different removal positions.  
         [0040]    The configuration of structures  18  according to FIG. 5 assures that the lid must complete an approximately 360° turn before it can be removed from the housing. The corresponding time required for the removal of the lid gives the residual lubricating oil inside the housing enough time to run out through an oil drain or outlet  14 . As a result, the filter cartridge is largely free from oil residues after the lid has been opened, so that it can be removed without dripping. The described thread turn can also be multiply repeated in series. This results in a rotation angle greater than 360° until opening. The lid, however, becomes correspondingly longer.  
         [0041]    The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations falling within the scope of the appended claims and equivalents thereof.