Patent Publication Number: US-11639675-B2

Title: Oil filter assembly

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a Continuation of U.S. application Ser. No. 17/528,884, which was filed on Nov. 17, 2021 as a Continuation of U.S. application Ser. No. 17/406,639, which was filed on Aug. 19, 2021 and claimed the benefit of U.S. Provisional Application No. 63/068,759, filed on Aug. 21, 2020, each of which is incorporated herein by reference as if fully set forth. 
    
    
     FIELD OF INVENTION 
     The invention relates generally to the lubrication of mechanical engines that utilize oil as a lubricating fluid that circulates though defined galleries in the engine. More particularly, the invention relates to a lubrication system where the lubricating fluid is routinely passed through a filter element, which is generally replaceable at certain intervals, and potentially and oil cooler. Most particularly, the invention relates to an adaptor for a lubrication system that incorporates the oil filter housing and an oil cooler in an assembly that is often located within the motor valley. 
     BACKGROUND 
     Modern engines, especially though used in motor vehicles, seek to reduce weight and size while maintaining the desired power. As part of the effort to reduce weight, many parts are being made in plastic and many parts are being combined in assemblies to further reduce weight by eliminating individual connection points. While this trend has proven successful in some areas, it has introduced problems where one or more portions of a plastic assembly experience a failure. Under these conditions, it is often necessary to disassemble unrelated parts of the engine in order to gain access to the assembly and make the necessary repairs. 
     Another drawback to plastic assemblies is the need to made accommodations for various sensors and system components that need to be connected to the assembly. These connections are most often achieved by molding an opening in the plastic component and attaching a metallic insert to achieve the connection. This plastic to metal connection can be difficult to properly seal. An addition failure point of this metal-plastic connector is the possibility of over tightening the inserted component, such as a sensor fitting or cap, and stressing or damaging the surrounding plastic. 
     In addition to the above associated with a hybrid plastic-metallic assembly, the molding process requires certain concessions in order to permit molding cores to be inserted and removed during the molding process. An associated drawback with the plastic molding is the need to remove core elements used in the process and reseal the molding which leads to further potential failure points. In addition, the unused molded openings that require closing plugs that must be glued or welded in the unused openings. These plugs represent another failure point in the plastic-metallic assembly. 
     SUMMARY 
     The applicants have discovered that a cast metallic part provides a robust assembly that avoids the needs for inserts, eliminates the need for plugs, and provides for direct threading of components to the adaptor. As a result of eliminating the assembly of multiple molded parts, the performance and durability is improved against burst pressure, heat and age degradation, and conditions related to cycling. In addition, the single metallic casting provides a flow path without the need for adhesives and resealing of the flow path. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of a prior art oil filter adaptor and cooler assembly; 
         FIG.  2    is a partial rear view of the prior art assembly in  FIG.  1   ; 
         FIG.  3 A  illustrates the capping of the oil flow path in the prior art adaptor after removal of the core used in the plastic molding; 
         FIG.  3 B  is a section illustrating the flow path in the prior art adaptor; 
         FIG.  4    is a perspective view of an adaptor according to the invention prior to assembly of any related components; 
         FIG.  5    is a section view along the line  5 - 5  in  FIG.  4    showing the linear flow path in an adaptor according to the invention; and, 
         FIG.  6    is a perspective view of an adaptor according to the invention in a direction opposite to that of  FIG.  4   . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The prior art oil filter assembly shown in  FIGS.  1 - 3 B  is typical of the adaptor construction resulting from using moldable plastic materials. The prior art assembly  10  in  FIG.  1    has a base  20 , a filter housing  30  and an oil cooler  40 . The base  20  includes medal inserts  22  that are provided in the plastic construction at designated locations for the attachment of other associated components. The metal inserts and associated components are shown in  FIG.  1    at  22  and  24  respectively. Although the metal inserts are frequently molded in situ during the molding of the plastic base, they remain a failure point and can result in oil leakage or worse. The metal inserts  22  are also subject to overtightening during attachment of the associated components  24 , which can result in stress cracks in the plastic. 
     As shown in  FIG.  2   , the base  20 , due to the molding process requiring the ability to withdrawal a core, has a number of plugs  26  that are retrofitted after the base  20  is molded. The plugs  26  are assembled to the molded base with an adhesive or spin welding. In either event, the plugs  26  are a failure point in the base  20  that can result in oil leaking or worse. 
     In addition to the inserts  22  and plugs  26 , the base  20  has a number of metal inserts or sleeves, not shown, that are inserted to reinforce the plastic molded apertures for attachment of the various bolts  28  that hold the assembly  10  together. Here again, the inserts or sleeves introduce a potential failure point. Another potential failure point is the attachment of the cap  32  to the plastic filter housing  30 . Over tightening of the cap  32  can introduce stress fracture in the threaded housing  30 . 
     With reference to  FIGS.  3 A and  3 B , it can be seen that the prior art flow path  50  requires a cover  21 , at least partially over the flow path, that is adhered to the base after the molding core is removed by the adhesive or welding  23 . With reference to  FIG.  4 B , it can be seen that the flow path  50  bends or is angular; in other word, the flow path  50  does not have a common longitudinal axis. 
     With reference to  FIG.  4   , the preferred adaptor  110  has a filter housing  130  and base  120  that is formed of a casted metallic material, preferably aluminum. The base  120  and the filter housing  130  are casted together and the apertures  127  for receiving the bolts  128  do not required metal inserts or sleeves to avoid stressing or cracking do to the solid metallic construction. The casting is also threaded at  129  to receive fasteners for securing an oil cooler  40  to the adaptor  110 . 
     Still with reference to  FIG.  4   , the casted filter housing  130  has internal threaded  132  that mate with an OEM cap  32  to secure a filter within housing  130 . In a similar manner, the apertures  126  have internal threading to preferably mate with NPT plugs that are self-sealing. Depending on the type and construction of related components, such as sensors, it may be necessary to employ a gasket or sealing rings with their assembly. 
     With reference to  FIG.  5   , the flow path  150  for transporting the lubricant in base  120  is centered about the longitudinal axis  160  and consistent throughout the base  120 . The flow path  150  is symmetric about the axis  160  and there is no angular component in the flow path  150 . The flow path  150  is entirely within the unitary casting so there is no need for adding a closure to the flow path. 
     With the exception of the flow path  150 , the lubrication galleries and the location positions for associated components are identical to the OEM assembly so the casted metal adaptor is a direct replacement for the OEM part and no modifications or relocations of other components are necessary. 
     As shown in  FIGS.  4  and  6   , the adaptor  110 , including the filter housing  130  and the base  120  outwardly appearance the same as the OEM part and the base accepts the OEM cooler  40  and the filter housing accepts the cap  32  without any modification.