Abstract:
According to one embodiment a replaceable filter element includes a substantially annular filter media extending from a first end to a second end and has an exterior, a substantially hollow interior, and a first permeability. A first end plate is coupled to the first end of the substantially annular filter media. The first end plate includes an aperture leading to the substantially hollow interior of the substantially annular filter media. The replaceable filter element includes a filter media piece positioned adjacent the second end of the substantially annular filter media and has a second permeability less than the first permeability. The replaceable filter element includes an outer wrap extending from the second end of the substantially annular filter media along a portion of the exterior of the substantially annular filter media. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.

Description:
BACKGROUND 
       [0001]    Replaceable filter elements can be used in filtration systems for a variety of applications including, for example, in connection with fuels, lubricants, coolants, hydraulic and other liquids of internal combustion engines such as diesel engines. Replaceable filter elements can be used in filtration systems to remove particulates and other undesirable matter from fluids. Present approaches to such elements and systems suffer from a variety of disadvantages, drawbacks, limitations and problems including those respecting pressure regulation and relief, component interconnection, complexity, part count, and others. There is a need for the unique and inventive replaceable filter elements and systems disclosed herein. 
       SUMMARY 
       [0002]    According to one embodiment a replaceable filter element includes a substantially annular filter media extending from a first end to a second end and has an exterior, a substantially hollow interior, and a first permeability. A first end plate is coupled to the first end of the substantially annular filter media. The first end plate includes an aperture leading to the substantially hollow interior of the substantially annular filter media. The replaceable filter element includes a filter media piece positioned adjacent the second end of the substantially annular filter media and has a second permeability less than the first permeability. The replaceable filter element includes an outer wrap extending from the second end of the substantially annular filter media along a portion of the exterior of the substantially annular filter media. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0003]      FIG. 1  is a side view of a vehicle including an engine and a fuel filtration system. 
           [0004]      FIG. 2  is a perspective view of a replaceable filter element. 
           [0005]      FIG. 2A  is a sectional view of  FIG. 2 . 
           [0006]      FIG. 3  is a perspective view of a replaceable filter element. 
           [0007]      FIG. 3A  is a sectional view of  FIG. 3 . 
           [0008]      FIG. 4  is a perspective view of a replaceable filter element. 
           [0009]      FIG. 4A  is a sectional view of  FIG. 4 . 
           [0010]      FIG. 5  is a side view of a filtration system including a replaceable filter element. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the figures 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 created, and that the invention includes and protects such alterations and modifications to the illustrated embodiments, and such further applications of the principles of the invention illustrated therein as would occur to one skilled in the art to which the invention relates. 
         [0012]    With reference to  FIG. 1  there is illustrated a vehicle  600 . Vehicle  600  is shown as a semi tractor, but could also be a variety of types of vehicles, for example, light duty trucks, medium duty trucks, heavy duty trucks, buses, cars, motorhomes, fire and emergency vehicles, construction, vehicles, boats and other marine vehicles, and rail vehicles such as locomotives. Vehicle  600  includes an engine  610 , which is preferably a diesel engine but could be a spark ignition or other type of internal combustion engine, and a fuel filtration system  620  which is operable to filter fuel to be provided to engine  610 . Fuel filtration system  620  could be the same as or similar to fuel filtration system  500  described below in connection with  FIG. 5  or could be another type of fuel filtration system. Further embodiments contemplate that engine  610  could be used in other applications including, for example, in generator sets, or industrial, mining, or oil and gas equipment. 
         [0013]    With reference to  FIGS. 2 and 2A , there is illustrated an exemplary replaceable filter element  200 . Replaceable filter element  200  includes filter media  230  which is in an annular pleated configuration, plastic end plate  210  which is coupled to one end of filter media  230 , preferably by a portion of filter media  230  being embedded in plastic end plate  210 , plastic end plate  240  which is coupled to another end of filter media  230 , preferably by a portion of filter media  230  being embedded in plastic end plate  240 , and plastic outer wrap  220  which is coupled to plastic end plate  210  and extends from about one end of filter media  230  along a portion of its exterior, and in which a portion of filter media  230  is preferably embedded. 
         [0014]    Replaceable filter element  200  further includes a filter media piece  212  which is preferably embedded in plastic end plate  210 . While filter media piece  212  is illustrated as having a substantially circular or disc shape, it should be appreciated that filter media pieces having a variety other shapes, for example, ellipsoid, oval, square, rectangular or other polygon shapes could be used. 
         [0015]    Replaceable filter element  200  also includes plastic center tube  250  which is positioned in the substantially hollow interior of filter media  230 , and may extend over part or all of the distance intermediate plastic end plate  210  and plastic end plate  240 , and may contact or be coupled with plastic end plate  210  and/or plastic end plate  240 . A gasket  260  can be inserted into an opening formed in plastic end plate  240  to provide sealing between replaceable filter element and other components of a filtration system. Other embodiments may omit a plastic center tube or may have a plastic center tube which differs from plastic center tube  250 . 
         [0016]    Embedding of the various elements referred to herein is preferably accomplished by sonic welding. Embedding could also be accomplished by other techniques and processes, for example, use of a potting material such as plastisol or other adhesives or glues, by forming or molding one element around a portion of another, by flame embedding, by laser welding, by heat welding, or by combinations of these and other techniques and processes. 
         [0017]    Replaceable filter element  200  is preferably of the type appropriate for filtration of diesel fuel, but can also be of the types appropriate for filtration of other fuels, or other engine fluids such as lubricants, coolants, hydraulic fluids, as well as other types of fluids. During operation fuel is introduced into the substantially hollow interior of filter media  230 . Filtration occurs as fuel passes through filter media  230  while contaminants such as particulates and other matter are trapped by filter media  230 . 
         [0018]    During operation, fuel may rise within the substantially hollow interior of filter media  230  from plastic end plate  240  to about the level of the bottom of plastic outer wrap  220 . As fuel rises over this range gasses occupying the portion of the substantially hollow interior of filter media  230  may escape through filter media  230  to accommodate the increasing fuel volume. Once the fuel level rises above level of the bottom of plastic outer wrap  220 , gasses may no longer escape or may escape only with greater difficulty or at a lesser rate. As the fuel level continues to rise, gasses within the substantially hollow interior of filter media  230  are compressed and a head of pressure is created. 
         [0019]    A certain magnitude of pressure can contribute to filtration. Pressure of too great a magnitude, however, may lead to undesirable consequences, such as the inability of a fueling system to continue to provide fuel to replaceable fuel filter  200  or failure of replaceable fuel filter  200 . Filter media piece  212  provides a means for releasing pressure. After pressure is released, the fuel level may transition to a lower level. Multiple fuel level rises, pressure releases and falls may occur over the useful life of the filter element. 
         [0020]    Filter media piece  212  is in flow communication with the substantially hollow interior of filter media  230 . Filter media piece  212  has a lesser permeability than filter media  230 . As used herein, permeability refers to the capacity of a given filter media article to pass fluid. The permeability of a filter media article may be greater or less than the permeability of another filter media article due to the two filter media articles including different materials, having different thicknesses, different porosities, different numbers of layers, different internal structures or voids, different dimensions, and/or differences in other properties or characteristics. The lesser permeability of filter media piece  212  allows a head of pressure to be created within the substantially hollow interior of filter media  230  while avoiding overpressuriziation. The desired degree or range of pressure may vary between embodiments and the characteristics of filter media piece may be selected to provide different predetermined pressure magnitudes as may be appropriate from embodiment to embodiment. 
         [0021]    It should be appreciated that additional embodiments contemplate variations on the illustrated embodiment of replaceable fuel filter  200 . In further embodiments, filter media  230  could be in a variety of alternate configurations which also provide means for filtering fuel or other liquid(s), for example, filter media, having a variety of different cross sectional shapes such as oval, rectangular or others, a z-type configuration, flutes and still other filter media arrangements. 
         [0022]    In additional embodiments, endplate  210 , endplate  240 , outer wrap  220 , and/or center tube  250  could include or be formed from additional or alternate materials, for example, composites, metals or other materials. In other embodiments, endplate  210 , endplate  240 , outer wrap  220 , and/or center tube  250  could have a variety of different shapes and dimensions or might be absent or provided separately from replaceable filter element  200 . 
         [0023]    Additional embodiments may include other means for coupling with filter media  230  and/or media disc  212  in addition to or instead of endplates  210  and  240  and/or outer wrap  220 , for example, one or more couplings other than embedding. Further embodiments may include other means for creating a pressure head instead of or in addition to outer wrap  220 , for example, outer members having different dimensions, or formed of different materials. 
         [0024]    With reference to  FIGS. 3 and 3A , there is illustrated another exemplary replaceable filter element  300 . Replaceable filter element  300  includes filter media  330  which is in an annular pleated configuration, plastic member  320  which includes an end plate portion  321  which is coupled to one end of filter media  330 , preferably by a portion of filter media  330  being embedded in plastic end plate  310 , and plastic outer wrap portion  322  which extends from one end of filter media  330  along a portion of its exterior, and in which a portion of filter media  330  is preferably embedded. 
         [0025]    Replaceable filter element  300  also includes plastic end plate  340  which is coupled to another end of filter media  330 , preferably by an end of filter media  330  being embedded in plastic end plate  340 . Replaceable filter element  300  further includes a filter media piece  312  preferably embedded in plastic end plate portion  321 . 
         [0026]    Replaceable filter element  300  also includes plastic center tube  350  which is positioned in the substantially hollow interior of filter media  330 , extends intermediate plastic end plate portion  321  and plastic end plate  340 , and may contact or be coupled to plastic end plate portion  321  and plastic end plate  340 . A gasket  360  can be inserted into an opening formed in plastic end plate  340  to provide sealing between replaceable filter element  300  and other components of a filtering system. Other embodiments may omit a plastic center tube or may have a plastic center tube which differs from plastic center tube  350 . 
         [0027]    Replaceable filter element  300  is preferably of the type appropriate for diesel fuel filtration, but can be used for various additional and alternative applications as described above in connection with replaceable fuel filter element  200 . Additionally, the operation of replaceable filter element  300  can be the same as or similar to that of replaceable filter element  200 . Furthermore, the additional embodiments, alternatives, variations, modifications, materials, means and/or options described above in connection with replaceable fuel filter element  200  are also applicable to replaceable fuel filter element  300 . 
         [0028]    With reference to  FIGS. 4 and 4A , there is illustrated a replaceable filter element  400 . Replaceable filter element  400  includes filter media  430  which is in an annular pleated configuration, plastic end plate  440  which is coupled to an end of filter media  430 , preferably by an end of filter media  430  being embedded in plastic end plate  440 , and plastic outer wrap  420  which is coupled to plastic end plate  410  and extends from one end of filter media  430  along a portion of its exterior, and in which a portion of filter media  430  is preferably embedded. Replaceable filter element  400  further includes a filter media piece  412  which is preferably embedded in a flange of plastic outer wrap  420  that extends radially inward along the end of filter media  430 . Replaceable filter element  400  also includes plastic center tube  450  which is positioned in the substantially hollow interior of filter media  430 , extends intermediate filter media piece  412  and plastic end plate  440 , and may contact or be coupled to filter media piece  412  and plastic end plate  440 . A gasket  460  can be inserted into an opening formed in plastic end plate  440  to provide sealing between replaceable filter element  400  and other components of a fuel filtering system. Other embodiments may omit a plastic center tube or may have a plastic center tube which differs from plastic center tube  450 . 
         [0029]    Replaceable filter element  400  is preferable of the type appropriate for diesel fuel filtration, but can be used for the various additional and alternative applications as described above in connection with replaceable fuel filter element  200 . Additionally, the operation of replaceable filter element  400  can be the same as or similar to that of replaceable filter element  200 . Furthermore, the additional embodiments, alternatives, variations, modifications, materials, means and/or options described above in connection with replaceable fuel filter element  200  are also applicable to replaceable fuel filter element  400 . 
         [0030]    With reference to  FIG. 5  there is illustrated a fuel filtration system  500 . Fuel filtration system  500  includes replaceable fuel filter element  510 , a head  530 , a housing  529 , and a lid  540 . Replaceable fuel filter element  510  includes filter media  511  and outer wrap  512 . Replaceable fuel filter element  510  is received within a housing  529  and extends intermediate head  530  and lid  540 . Replaceable fuel filter element  510  could be the same as or similar to replaceable fuel filter elements  200 ,  300 , or  400  described above. Lid  540  can include a vent. A spring can be positioned intermediate replaceable fuel filter element  510  and shell lid  540  to bias replaceable fuel filter element  510  toward filter head  520  when fuel filtration system  500  is assembled. Filter head  520  includes a nozzle which coupled with filter head  520  and directs fuel into a substantially hollow interior portion of replaceable fuel filter element  510 . Filter head  520  includes a fuel inlet, a fuel outlet and can also include a check valve, an access valve, a drain valve, a water in fuel sensor, a DC electric heater and/or an AC electric heater. Fuel level  523  is visible through housing  529  and could be higher or lower as indicated by reference numerals  520  and  522 . 
         [0031]    As is clear from figures and related text presented above, a variety of embodiments according to the present invention are contemplated. Certain exemplary embodiments comprise a replaceable filter element including a substantially annular filter media extending from a first end to a second end and having an exterior, a substantially hollow interior, and a first permeability; a first end plate coupled to the first end of the annular filter media, the first end plate including an aperture leading to the substantially hollow interior of the annular filter media; a media piece positioned adjacent the second end of the annular filter media, the filter media piece having a second permeability, the first permeability being greater than the second permeability; and an outer wrap extending along a portion of the exterior of the annular filter media. Further exemplary embodiments include a second end plate coupled to the second end of the annular filter media and coupled to the filter media piece; a center tube positioned in the substantially hollow interior of the annular filter media; the filter media piece having a greater thickness than the annular filter media; the filter media piece covering substantially the entire second end of the annular filter media; the filter media piece being coupled directly to the annular filter media; the filter media piece being embedded in a second end plate; or may further include a fuel filtration system including a receptacle which receives the replaceable filter element. 
         [0032]    Additional exemplary embodiments comprise a replaceable filter element including means for filtering liquid having a first end, a second end, an exterior, a substantially hollow interior, and a first thickness; an end plate coupled with the first end having an opening providing access to the substantially hollow interior; means for releasing pressure positioned adjacent the second end, the means for releasing pressure having a second thickness being greater than the first thickness; and means for creating a pressure head during filtration extending along a portion of the exterior of the means for filtering liquid. In further exemplary embodiment the means for filtering liquid includes a pleated annular filter media; the means for releasing pressure includes a filter media disc; the means for creating a pressure head during filtration includes an outer wrap; the means for releasing pressure covers substantially all of an end of the pleated annular filter media; and/or the means for creating a pressure head includes a lip which overlaps the means for releasing pressure. 
         [0033]    Additional exemplary embodiments comprise a replaceable filter element including a filter media extending from a first end to a second end and having an exterior and a substantially hollow interior, the filter media having a first permeability; a first end portion coupled to the first end of the filter media, the first end portion including an aperture leading to the substantially hollow interior of the filter media; a second end portion coupled to the second end of the filter media; an outer cover extending from the second end of the filter media along a portion of the exterior of the filter media; and a filter media piece positioned embedded in one of the second end portion and the outer cover, the filter media piece having a second permeability, the first permeability being different than the second permeability. In further exemplary embodiments at least a portion of the filter media is embedded in the outer cover; the outer cover and the second end portion are a unitary piece; the second end portion is a flange of the outer cover; the second end portion and the outer cover are discrete pieces that are bonded to one another. 
         [0034]    Certain embodiments include replaceable filter elements which include indication means for changing a visible color based upon the pH of a fluid in contact with the indication means. Such embodiment may include, for example, those discussed above in connection with  FIGS. 1-5  as well as others. In one example of such an embodiment a filter media piece, such as, for example, filter media piece  212 ,  312 , or  412 , includes a color indicator which changes color in response to a change in pH of fluid in contact with the color indicator. Such embodiments may involve, for example, by applying a indicative reagent to a filtration substrate. Certain specific examples include application of one or more compounds which express a change in a visible color based upon the pH of a fluid in contact with the compound. These and other embodiments may involve, for example, formation by co-forming one or more indicative reagents and a filtration substrate wherein one or more compounds which provide filtration are coformed with one or more compounds which provide means for indicating filter life which includes display of a visible color. Examples of coforming include mixing, spraying cospinning, coreaction, sintering, fluidic mixing, chemical vapor deposition, and/or physical deposition. Further examples include combinations of the foregoing and the other features, techniques and configurations disclosed, implied and evident herein. 
         [0035]    Certain embodiments may include a fuel filtration system including a receptacle which receives the replaceable filter element; wherein the filter media piece provides limp home filtration once the filtration capacity of the filter media is substantially depleted. Such embodiment may include, for example, those discussed above in connection with  FIGS. 1-5  as well as others. 
         [0036]    While exemplary embodiments of the invention have been illustrated and described in detail in the figures 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 invention 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, so 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.