Patent Description:
Correlated magnet designs were introduced in <CIT>, entitled "FIELD EMISSION SYSTEM AND METHOD" (the " '<NUM> Patent"). This patent describes field emission structures having electric or magnetic field sources. The magnitudes, polarities, and positions of the magnetic or electric field sources are configured to have desirable correlation properties, which are in accordance with a predetermined code. The correlation properties correspond to a special force function where spatial forces correspond to relative alignment, separation distance, and a spatial force functions.

In <CIT>, titled "APPARATUS AND METHODS RELATING TO PRECISION ATTACHMENTS BETWEEN FIRST AND SECOND COMPONENTS (a related patent to the '<NUM> Patent), an attachment scheme between first and second components is taught. Generally, a first component includes a first field emission structure and the second component includes a second field emission structure, wherein each field emission structure includes multiple magnetic field emission sources (magnetic array) having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of the field emission structures. The components are adapted to be attached to each other when the first field emission structure is in proximity of the second field emission structure.

When correlated magnets are brought into alignment with complementary or mirror image counterparts, the various magnetic field emission sources that make up each correlated magnet will align causing a peak spatial attraction force, while a misalignment will cause the various magnetic field emission sources to substantially cancel each other out. The spatial forces (attraction, repulsion) have a magnitude that is a function of the relative alignment of two magnetic field emission structures, the magnetic field strengths, and their various polarities.

It is possible for the polarity of individual magnet sources can be varied in accordance with a code without requiring a holding mechanism to prevent magnetic forces from "flipping" a magnet. As an illustrative example of this magnetic action, an apparatus <NUM> of the prior art is depicted in <FIG>. Apparatus <NUM> includes a first component <NUM> and a second component <NUM>. The first component includes a first field emission structure <NUM> comprising multiple field emission sources <NUM>. The second component includes a second field emission structure <NUM> comprising multiple field emission sources <NUM>. The first and second components are adapted to attach to one another when the first field emission structure <NUM> is in proximity of the second field emission structure <NUM>, that is, they are in a predetermined alignment with respect to one another.

The first field emission structure <NUM> may be configured to interact with the second field emission structure <NUM> such that the second component <NUM> can be aligned to become attached (attracted) to the first component <NUM> or misaligned to become removed (repulsed) from the first component. The first component <NUM> can be released from the second component <NUM> when their respective first and second field emission structures <NUM> and <NUM> are moved with respect to one another to become misaligned.

Generally, the precision within which two or more field emission structures tend to align increases as the number N of different field emission sources in each field emission structure increases, including for a given surface area A. In other words, alignment precision may be increased by increasing the number N of field emission sources forming two field emission structures. More specifically, alignment precision may be increased by increasing the number N of field emission sources included within a given surface area A.

In <CIT>, titled "CORRELATED MAGNETIC COUPLING DEVICE AND METHOD FOR USING THE CORRELATED COUPLING DEVICE," a compressed gas system component coupling device is taught that uses the correlated magnet attachment scheme discussed above.

An illustrative example of this coupling device is shown in <FIG>, which depicts a quick connect air hose coupling <NUM> having a female element <NUM> and a male element <NUM>.

The female element <NUM> includes a first magnetic field emission structure <NUM>. The male element <NUM> includes a second magnetic field emission structure <NUM>. Both magnetic field emission structures are generally planar and are in accordance with the same code but are a mirror image of one another. The operable coupling and sealing of the connector components <NUM>, <NUM> is accomplished with sufficient force to facilitate a substantially airtight seal therebetween.

The removal or separation of the male element <NUM> from the female element <NUM> is accomplished by separating the attached first and second field emission structures <NUM> and <NUM>. The male element is released when the male element is rotated with respect to the female element, which in turn misaligns the first and second magnetic field emission structures.

When conventional magnets are in close proximity, they create a force between them depending on the polarity of their adjacent faces, which is typically normal to the faces of the magnets. If conventional magnets are offset, there is also a shear force toward the alignment position, which is generally small compared to the holding force. However, multipole (coded polymagnets) magnets are different. As multipole magnets are offset, attraction and repulsion forces combine at polarity transitions to partially cancel normal forces while simultaneously establishing stronger shear forces.

Prior art filter interconnects present numerous technical hurdles, particularly with respect to installation, as well as removal and replacement of the filter cartridge when the filter media has served its useful life. Such technical hurdles include providing effective latching and unlatching mechanisms to retain manually-inserted filter cartridges in mating manifolds after installation, while including mechanisms such as switch-activated valve mechanisms so as to prevent the flow of water when the filter cartridge is removed for replacement. Other technical hurdles include incorporating effective authentication and/or anti-counterfeiting means to ensure that only authorized or OEM filter cartridges can be installed.

<CIT> and <CIT> teach water filter assemblies, such as for refrigerator appliances, for facilitating mounting and removal of a water filter cartridge to and from a manifold. The manifold defines a cavity with a magnet and a conducting coil disposed in the cavity, wherein the conducting coil is in electrical communication with a power supply. A removable filter cartridge assembly includes a magnetic member projecting from the housing thereof, wherein when the filter cartridge is mounted to the manifold, the magnetic member is received within the cavity of the manifold such that the conducting coil surrounds at least a portion of the magnetic member and the magnetic member is attracted to the magnet.

Document <CIT> to Cummins Filtration IP teaches a system and method for preventing assembly of a fluid filter apparatus unless a filter cartridge is installed and preventing assembly of a fluid filter apparatus if an incorrect filter cartridge is installed. A mechanism includes cooperation of a movable member and a structure that can move the movable member to ensure that a fluid filter apparatus cannot be completely assembled, for example connecting its filter head to its shell, when there is no cartridge installed inside the shell or when there is an attempt to install an incorrect cartridge.

Therefore, a need exists for an improved filter interconnect which overcomes these technical hurdles, without substantially increasing the cost and complexity of manufacture.

The present invention adapts the correlated magnet technology described above to an interconnection structure for a filter cartridge and a corresponding manifold to resolve many of the technical hurdles of prior art filter interconnects.

As described herein, the correlated magnet technology has a variety of implementations in filter interconnect structures, including, for example, in actuation of switches or valves to permit or prevent fluid flow, as well as in filter authentication and anti-counterfeiting measures, such as permitting the actuation of blocking or engagement mechanisms to allow for proper attachment of only OEM or otherwise authorized replacement filter cartridges to a mating manifold.

Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide an improved filter interconnect structure for a filter cartridge and a corresponding filter manifold which utilizes correlated magnetism.

It is another object of the present invention to provide an improved filter interconnect which prevents leaking by dissociating the initial filter cartridge installation from the actuation of an upstream and/or downstream valve.

It is yet another object of the present invention to provide an improved filter interconnect and method of installing a filter cartridge in a corresponding filter manifold which utilizes correlated magnetism to move a blocking mechanism or position stop, or to actuate an attachment or latching mechanism to allow for proper filter cartridge installation.

Yet another object of the present invention is to provide an improved filter interconnect which utilizes correlated magnetism to provide an effective authentication and/or anti-counterfeiting means for ensuring proper filter cartridge installation.

Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed in one aspect to a filter interconnect comprising a filter manifold having ingress and egress fluid ports, a sump having an inner cavity receiving a mating filter cartridge, an upwardly-extending alignment channel proximate the sump inner cavity, and a resilient blocking mechanism at least partially extending within the alignment channel when in a biased position and comprising a first correlated magnetic structure disposed therein. The correlated magnetic structure includes a magnet having a plurality of magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of said magnetic field emission sources. The blocking mechanism is movable in a first direction to a retracted position in response to a magnetic repulsion force generated when a complementary or paired second correlated magnetic structure is positioned within close proximity to the first magnetic structure.

The mating filter cartridge comprises a housing having a body, a top surface, an axial length, and an internal cavity, and an annular collar circumferentially located about the housing top surface and having an outer wall. The annular collar includes securing lugs or threads extending radially outwards from the annular collar outer wall. The complementary or paired second correlated magnetic structure is located on or within the annular collar and has a radially outwardly-facing surface that extends at least no further than an outward most radial extension of the securing lugs or threads. In an embodiment, the second correlated magnetic structure is provided within a tab extending in an axial direction from the annular collar. The tab may be positioned off-axial center of the filter cartridge body, and the securing lugs or threads may include upwardly-extending ramped segments.

Upon movement of the mating filter cartridge in a second direction, such as a rotational direction, to an alignment position within the filter manifold sump, the first and second correlated magnetic structures are within close proximity to one another such that the magnetic repulsion force is generated, which causes the blocking mechanism to move to the retracted position and allows the securing lugs or threads to continue moving in the second direction to complete attachment of the filter cartridge to the filter manifold.

In another aspect, the present invention is directed to a method of interconnecting a filter cartridge and a mating filter manifold. The method comprises inserting the filter cartridge into a sump of the mating filter manifold, the filter cartridge comprising a housing having a body with a top surface, and an annular collar circumferentially located about the housing top surface and having an outer wall, the annular collar including securing lugs or threads extending radially outwards from the annular collar outer wall and a first correlated magnetic structure located on or within the annular collar and having a radially outwardly-facing surface that extends at least no further than an outward most radial extension of the securing lugs or threads, wherein the first correlated magnetic structure includes a magnet having a plurality of magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of said magnetic field emission sources. The method further comprises aligning the securing lugs or threads with an alignment channel of the filter manifold, rotating the filter cartridge within the filter manifold sump in a first direction, and aligning the first magnetic structure plurality of magnetic field emission sources with a plurality of magnetic field emission sources of a complementary or paired second magnetic structure disposed within a resiliently biased blocking mechanism at least partially extending within the alignment channel of the filter manifold, such that a magnetic repulsion force is generated. The method further comprises displacing the blocking mechanism to a retracted position in a second direction in response to the magnetic repulsion force, wherein the second direction is approximately perpendicular to said first direction, and continuing to rotate the filter cartridge in the first direction such that the securing lugs or threads pass in front of the displaced blocking mechanism to complete attachment of the filter cartridge to the filter manifold.

In yet another aspect, the present invention is directed to a filter interconnect comprising a filter manifold receiving a mating filter cartridge, the filter manifold having a top surface including ingress and egress stanchions for receiving ingress and egress fluid ports of the mating filter cartridge, a pivotable latch extending axially with respect to the top surface of the manifold and normally biased in an open position, and a first correlated magnetic structure disposed in or on the latch. The first magnetic structure includes a correlated magnet having a plurality of magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of said magnetic field emission sources. The latch further includes a protrusion or projection proximate the first correlated magnetic structure, and is pivotally responsive to a magnetic repulsion force generated when a complementary or paired second correlated magnetic structure is positioned within close proximity to the first magnetic structure.

The mating filter cartridge comprises a body and a filter head forming a fluid-tight seal with the body. The filter head includes the ingress and egress fluid ports and the complementary or second correlated magnetic structure located on or connected to an axially-extending portion of the filter head, the axially-extending portion further including a notch or cutout proximate the second correlated magnetic structure. The second correlated magnetic structure may include a magnet having a plurality of complementary magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of said magnetic field emission sources. In an embodiment, the correlated magnetic structure is provided within a tab extending in an axial direction from said filter head. The tab may extend parallel to a longitudinal axis of the filter cartridge body, and be radially offset from the ingress and egress fluid ports.

Upon insertion of the filter cartridge ingress and egress ports within the manifold ingress and egress stanchions, the first and second correlated magnetic structures are brought within close proximity to one another such that the magnetic repulsion force is generated, which causes the latch to pivot about a pivot axis to a closed position to engage the latch projection with the filter head notch or cutout to secure the filter cartridge.

In an embodiment, the filter manifold may further include a latch release button being manually actuable in a direction perpendicular to a longitudinal axis of the manifold to pivot the latch from the closed position to the open position to permit removal of the filter cartridge.

In at least one embodiment, the filter manifold may include axially-extending supports on opposing sides of the latch and integral with or connected to the manifold top surface, wherein the latch is coupled to the axially-extending supports via a pin or shaft extending transversely therebetween, the pin or shaft comprising the pivot axis.

In still yet another aspect, the present invention is directed to a method of interconnecting a filter manifold and a mating filter cartridge. The method comprises inserting ingress and egress fluid ports of the filter cartridge into ingress and egress stanchions of the filter manifold, wherein the filter cartridge further comprises a body and a filter head forming a fluid-tight seal with the body and including the ingress and egress fluid ports and a first correlated magnetic structure located on or connected to an axially-extending portion of the filter head. The axially-extending portion further includes a notch or cutout proximate the first correlated magnetic structure, wherein the first correlated magnetic structure includes a magnet having a plurality of magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of said magnetic field emission sources. The method further comprises aligning the first correlated magnetic structure plurality of magnetic field emission sources with a plurality of magnetic field emissions sources of a complementary or second correlated magnetic structure disposed in or on a pivotable latch extending from the top surface of the manifold, such that a magnetic repulsion force is generated, pivoting the latch from a biased open position to a closed position in response to the magnetic repulsion force, and engaging a protrusion or projection proximate the second correlated magnetic structure of the latch with a notch or cutout proximate the first magnetic structure of the filter head to complete attachment of the filter cartridge to the filter manifold.

The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:.

In describing the embodiments of the present invention, reference will be made herein to <FIG> of the drawings in which like numerals refer to like features of the invention.

Certain terminology is used herein for convenience only and is not to be taken as a limitation of the invention. For example, words such as "upper," "lower," "left," "right," "front," "rear," "horizontal," "vertical," "upward," "downward," "clockwise," "counterclockwise," "longitudinal," "lateral," or "radial", or the like, merely describe the configuration shown in the drawings. Indeed, the referenced components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. For purposes of clarity, the same reference numbers may be used in the drawings to identify similar elements.

Additionally, in the subject description, the words "exemplary," "illustrative," or the like, are used to mean serving as an example, instance or illustration. Any aspect or design described herein as "exemplary" or "illustrative" is not necessarily intended to be construed as preferred or advantageous over other aspects or design. Rather, the use of the words "exemplary" or "illustrative" is merely intended to present concepts in a concrete fashion.

Correlated magnets, also interchangeably referred to herein as coded polymagnets, contain areas of alternating poles. These patterns of alternating poles can concentrate and/or shape magnetic fields to give matching pairs of magnets unique properties. The present invention utilizes correlated magnet designs with "high auto-correlation and low cross-correlation" which is a characteristic of correlated magnets which only achieve peak efficacy (magnet attraction or repulsion) when paired with a specific complementary magnet. An example of such use of correlated magnets is disclosed in <CIT>, entitled "KEY SYSTEM FOR ENABLING OPERATION OF A DEVICE. " Correlated magnets are also characterized by dense and tunable magnetic fields, allowing for specifically engineered force curves with higher force at shorter working distances.

In addition, correlated magnets can be designed to have varying magnetic forces depending on the relative rotational orientation of the pair of magnets (e.g., repulsion-attraction-repulsion-attraction at <NUM>-degree intervals) as illustrated on the graph below.

The present invention utilizes a magnetic repulsion model applied to a filter interconnect, which allows for a higher degree of control and flexibility over the timing and actuation of critical system functions through an engineered system of correlated magnets, springs and simple machines. Integral to the design is a matching set of "keyed" correlated magnets disposed in/on the filter cartridge housing and filter manifold, respectively, which provide the initial drive to engage downstream functions through non-electric and non-contacting actuation of an electronic system. The embodiments of the present invention described herein illustrate the actuation of a downstream valve (e.g., spool valve or other valve design) to allow for the flow of water; however, it should be understood by those skilled in the art that actuation of a valve is only one example of a downstream component intended to be within the scope of the present invention and that other components are not precluded, such as a dosing system or other electronic system.

This is accomplished by having a pair of magnets, preferably correlated magnets, oriented parallel to one another on each component of the connecting pair when in an alignment position, wherein a first coded polymagnet is disposed on a filter cartridge and a complementary, paired coded polymagnet is located on the manifold designed to secure the filter cartridge into position. It should be understood by those skilled in the art that a "correlated magnet" or "coded polymagnet" as referred to herein may comprise a single magnet with a plurality of polarity regions or, alternatively, may comprise multiple magnets arranged to create a polarity pattern with the desired characteristics. In at least one embodiment, a thin layer of material is introduced, physically separating the two polymagnets so they cannot have physically contacting surfaces, but they can still magnetically repel one another.

When a correct set of "keyed" polymagnets are aligned and brought into an effective working distance, the result is a repulsion force between the two magnets. The polymagnet disposed on the filter cartridge is fixed; however, the corresponding polymagnet disposed in/on the mating filter manifold is permitted to translate, acting against the mechanical force of a spring. The function of the magnet located on the manifold is to assist in actuating a valve (e.g., spool valve, cam and poppet valve, and other valve types) through activation of an electronic switch, normally biased in a first position by a spring. As will be described in more detail below, the force curves of the spring and correlated magnet couple are engineered such that only a set of corresponding "keyed" polymagnets will provide sufficient magnetic force to overcome the spring force to activate the switch. When the spring is fully depressed, one or more critical system functions are actuated, i.e., upstream and/or downstream valves, dosing systems, or other electronic systems, for example.

During installation, the filter cartridge may be guided by an alignment rail or thread and boss/lug system so that the correlated magnet disposed on the filter cartridge and the corresponding correlated magnet on the manifold are aligned (in-phase forming a repulsion force) but not in contact, when in the INSTALLED-LOCKED position. In at least one embodiment, the correlated magnet in the manifold physically actuates a limit switch when repelled by the filter magnet. When the filter is first fully inserted into the manifold in an INSTALLED-UNLOCKED position, the O-rings are sealed but the filter and manifold magnets are not aligned, and consequently, the upstream and/or downstream valve(s) are not open and water is not permitted to flow through the filter element. The filter assembly is then rotated <NUM>-degrees into the INSTALLED-LOCKED position, which brings the "keyed" correlated magnets into alignment, thereby achieving peak efficacy (magnetic repulsion), overcoming a spring force and causing the manifold magnet to translate linearly to actuate a limit switch. In an embodiment, the positive engagement of the switch opens upstream and/or downstream valves and allows for the flow of water.

Referring now to <FIG>, collectively, one embodiment of the filter cartridge and manifold of the present invention is shown. Replaceable filter cartridge <NUM> comprises a filter media <NUM> encased between end caps <NUM>, <NUM> and includes a correlated magnet <NUM> located at the cartridge top end proximate the outside surface of the cartridge body. End cap <NUM> includes a manifold cup <NUM> integral therewith for securing filter media <NUM> and facilitating connection to manifold <NUM>. As shown in <FIG>, end cap <NUM> may include a downward, axially-extending magnetic housing <NUM> which secures on its outside surface or embedded therein magnet <NUM>. Filter cartridge <NUM> further includes an axial stem <NUM> comprising ingress and egress fluid ports. Filter cartridge <NUM> is initially insertable within a sump <NUM> in manifold <NUM> into a partially-INSTALLED position, wherein the O-rings are sealed but the downstream valve(s) are not open and water is not permitted to flow (<FIG>). Surrounding filter media <NUM> and filter cup <NUM> is a dry change sleeve <NUM> forming the filter cartridge body, which is disposed between filter media <NUM> and sump <NUM> when the filter cartridge is inserted into the sump.

As shown in <FIG>, and best seen in <FIG>, in an embodiment, manifold <NUM> may include a radially-extending locking plate <NUM> including an aperture for permitting insertion of filter cartridge <NUM> into sump <NUM> and further including an alignment rail or thread <NUM> representing an "entry track" for filter cartridge <NUM> by receiving filter boss or lug <NUM> of locking cover <NUM> when filter cartridge <NUM> is inserted within sump <NUM> and connected to manifold <NUM>. Thread <NUM> may be a "Z-thread" and is threaded to allow for <NUM>-degree rotation of the filter cartridge <NUM> from a first, unlocked position to a second, locked position, as shown in <FIG>. It should be understood by those skilled in the art that alignment thread <NUM> is not limited to a "Z-thread" or other continuous, segmented path, and that otherwise-shaped continuous pathways or threads are within the scope of the invention so long as the thread functions to bring the correlated magnets <NUM>, <NUM> within an effective working distance as the filter cartridge is inserted within the sump. As shown in <FIG> and <FIG>, a locking cover <NUM> may be connected to filter cartridge end cap <NUM> to aid in filter assembly installation. As the locking cover <NUM> is rotated, boss or lug <NUM> travels along alignment rail <NUM> to its end, pushing the filter cartridge axially downward (i.e., into the sump). As can be seen in <FIG>, this end rotational position of boss or lug <NUM> within alignment rail <NUM> places the filter cartridge <NUM> and filter magnet <NUM> in an alignment position for filtering operation. In the embodiment shown, locking cover <NUM> is rotatable about the longitudinal axis of the sump, while the filter cartridge translates axially and does not rotate; however, it should be understood by those skilled in the art that in other embodiments, end cap <NUM> and locking cover <NUM> may be one molded piece rather than two connected structures, such that the filter cartridge rotates into the alignment position. In still other embodiments, the filter assembly does not include a locking cover and the filter cartridge end cap includes a boss or lug radially disposed on an outer surface thereof for being received in an alignment channel or track of the manifold.

As further shown in <FIG>, and best seen in <FIG>, manifold <NUM> includes a correspondingly "keyed" or paired correlated magnet <NUM> positioned for alignment with filter magnet <NUM> when boss or lug <NUM> is at the end of alignment rail <NUM>. Magnet <NUM> is part of a switch assembly <NUM> for actuating a downstream valve. As shown in <FIG>, switch assembly <NUM> is disposed within mounting bracket <NUM> and comprises magnet <NUM>, spring <NUM> and actuator <NUM> mechanically linked to a set of contacts for limit switch <NUM>. Magnet <NUM> is non-rotatable but slidable linearly within magnet housing or holder <NUM> in a direction normal to the longitudinal axis of the sump. Holder <NUM> with magnet <NUM> is operably coupled with limit switch <NUM>, which is normally biased in the closed position by spring <NUM>.

When filter magnet <NUM> and manifold magnet <NUM> are in alignment and brought into an effective working distance, as shown in <FIG>, the result is a repulsion force between the two magnets. The force curves of the spring <NUM> and magnet couple <NUM>, <NUM> are engineered such that at peak efficacy, there is sufficient magnetic repulsion force to overcome the spring force of the switch, compressing the spring in the direction of the arrow, as shown in <FIG>, and causing holder <NUM> to come into contact with actuator <NUM> to make the electrical connection to activate limit switch <NUM>. When the spring is fully depressed, limit switch <NUM> is activated, which in turn actuates a valve (not shown), allowing for the flow of water. In one embodiment, as best seen in <FIG>, when the filter cartridge <NUM> is in the INSTALLED-LOCKED position, filter magnet <NUM> and manifold magnet <NUM> are in an effective working distance of approximately <NUM>. Disposed between the magnets when the filter cartridge is connected to the manifold is a portion of sump <NUM>, which prevents contact between magnets <NUM>, <NUM> while still allowing for magnetic cooperation. Sump <NUM> is a molded piece of the filter manifold and acts as the pressure vessel for the filter cartridge, which is typically a plastic filter housing surrounding the filter media. The lack of a pressure bearing filter housing on the replaceable filter cartridge reduces the amount of plastic needed during manufacture of the filter cartridge and promotes "green" filtering. In an embodiment, filter cartridge <NUM> may include a sheath or other thin material layer comprising the filter cartridge "body," shown in <FIG> as polyethylene dry change sleeve <NUM>, surrounding the filter media (which cannot absorb pressure) and is intended to allow for removal and replacement of the filter cartridge from the manifold by a user without contacting the wet filter media.

As further shown in <FIG>, in an embodiment, spring <NUM> requires an additional <NUM> of travel to activate the limit switch <NUM>, and therefore the paired correlated magnets <NUM>, <NUM> are adapted to produce sufficient magnetic repulsion force for a distance of approximately <NUM>. Providing a magnetic repulsion force sufficient to double the required distance will safely accommodate design and manufacturing tolerances, and ensure switch activation. In that correlated magnets are characterized by dense and tunable magnetic fields, it is possible to specifically engineer force curves with higher force at shorter working distances. A conventional magnet would be unable to produce sufficient magnetic force over such a short effective distance without significantly increasing the physical size of the magnet, which would present design feasibility issues. It should be understood by those skilled in the art that for physically small magnets like those used in the present invention, correlated magnets are preferable because of the strength advantage attainable at very short working distances. It should be further understood by those skilled in the art that <NUM> is shown as an effective working distance between the magnets for exemplary purposes only, and that in other embodiments the effective working distance may be shorter than <NUM>, in accordance with design requirements. An effective working distance of greater than <NUM> is also achievable.

In addition to providing the initial drive to engage downstream system functionality, the magnetic communication between the filter and manifold magnets <NUM>, <NUM> has the added benefit of providing filter authentication and anti-counterfeiting measures. Unless the polarity arrays or patterns of the correlated magnets <NUM>, <NUM> are correspondingly "keyed" or paired, the magnetic communication will not actuate the switch assembly <NUM> and therefore the valve will not open to allow for water flow. As such, only a genuine OEM filter cartridge will function and a non-OEM or counterfeit filter cartridge will be non-operational. This also limits the counterfeiting market, which is especially important with respect to the safety of consumers seeking clean drinking water who believe that they may be able to save money by purchasing a non-authentic replacement filter cartridge which mechanically may connect to a mating manifold, but may nonetheless not have an enclosed filter media which is as effective for removal of contaminants or impurities in water as that of the filter media of a genuine replacement part.

In other embodiments, the magnetic communication between the filter and manifold magnets can be used for enhanced mechanical filter authentication purposes, such as to move a blocking mechanism which normally prevents insertion of a filter cartridge in a manifold, or to actuate an attachment or latch mechanism for the filter cartridge.

One such use is shown in <FIG>, inclusive, showing a translatable, resilient blocking mechanism or position stop which prevents insertion and/or attachment of a filter cartridge into a corresponding manifold. During installation, the filter cartridge may be guided by securing lugs or treads on the cartridge into a corresponding alignment track on the filter manifold. A blocking mechanism or position stop and manifold magnet integral with or mounted thereon are normally biased in a closed position by a spring to block the alignment track and prevent insertion of a filter cartridge, but are linearly or radially translatable about the filter manifold to allow for attachment of the cartridge. A corresponding polymagnet is disposed on the filter cartridge, such that when the filter cartridge is inserted into the alignment track on the filter manifold, the "keyed" polymagnets become aligned when in proximity (in-phase generating a repulsion or shear force), resulting in a force strong enough to overcome the spring force and causing the blocking mechanism or position stop to be moved to the open position and allowing the securing threads on the filter cartridge to pass by, thus permitting attachment of the filter cartridge to the manifold.

As shown in <FIG>, filter cartridge <NUM> includes a body <NUM> having an axial length and a top surface <NUM> about which annular collar <NUM> is circumferentially located. Internal cavity <NUM> includes a filter media (not shown, for clarity) for filtering fluid received from the manifold <NUM>. Securing lugs or threads <NUM> extend from annular collar <NUM>, and as shown in the Figures, may comprise radially-positioned, upwardly-extending ramped segments for rotational interconnection with manifold <NUM> upon initial axial insertion of the filter cartridge. Annular collar <NUM> further includes an axially upwardly-extending portion comprising a tab or magnetic structure <NUM> integral with and off axial center of the filter housing body, within which coded polymagnet <NUM> is disposed. Polymagnet <NUM> may be a correlated magnet as described herein, having a plurality of magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of the magnetic field emission sources. In the embodiment shown, magnetic structure <NUM> with magnet <NUM> embedded therein extends parallel to the longitudinal axis of the filter cartridge body <NUM> and has a radially outwardly-facing surface <NUM> that extends at least no further than an outward most radial extension of securing lugs or threads <NUM>, and in the embodiment shown, extends no further than the outside wall <NUM> of annular collar <NUM>, so as to not interfere with rotation of the filter cartridge upon interconnection with the mating manifold.

<FIG> show various views of the mating manifold <NUM>. As best seen in <FIG>, manifold <NUM> may include an internal cavity or sump <NUM> having a channel <NUM> proximate the inner cavity on an inner surface thereof representing an alignment track for filter cartridge <NUM>. Channel or track <NUM> receives securing lugs or threads <NUM> extending from annular collar <NUM> of filter cartridge <NUM>. Manifold <NUM> further includes a biased position stop or blocking mechanism <NUM> in the form of a linearly-translatable magnet shuttle within which a correspondingly "keyed" coded polymagnet <NUM> is disposed. Magnet <NUM> includes a plurality of complementary magnetic field emission sources having positions and polarities relating to a predefined spatial force function, such that a magnetic repulsion force is generated when magnet <NUM> is brought within close proximity of magnet <NUM> during filter interconnection. Position stop <NUM> is non-rotatable but translatable linearly in a radial direction, i.e., perpendicular to the longitudinal axis of the manifold <NUM>. Resilient blocking mechanism <NUM> is normally biased by spring <NUM> to at least partially extend within the sump channel <NUM>, such that filter cartridge alignment lug or thread <NUM> contacts a side surface of position <NUM> as the filter cartridge <NUM> is axially inserted into the manifold and rotated toward an INSTALLED position, preventing proper installation. Manifold <NUM> has fluid ingress and egress ports <NUM>, <NUM> which allow incoming fluid to be received by the manifold, flow into filter cartridge <NUM>, and receive filtered fluid from the filter cartridge. Lugs or threads <NUM> secure filter cartridge <NUM> to manifold <NUM> upon rotation against pressurized fluid flow. A locking mechanism may also be employed to secure further the filter cartridge from reverse rotation.

As shown in <FIG>, lugs or threads <NUM> are shown extending radially outwards from an outside wall of annular collar <NUM>. It is also possible to have receiving apertures and/or receiving threaded grooves on the outside wall of the annular collar <NUM> to receive lugs or threads on the manifold. Tab or magnetic structure <NUM> is shown extending axially upwards from annular collar <NUM> and radially outwards at least less than the outward most radial extension of lugs <NUM>, and preferably no further radially outwards than the outside wall of annular collar <NUM>, such that tab <NUM> does not interfere with the rotation of the filter cartridge within the receiving manifold. It is also possible for tab <NUM> to be form-fit within the annular collar or on the inside wall of the annular collar, and it need not extend axially upwards from the annular collar. The necessary condition for attachment is that there is magnetic communication between the polymagnet located on the filter cartridge and the complementary polymagnet located on the manifold.

<FIG> depict an exemplary method of interconnection of filter cartridge <NUM> to manifold <NUM>. As shown in the Figures, a portion of the outer wall of the manifold has been partially cutaway to more clearly depict the movement of the resilient blocking mechanism as the filter cartridge is moved toward the INSTALLED position. <FIG> shows the filter cartridge <NUM> prior to axial insertion within sump <NUM> of manifold <NUM>. Alignment lugs or threads <NUM> are positioned for receipt within alignment channel <NUM> of the manifold <NUM>, such that upon rotation, cartridge <NUM> is urged into sump <NUM> in the direction of arrow <NUM>.

As best seen in <FIG>, during rotation of filter cartridge <NUM> in the direction of arrow <NUM>, magnet <NUM> is positioned for alignment in close proximity with filter cartridge magnet <NUM> when thread <NUM> approaches the end of the sump alignment channel <NUM>. When filter magnet <NUM> and manifold magnet <NUM> are in alignment and brought into an effective working distance, the result is a repulsion force between the two magnets. The polymagnets are correspondingly coded, such that the polymagnets generate a repulsion force to cause blocking mechanism <NUM> and manifold magnet <NUM> to move radially (with respect to the longitudinal axis of the sump) into recess <NUM> and out of the path of filter cartridge radial thread <NUM>, shown in the direction of arrow <NUM> (<FIG>). Position stop <NUM> is normally biased in an extended position by spring <NUM>, such as a coil spring, disposed within recess <NUM>, such that when filter magnet <NUM> and manifold magnet <NUM> are in alignment, the repulsion force generated is sufficient to overcome the spring force and compress spring <NUM>, thus retracting position stop <NUM> and clearing a path for lugs <NUM> to complete rotation of filter cartridge <NUM>.

When the filter cartridge is in an INSTALLED position, as shown in <FIG>, the outer surface of annular collar <NUM> is in contact with blocking mechanism <NUM> to maintain the blocking mechanism in a retracted position, such that when the filter cartridge is rotated in an opposite direction and removed, spring <NUM> is permitted to extend as thread <NUM> passes by.

Only filter cartridges including a "coded" polymagnet having a pre-designed or predetermined polarity profile which corresponds to that of the polymagnet in the filter manifold will operate correctly, i.e., remove blocking mechanism <NUM> to allow for filter cartridge installation. Therefore, only genuine replacement filter cartridges from the manufacturer or its licensee will be authenticated. This limits the counterfeiting market, which is especially important with respect to the safety of consumers who believe that they may be able to save money by purchasing a non-authentic replacement filter cartridge which mechanically may connect to a mating manifold, but may nonetheless not have an enclosed filter media which is as effective for removal of contaminants or impurities in water as that of the filter media of a genuine replacement part.

In still another embodiment, as shown in <FIG>, inclusive, the magnetic force generated by the coded polymagnets is used to actuate a latch mechanism for the filter cartridge as the cartridge is inserted into a mating filter manifold. Enhanced filter authentication is achieved in that a non-OEM filter cartridge would not include the required complementary correlated magnetic structure to generate sufficient magnetic force and thus would be unable to actuate the latch mechanism to secure the filter cartridge against pressurized fluid flow.

As best seen in <FIG>, a latch <NUM> is attached to or at least partially-integral with the filter manifold <NUM> via axially-extending supports <NUM>, <NUM> coupled to a pin or shaft extending transversely between opposing sides of the latch and is normally biased in a first, open position to allow a filter cartridge to be inserted within the sump. Latch <NUM> is pivotable about a first pivot axis or shaft <NUM> extending transversely between supports <NUM>, <NUM> to allow for attachment of the cartridge. In the embodiment shown, latch <NUM> extends substantially upwards, off-axial center of the manifold <NUM> adjacent fluid ingress and egress stanchions <NUM>, <NUM>, and includes a first magnetic structure comprising a coded polymagnet <NUM> disposed therein and having a surface <NUM> facing inward in the direction of stanchions <NUM>, <NUM> (<FIG>, <FIG>). Magnet <NUM> may be a correlated magnet having a plurality of magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of the magnetic field emission sources. As shown in at least <FIG>, proximate the first magnetic structure <NUM> at an upper portion of the latch is a projection or protrusion <NUM> which is adapted to mate with a corresponding notch or cutout <NUM> in filter head <NUM> when the filter cartridge is inserted into the manifold and the latch is in the closed, latching position. Latch <NUM> is normally biased in a first, open position by return spring <NUM>, or any other suitable resilient member such as a rubber grommet, torsion spring or any other form known in the art.

As shown in <FIG>, filter head <NUM> includes fluid ingress and egress ports <NUM>, <NUM> for insertion into ingress and egress stanchions <NUM>, <NUM> of the mating manifold, and a magnetic structure or tab <NUM> extending from a top surface <NUM> of the filter head, radially offset from ports <NUM>, <NUM> and extending parallel to the longitudinal axis of the filter cartridge body. Disposed within tab <NUM> is a second, corresponding polymagnet <NUM> having a radially outwardly-facing surface that presents in a direction away from a center axis of the filter head so as to be in close proximity with the latch when the filter cartridge moves toward the INSTALLED position. Polymagnet <NUM> has a plurality of complementary magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of the magnetic field emission sources, such that when the filter cartridge is inserted into the manifold <NUM>, as shown in <FIG>, the "keyed" polymagnets <NUM>, <NUM> become aligned when in proximity (in-phase generating a repulsion force), and causing the latch <NUM> to pivot about pivot axis <NUM> to the second, latching position in the direction of arrow <NUM>, overcoming the force of return spring <NUM> and thereby causing the latch protrusion <NUM> to extend into filter head notch or cutout <NUM> proximate polymagnet <NUM>, locking the filter cartridge in an INSTALLED position against pressurized fluid flow.

To remove the filter cartridge, as best seen in <FIG>, a latch release button <NUM> is manually actuable by an end user in the direction of the center axis of the manifold (direction of actuation is shown by arrow <NUM>), overcoming the magnetic repulsion force between magnets <NUM>, <NUM> to compress the return spring <NUM> and causing latch <NUM> to pivot about pivot point <NUM> in an opposite direction toward the first, open position and thereby pulling latch protrusion <NUM> away from the filter head <NUM> and notch <NUM>, and allowing for removal of the filter cartridge. As the filter cartridge is removed, magnets <NUM>, <NUM> move out of phase, decreasing the repulsion force and permitting latch <NUM> to be reset to the biased, open position by spring <NUM>.

In that correlated magnets are characterized by dense and tunable magnetic fields, it is possible to specifically engineer force curves with higher force at shorter working distances, such as those shown in <FIG>. A conventional magnet would be unable to produce sufficient magnetic repulsion force over such a short effective distance without significantly increasing the physical size of the magnet, which would present design feasibility issues. Only filter cartridges including a "coded" polymagnet having a pre-designed or predetermined polarity profile which corresponds to that of the polymagnet in the filter manifold will operate correctly, i.e., generate a sufficient repulsion force to pivot the latch into a locked position to secure the filter cartridge. Unless the polarity arrays or patterns of the correlated magnets are correspondingly "keyed", the magnetic communication will not actuate the latch. As such, only a genuine OEM filter cartridge will function and a non-OEM or counterfeit filter cartridge will be non-operational. While the embodiment of the present invention shown herein depicts a pivotal movement of the latch, other means of engaging the latch are not precluded, such as by translational means.

In yet another embodiment, as shown in <FIG>, inclusive, the magnetic force generated by the coded polymagnets is used to actuate a bypass valve as the filter cartridge is inserted into a mating filter manifold, allowing for filtered egress fluid flow. As best seen in <FIG>, filter manifold <NUM> includes fluid ingress and egress stanchions <NUM>, <NUM> with a bypass valve <NUM> disposed therebetween for permitting fluid to flow transversely between the stanchions without passing through (thus, bypassing) the filter cartridge, as shown in <FIG>. Bypass valve <NUM> includes a coded polymagnet <NUM> (i.e., bypass magnet) connected to or disposed therein, for aligning with a mating or paired polymagnet disposed in or on a filter cartridge during installation. The magnets have a plurality of complementary magnetic field emission sources having positions and polarities relating to a predefined spatial force function that corresponds to a predetermined alignment of the magnetic field emission sources, such that a magnetic repulsion force is generated when the magnets are in close proximity. When no filter cartridge is installed, or a non-OEM or counterfeit filter cartridge (without the corresponding mating or paired polymagnet) is installed, the bypass valve will remain in a biased open or "home" position, allowing fluid ingress to flow directly through aperture <NUM> formed in bypass valve <NUM> between ingress stanchion <NUM> and egress stanchion <NUM> (<FIG> and <FIG>). In this manner, a user will still be able to access unfiltered water. Bypass valve <NUM> is actuable in an axial direction upon axial insertion of a filter cartridge having a mating or paired polymagnet into an alignment position, against the force of valve or bypass spring <NUM> or similar resilient member which normally biases the bypass valve into the "home" position.

As seen <FIG>, filter head <NUM> includes fluid ingress and egress ports <NUM>, <NUM> for insertion into manifold ingress and egress stanchions <NUM>, <NUM>, and disposed between the ports and approximately axially-centered is a second, corresponding coded polymagnet <NUM> (i.e., filter magnet) embedded in a top surface <NUM> of the filter head. It should be understood by those skilled in the art that filter head <NUM> is integral with or connected to a filter cartridge (not shown, for clarity) having a body and forms a fluid tight seal with the filter cartridge body. When the filter cartridge is inserted into the sump, as shown in <FIG>, the "keyed" polymagnets become aligned when in proximity (in-phase generating a repulsion force), causing the bypass valve <NUM> to actuate to a second, closed position in the direction of arrow <NUM>, overcoming the force of valve spring <NUM>. As valve <NUM> is pushed against resilient spring <NUM>, aperture <NUM> (formed in valve <NUM>) shifts away from channel <NUM>, thus closing channel <NUM> to water flow. With the bypass valve in a closed position, channel <NUM> is completely cut off by valve <NUM> and thus the ingress fluid flow path is altered, as shown by arrow <NUM> in <FIG>, such that the fluid flows through ingress stanchion <NUM> and port <NUM>, through filter media (not shown) in the filter cartridge, and filtered fluid flows back out of the filter cartridge through egress port <NUM> and egress stanchion <NUM>.

<FIG> depict an exemplary embodiment of a method of installation of a filter cartridge to actuate a bypass valve in accordance with the present invention. The filter head and filter manifold are shown in partial cross-section to more clearly depict the positions of the corresponding polymagnets <NUM>, <NUM>, bypass valve <NUM> and bypass spring <NUM>, respectively, as the filter cartridge is moved toward an INSTALLED position. As shown in <FIG>, prior to filter cartridge installation, bypass magnet <NUM> is in a biased "home" position, and the valve is in bypass mode. As the filter cartridge is inserted into the sump and the "keyed" polymagnets become aligned when in proximity, as shown in <FIG>, the bypass magnet <NUM> begins to repel in the direction of the filter manifold as a result of the magnetic repulsion force between the magnets <NUM>, <NUM> becoming sufficient to overcome the force of valve spring <NUM>, and the valve <NUM> starts to block the bypass. When the filter cartridge is in a fully-installed position, as shown in <FIG>, bypass valve <NUM> has actuated to the second, closed position, thereby completely blocking the bypass and allowing fluid to flow through the filter cartridge.

In one or more embodiments, manifold <NUM> may include a translatable position stop blocking axial motion of bypass valve <NUM>, such that the valve cannot be manually depressed by a protruding portion of a non-OEM filter cartridge. In such an embodiment, the position stop may be translatable such as through a magnetic shear force generated between the existing (or additional) coded polymagnet pairs.

Thus, the present invention achieves one or more of the following advantages. The present invention provides an improved filter interconnect which utilizes correlated magnetism to provide the initial drive to engage downstream system functionality, allowing for a higher degree of control and flexibility over the timing and actuation of downstream system function. By utilizing magnetic repulsion, the present invention further allows for non-electronic and non-contacting actuation of a downstream electronic system, which overcomes the technical hurdles of using electronic interconnects of the prior art which present issues of fluid reaching the electronic components, and provides an improved filter interconnect which prevents leaking by dissociating the initial filter cartridge installation from the actuation of an upstream and/or downstream valve. The present invention further has applications in alternate methods of filter authentication and anti-counterfeiting.

In the embodiments described above, a magnetic repulsion force is generated when a set of "keyed" or coded polymagnets are aligned and brought into an effective working distance, which results, in some instances, in the movement and removal of a blocking mechanism or position stop which normally prevents a filter cartridge from being secured within a manifold sump.

In that correlated magnets are characterized by dense and tunable magnetic fields; it is possible to specifically engineer force curves with higher force at shorter working distances. A conventional magnet would be unable to produce sufficient magnetic repulsion force over such a short effective working distance without significantly increasing the physical size of the magnet, which would present design feasibility issues. Alignment polymagnets, such as those of the present invention, allow for attraction and repel forces to combine at polarity transitions to partially cancel normal forces and create stronger forces over shorter linear offset distances.

Another advantage of the present invention is that by utilizing corresponding coded or "keyed" polymagnets with specifically-engineered magnetic fields, the present invention further has applications in alternate methods of filter cartridge authentication and counterfeiting prevention. Only filter cartridges including a "coded" polymagnet having a pre-designed or predetermined polarity profile which corresponds to that of the polymagnet in the filter manifold will operate correctly, such as removing a blocking mechanism to allow for filter cartridge installation. Therefore, only genuine replacement filter cartridges from the manufacturer or its licensee can be authenticated. This limits the counterfeiting market, which is especially important with respect to the safety of consumers who unbeknownst to them, may purchase inferior filter cartridges which would otherwise attach to the manifold, and such replacement filter cartridges can no longer be secured to the manifold sump. This safety mechanism ensures the use of an enclosed filter media which is effective for removal of contaminants or impurities in water.

Claim 1:
A filter interconnect, comprising:
a filter manifold (<NUM>) having ingress and egress fluid ports (<NUM>, <NUM>), a sump having an inner cavity (<NUM>) receiving a mating filter cartridge (<NUM>), an upwardly-extending alignment channel (<NUM>) proximate the sump inner cavity, and a resilient blocking mechanism (<NUM>) at least partially extending within the alignment channel when in a biased position and comprising a first correlated magnetic structure (<NUM>) disposed therein, the blocking mechanism (<NUM>) movable in a first direction (<NUM>) to a retracted position in response to a magnetic repulsion force generated when a complementary or paired second correlated magnetic structure (<NUM>) is positioned within close proximity to the first magnetic structure; and
said mating filter cartridge (<NUM>), comprising:
a housing having a body (<NUM>), a top surface (<NUM>), an axial length, and an internal cavity (<NUM>); and
an annular collar (<NUM>) circumferentially located about the housing top surface (<NUM>) and having an outer wall (<NUM>), the annular collar including securing lugs or threads (<NUM>) extending radially outwards from the annular collar outer wall; and said complementary or paired second correlated magnetic structure (<NUM>) located on or within the annular collar and having a radially outwardly-facing surface (<NUM>) that extends at least no further than an outward most radial extension of the securing lugs or threads;
wherein upon movement of the mating filter cartridge (<NUM>) in a second direction (<NUM>) to an alignment position within the filter manifold sump, the first and second correlated magnetic structures (<NUM>, <NUM>) are within close proximity to one another such that the magnetic repulsion force is generated, the magnetic repulsion force causing the blocking mechanism (<NUM>) to move to the retracted position and allowing the securing lugs or threads (<NUM>) to continue moving in the second direction to complete attachment of the filter cartridge to the filter manifold.