Patent Description:
Correlated magnet designs were introduced in <CIT>, entitled "FIELD EMISSION SYSTEM AND METHOD. " 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 function.

In <CIT>, titled "APPARATUS AND METHODS RELATING TO PRECISION ATTACHMENTS BETWEEN FIRST AND SECOND COMPONENTS (a related patent to <CIT>), 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 or repulsion 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 field emissions sources of correlated magnets to be varied in accordance with a "code", such that magnetic systems can be made to have a desired behavior without mechanical constraint, or 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.

A description of the precision alignments of polymagnets can be found at:
http://www. polymagnet. com/media/Polymagnet-White-Paper-<NUM>-Smart-Magnets-for-Precision-Alignment.

Prior art filter interconnects present numerous technical hurdles, particularly with respect to downstream electronic functionality. Such technical hurdles include preventing fluid from leaking into or reaching the electronic components of the filter housing either during initial filter cartridge installation or during operation.

<CIT> teaches a filter system comprising a filter housing for receiving a filter element and including a housing pot and a housing cover for releasably closing the housing pot, a magnetic cover lock, and a control device by means of which the magnetic cover lock can be activated and deactivated.

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 with downstream electronic functionality.

As described herein, the correlated magnet technology has a variety of implementations in filter interconnect structures, including, for example, in actuation of valves or switches, as well as in improved filter authentication and anti-counterfeiting measures.

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 utilizes correlated magnetism to provide the initial drive to engage downstream system functionality.

It is yet 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.

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 filtration system comprising a filter manifold including a sump, an electronic switch assembly comprising a switch actuable between open and closed positions, the switch assembly radially disposed with respect to the sump, and a correlated magnet operably coupled to the switch assembly. The correlated magnet comprises 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 plurality of magnetic field emission sources. The filtration system further comprises a filter cartridge including a filter media, first and second end caps sealed to the filter media, a body disposed between the first and second end caps and surrounding the filter media, and a complementary or paired correlated magnet radially disposed on one of the first or second end caps proximate an outside surface of the filter cartridge body. In an embodiment, one of the filter cartridge first or second end caps includes an axially-extending portion integral with or connected thereto and proximate the outside surface of the filter cartridge body, and the correlated magnet of the filter cartridge is disposed within the axially-extending portion.

The correlated magnets are interconnected via magnetic communication upon insertion of the filter cartridge into the sump housing, and upon movement of the filter cartridge into an alignment position, the correlated magnet of the filter manifold translates transversely with respect to a longitudinal axis of the sump as a result of the magnetic communication to contact an actuator to activate the switch. In at least one embodiment, the manifold further includes a valve, wherein activation of the switch actuates the valve to turn on and turn off fluid flow to the filter cartridge.

In an embodiment, the plurality of magnetic field emission sources of the correlated magnet of the filter manifold are aligned with a plurality of magnetic field emission sources of the correlated magnet of the filter cartridge, such that a repulsion force is generated between the magnets when the filter cartridge is inserted within the sump and rotated to the alignment position.

The sump may include an alignment thread or channel for mechanically coupling with a filter boss or lug extending radially outwards from one of the first or second end caps when the filter cartridge is inserted within the sump and rotated to the alignment position. In an embodiment, the filter cartridge rotates approximately <NUM>-degrees in a first direction from an initial insertion position within the sump to the alignment position.

The filtration system may further include a radially-extending locking plate including an aperture for permitting insertion of the filter cartridge into the sump, the locking plate including an alignment thread or channel for mechanically coupling with a boss or lug of a removable locking cover when the filter cartridge is inserted within the sump. The locking cover is rotatable about the longitudinal axis of the sump to translate the filter cartridge axially into the alignment position.

In an embodiment, the correlated magnet of the filter manifold is disposed within a translatable magnet housing of the switch assembly, the magnet housing normally biased towards the longitudinal axis of the sump by a spring and slidable linearly as a result of the magnetic communication in a direction normal to the longitudinal axis of the sump to contact the actuator to activate the switch upon movement of the filter cartridge into an alignment position.

In another aspect, the present invention is directed to a filter cartridge comprising a filter media, first and second end caps sealed to the filter media, a body disposed between the first and second end caps and surrounding the filter media, and a correlated magnet radially disposed on one of the first or second end caps proximate an outside surface of the filter cartridge body. One of the first or second end caps may include an axially-extending portion integral with or connected thereto and proximate the outside surface of the body, and the correlated magnet may be disposed within the axially-extending portion. The correlated magnet comprises 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 plurality of magnetic field emission sources. The correlated magnet of the filter cartridge is adapted to be in close proximity to a complementary or paired correlated magnet of a mating filter manifold when the filter cartridge is inserted within a sump of the filter manifold and moved into an alignment position.

The filter cartridge body may further include a sheath or sleeve covering the filter media and disposed between the first and second end caps. In an embodiment, the filter cartridge may further include a filter boss or lug extending radially outwards from one of the first or second end caps, the filter boss or lug adapted for mechanically coupling with an alignment thread or channel of the sump housing as the filter cartridge is rotated to the alignment position.

For interconnecting a filter cartridge and filter manifold, the following steps are performed: inserting the filter cartridge comprising a correlated magnet radially disposed on one of the first or second end caps proximate an outside surface of the filter cartridge body as described above into a sump of the filter manifold; moving the filter cartridge within the sump into an alignment position; aligning the plurality of magnetic field emission sources of the correlated magnet of the filter cartridge with a plurality of magnetic field emission sources of a complementary or paired correlated magnet of the filter manifold such that a repulsion force is generated between the magnets, the correlated magnet of the filter manifold operably coupled to a switch assembly radially disposed with respect to the sump; and causing the correlated magnet of the filter manifold to translate transversely with respect to a longitudinal axis of the sump as a result of magnetic repulsion to contact an actuator to activate the switch.

The sump may include an alignment thread. or channel for mechanically coupling with a filter boss or lug extending radially outwards from one of the first or second end caps, and the method may further comprise the steps of: aligning the filter boss or lug with the alignment thread or channel while inserting the filter cartridge within the sump, and causing the filter boss or lug to travel to an end of the alignment thread or channel while rotating the filter cartridge to the alignment position.

In an embodiment, the filter manifold may further include a radially-extending locking plate including an aperture for permitting insertion of the filter cartridge into the sump, the locking plate including an alignment thread or channel for mechanically coupling with a boss or lug of a removable locking cover when the filter cartridge is inserted within the sump, the locking cover rotatable about the longitudinal axis of the sump to translate the filter cartridge axially into the alignment position, and the method may further include the steps of: aligning the locking cover boss or lug with the locking plate alignment thread or channel while inserting the filter cartridge within the sump; and rotating the locking cover to cause the boss or lug to travel to an end of the alignment thread or channel to move filter cartridge to the alignment position.

In another unclaimed aspect, the present invention is directed to a filtration system comprising a filter manifold including a sump, an electronic switch assembly comprising a circuit actuable between open and closed positions, the switch assembly axially disposed with respect to the sump, and a first correlated magnet operably coupled to the switch assembly, the first correlated magnet comprising 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 plurality of magnetic field emission sources. The filtration system further comprises a filter cartridge including a housing having a body, a filter media disposed with the housing body, a filter head forming a fluid-tight seal with the body, and a complementary or paired second correlated magnet disposed within or connected to the filter head and having a face oriented parallel to a top surface thereof, the second correlated magnet rotatable with the filter cartridge. In an embodiment, the filter cartridge further includes an axial stem and the second correlated magnet is disposed within the axial stem, parallel to the top surface of the filter head. The first and second correlated polymagnets are interconnected via magnetic communication upon insertion of the filter cartridge into the sump housing, and upon rotation of the filter cartridge into an alignment position, the first correlated magnet translates axially with respect to a longitudinal axis of the sump as a result of the magnetic communication to contact an actuator to activate the switch. In at least one embodiment, the manifold further includes a valve, wherein activation of the switch actuates the valve to turn on and turn off fluid flow to the filter cartridge.

In an embodiment, the first correlated magnet plurality of magnetic field emission sources are aligned with a plurality of magnetic field emission sources of the second correlated magnet, such that a repulsion force is generated between the magnets when the filter cartridge is inserted within the sump and rotated to the alignment position.

The sump may further include an alignment thread or channel for mechanically coupling with a filter boss or lug extending radially outwards from the filter cartridge housing body when the filter cartridge is inserted within the sump and rotated to the alignment position. In an embodiment, the filter cartridge rotates approximately <NUM>-degrees in a first direction from an initial insertion position within the sump to the alignment position.

In an embodiment, the first correlated magnet is disposed within a translatable magnet holder of the switch assembly, the magnet holder normally biased towards the filter head by a spring and slidable axially along the longitudinal axis of the sump as a result of the magnetic communication to contact the actuator to activate the switch upon rotation of the filter cartridge into an alignment position.

In another unclaimed aspect, the present invention is directed to a filtration system comprising a filter manifold including a sump, an electronic switch assembly comprising a circuit actuable between open and closed positions, the switch assembly axially disposed with respect to the sump, and a first correlated magnet operably coupled to the switch assembly, the first correlated magnet comprising 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 plurality of magnetic field emission sources. The filtration system further comprises a filter cartridge including a housing having a body, a filter media disposed with the housing body, a filter head forming a fluid-tight seal with the body, and a complementary or paired second correlated magnet disposed within or connected to the filter head and having a face oriented parallel to a top surface thereof. The first correlated magnet plurality of magnetic field emission sources are aligned with a plurality of magnetic field emission sources of the second correlated magnet such that a repulsion force is generated between the magnets when the filter cartridge is inserted within the sump and translated axially to an alignment position, and upon axial movement of the filter cartridge into the alignment position, the first correlated magnet translates axially with respect to a longitudinal axis of the sump as a result of the magnetic repulsion to contact an actuator to activate the switch.

In an embodiment, the first and second correlated magnet plurality of magnetic field emission sources are arranged concentrically.

In yet another unclaimed aspect, the present invention is directed to a filter cartridge comprising a housing having a body, a filter media disposed within the housing body, a filter head forming a fluid-tight seal with the body, and a first correlated magnet disposed within or connected to the filter head and having a face oriented parallel to a top surface thereof. In an embodiment, the filter cartridge further includes an axial stem and the first correlated magnet is disposed in the axial stem, parallel to the top surface of the filter head. The first correlated magnet comprises 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 plurality of magnetic field emission sources. The first correlated magnet is adapted to be in close proximity to a complementary or paired second correlated magnet when the filter cartridge is inserted within a sump of a filter manifold and rotated into an alignment position.

The filter cartridge may further include a filter boss or lug extending radially from the housing body, the filter boss or lug adapted for mechanically coupling with an alignment thread or channel of the sump.

In still another unclaimed aspect, the present invention is directed to a method of interconnecting a filter cartridge and filter manifold, comprising: inserting a filter cartridge comprising a correlated magnet disposed within or connected to the filter head and having a face oriented parallel to a top surface thereof, as described above, into a sump of the filter manifold; rotating the filter cartridge within the sump into an alignment position; aligning the first correlated magnet plurality of magnetic field emission sources with a plurality of magnetic field emission sources of a complementary or paired second correlated magnet such that a repulsion force is generated between the magnets, the second correlated magnet operably coupled to a switch assembly axially disposed with respect to the sump; and causing the second correlated magnet to translate axially with respect to a longitudinal axis of the sump as a result of magnetic repulsion to contact an actuator to activate the switch.

The sump may further include an alignment thread or channel for mechanically coupling with a filter boss or lug extending radially outwards from the filter cartridge housing body, and the method may further comprise the steps of: aligning the filter boss or lug with the alignment thread or channel while inserting the filter cartridge within the sump; and causing the filter boss or lug to travel to an end of the alignment thread or channel while rotating the filter cartridge to the alignment position.

In still yet another unclaimed aspect, the present invention is directed to a filtration system comprising a filter manifold including a sump, an electronic switch assembly comprising a circuit actuable between open and closed positions, the switch assembly radially disposed with respect to the sump, and a first correlated magnet operably coupled to the switch assembly, the first correlated magnet comprising 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 plurality of magnetic field emission sources. The filtration system further comprises a filter cartridge including a housing having a body and a top portion forming a fluid-tight seal with the body, the top portion including ingress and egress fluid ports and an axially-extending protrusion integral with or connected to the housing top portion, a filter media disposed with the housing body, and a complementary or paired second correlated magnet disposed within or connected to the housing top portion axially-extending protrusion and having a face oriented parallel to a longitudinal axis of the housing body. The first and second correlated polymagnets are interconnected via magnetic communication upon axial insertion of the filter cartridge into an alignment position within the sump, and upon movement of the filter cartridge into the alignment position, the first correlated magnet translates in a direction normal to a longitudinal axis of the sump as a result of the magnetic communication to contact an actuator to activate the switch. In at least one embodiment, the manifold further includes a valve, wherein activation of the switch actuates the valve to turn on and turn off fluid flow to the filter cartridge.

In an embodiment, the first correlated magnet plurality of magnetic field emission sources are aligned with a plurality of magnetic field emission sources of the second correlated magnet, such that a repulsion force is generated between the magnets when the filter cartridge is axially inserted within the sump and moved to the alignment position.

The sump may further include an alignment thread or channel for mechanically coupling with a rib or fin extending radially outwards from the filter cartridge housing body when the filter cartridge is axially inserted within the sump.

In an embodiment, the first correlated magnet is disposed within a translatable magnet housing of the switch assembly, the magnet housing normally biased towards the longitudinal axis of the sump by a spring and slidable linearly as a result of the magnetic communication in a direction normal to the longitudinal axis of the sump to contact the actuator to activate the switch.

In still another unclaimed aspect, the present invention is directed to a filter cartridge, comprising a housing having a body and a top portion forming a fluid-tight seal with the body, the top portion including ingress and egress fluid ports, and an axially-extending protrusion integral with or connected to the housing top portion, a filter media disposed with the housing body, and a first correlated magnet disposed within or connected to the housing top portion axially-extending protrusion and having a face oriented parallel to a longitudinal axis of the housing body. In an embodiment, the axially-extending protrusion is off-axial center of the filter housing top portion. The first correlated magnet comprises 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 plurality of magnetic field emission sources. The first correlated magnet is adapted to be in close proximity to a complementary or paired second correlated magnet when the filter cartridge is axially inserted into an alignment position with a sump of a filter manifold.

In an embodiment, the filter cartridge further includes a rib or fin extending radially outwards from the housing body, the rib or fin adapted for mechanically coupling with an alignment thread or channel of the sump when the filter cartridge is axially inserted within the sump.

In still yet another unclaimed aspect, the present invention is directed to a method of interconnecting a filter cartridge and filter manifold, comprising: inserting a filter cartridge comprising a correlated magnet disposed within or connected to the housing top portion axially-extending protrusion and having a face oriented parallel to a longitudinal axis of the housing body, as described above, into a sump of the filter manifold; axially inserting the filter cartridge within the sump into an alignment position; aligning the first correlated magnet plurality of magnetic field emission sources with a plurality of magnetic field emission sources of a complementary or paired second correlated magnet such that a repulsion force is generated between the magnets, the second correlated magnet operably coupled to a switch assembly axially disposed with respect to the sump; and causing the second correlated magnet to translate in a direction normal to a longitudinal axis of the sump as a result of the magnetic communication to contact an actuator to activate the switch.

The sump may further include an alignment thread or channel for mechanically coupling with a rib or fin extending radially outwards from the filter cartridge housing body, and the method may further comprise the steps of: aligning the filter cartridge rib or fin with the alignment thread or channel while inserting the filter cartridge within the sump; and causing the filter cartridge rib or fin to travel to an end of the alignment thread or channel while axially inserting the filter cartridge to the alignment position.

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 autocorrelation 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 go-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 housing <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 housing <NUM> and connected to manifold <NUM>. Thread <NUM> may be a "Z-thread" and is threaded to allow for go-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 housing <NUM>, which prevents contact between magnets <NUM>, <NUM> while still allowing for magnetic cooperation. Sump housing <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 6o 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.

Referring now to <FIG>, collectively, another embodiment of the present invention is shown, wherein the polarity arrays or patterns of the correlated magnets are characterized by relative rotational-orientation specific force curves. <FIG> shows the filter interconnect in an UNINSTALLED position. Replaceable filter cartridge <NUM> comprises an otherwise conventional filter media disposed within filter housing body <NUM>. Filter cartridge <NUM> further includes an axial stem <NUM> and a first correlated magnet <NUM> disposed in the stem, parallel to the surface of the filter head <NUM> (<FIG>). Filter cartridge <NUM> is initially insertable within a sump <NUM> in manifold <NUM> into an INSTALLED-UNLOCKED position, wherein the O-rings are sealed but the downstream valve(s) are not open and water is not permitted to flow (<FIG>).

As shown in <FIG>, in this embodiment, the pair of correlated magnets are positioned parallel to the surface of the filter head and the mating surface of the manifold; respectively. The filter magnet <NUM> is fixed in place, while the mating "keyed" manifold magnet <NUM> is part of a switch assembly <NUM> for actuating a downstream valve (not shown) and is supported by a spring <NUM> but is prevented from rotating. As shown in <FIG>, switch assembly <NUM> comprises a second, paired correlated magnet <NUM> disposed within magnet holder or cap <NUM>, which is normally biased in an extended axial position (i.e., toward filter magnet <NUM>) by spring <NUM>. Disposed within spring <NUM> is limit switch <NUM>, which may be activated by actuator <NUM>, and switch <NUM> connected to PCB <NUM>. Base <NUM> completes the switch assembly.

As shown in <FIG>, PCB <NUM> may be connected to downstream system components, such as downstream valve(s), via lead wires.

The rotation of the filter during installation modulates the magnetic interaction from a region of net attraction/neutral to peak repulsion.

An alignment track or thread and associated filter boss system, comprising an alignment thread <NUM> on the manifold and a boss or lug <NUM> radially disposed on the filter cartridge housing <NUM>, may be incorporated to provide control over the timing of the filter-manifold magnet orientation and working distance. <FIG> depict one method of installation of filter cartridge <NUM> into manifold <NUM>. As shown in <FIG>, alignment thread <NUM> may be a "Z-thread" for receiving filter boss or lug <NUM> as filter cartridge <NUM> is rotated into an INSTALLED-LOCKED position. <FIG> shows filter cartridge <NUM> in an initial, uninstalled position. At position A, in the initial installation step, the thread or track system functions to bring the filter and manifold magnets <NUM>, <NUM> into an effective working distance and provides a mechanical advantage to seat the O-rings. At this relative orientation, the resulting magnetic force can be attractive, neutral or weakly-repulsive. As shown in the cross-sectional view of <FIG>, and also shown in <FIG>, at position A, magnets <NUM>, <NUM> are go-degrees out of phase or alignment.

At position B, as shown in <FIG>, the filter O-rings are fully seated and the correlated magnet pair are within an effective working distance, but approximately <NUM>-degrees out of phase. The relative orientation of the magnets enters a net repulsion region at approximately <NUM>-degrees from alignment; however, the magnetic repulsion force is not sufficient to overcome the opposing spring force and drive the correlated magnet-spring system. As shown in <FIG>, at position C, filter cartridge <NUM> is rotated into the INSTALLED-LOCKED position or state, and the correlated magnet pair continue to be within an effective working distance. However, the relative orientation of the magnets has now resulted in peak repulsion (i.e., the magnets are in phase), producing a repulsion force which is sufficient to drive the correlated magnet-spring system and actuate the intended downstream system function(s). As shown in <FIG>, the repulsion force between magnets <NUM>, <NUM> has caused magnet holder <NUM> to translate axially downward in the direction of the arrow, thereby compressing spring <NUM> and causing actuator <NUM> to activate limit switch <NUM>, thereby permitting intended downstream system function, such as actuation of a valve to allow filtered egress fluid flow.

In an embodiment, there may be a notch or detent at the end of the alignment thread to provide tactile feedback indicating successful installation of the filter cartridge.

The filter cartridge may be removed by reversing the actions described above and rotating the filter cartridge in the opposite direction, and extraction may be assisted by the magnetic repulsion force and the spring force. In at least one embodiment, there may be a dedicated exit track or rail which may exploit the net magnetic repulsion region to support extraction and removal of the filter cartridge.

<FIG> depicts the magnetic holding force as a function of rotation angle as the pair of correlated magnets are rotated within an effective working distance. As shown in <FIG>, in one embodiment the pair of correlated magnets are at an effective working distance of approximately <NUM> when the filter cartridge is in an INSTALLED-LOCKED position.

It should be understood by those skilled in the art that in other embodiments, the polarity arrays or patterns of the correlated magnets are not characterized by relative rotational-orientation specific force curves, and the repulsion force exists regardless of magnet orientation. In such an embodiment the magnet patterns may be concentric, for example, and would not require rotation of the filter cartridge and associated correlated magnet in the theta direction to align the polarity arrays between the paired magnets to produce the desired repulsion force.

Referring now to <FIG>, collectively, another embodiment of the filter cartridge and manifold of the present invention is shown. Filter cartridge <NUM> comprises a housing <NUM> having a body <NUM> and a top portion <NUM> forming a fluid-tight seal with the body. Top portion <NUM> includes fluid ingress and egress ports <NUM>, <NUM>. An otherwise conventional filter media <NUM> is sealed between end caps <NUM>, <NUM> within the filter housing body <NUM>. In this embodiment, filter cartridge <NUM> includes a filter magnet <NUM> extending axially from the filter cartridge housing top portion <NUM>, parallel to the longitudinal axis of the filter cartridge housing body <NUM>. As shown in <FIG>, filter housing <NUM> includes an upward axially-extending portion <NUM> extending from top portion <NUM> integral with and off axial center of the filter housing, within which magnet <NUM> is disposed. It should be understood by those skilled in the art that in other embodiments, magnet <NUM> may instead be positioned within a magnet housing attached to the filter cartridge housing by other means, such as being connected to housing top portion <NUM> by snap fit or friction fit. Other means of attachment, such as welding or bonding, are not precluded.

As shown in <FIG>, filter cartridge <NUM> is insertable in an axial direction (as shown by arrow <NUM>) within sump housing <NUM> between a first position, wherein the O-rings are sealed but the downstream valve(s) are not open and water is not permitted to flow, and a second alignment position (<FIG>). As further shown in <FIG>, manifold <NUM> includes a correspondingly "keyed" correlated magnet <NUM> positioned for alignment with filter magnet <NUM> when filter housing <NUM> is inserted fully into sump <NUM>, i.e., in the second alignment position, as shown in <FIG>. Manifold magnet <NUM> is non-rotatable but is translatable linearly in a direction normal to the longitudinal axis of the filter cartridge. Manifold magnet <NUM> is operably coupled with switch assembly <NUM> via magnet holder <NUM>, which is normally biased in the closed position by a spring <NUM> (<FIG>). Switch assembly <NUM> is disposed within mounting bracket <NUM> and comprises magnet <NUM>, spring <NUM> and actuator <NUM> for limit switch <NUM>. In an embodiment, spring assembly <NUM> may be identical or substantially similar to spring assembly <NUM> as shown in <FIG>. 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 force curves of the spring and magnet couple <NUM>, <NUM> are engineered such that at peak efficacy, there is sufficient magnetic repulsion force to overcome the spring <NUM> force of the switch, compressing the spring in the direction of the arrow, as shown in <FIG>. When the spring is fully depressed, holder <NUM> contacts actuator <NUM> to activate limit switch <NUM>, which in turn actuates a valve (not shown), allowing for the flow of water.

In one or more embodiments, manifold <NUM> may include an alignment channel for receiving at least a portion of filter cartridge <NUM> therein, to ensure that filter cartridge <NUM> is axially inserted into the sump <NUM> to allow for proper alignment of the filter and manifold magnets when in the alignment position. As shown in <FIG>, filter cartridge <NUM> includes a radially-extending rib or fin <NUM> on the housing body <NUM> which aligns with channel <NUM> in manifold <NUM> when filter cartridge <NUM> is properly inserted in sump <NUM>. As best seen in <FIG>, when the filter cartridge is in the alignment position, disposed between the magnets is a portion of manifold <NUM>, which prevents contact between magnets <NUM>, <NUM> while still allowing for magnetic cooperation.

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 are correspondingly "keyed", the magnetic communication will not actuate the switch <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.

It should be understood by those skilled in the art that the present invention is not limited to magnetic communication between the filter cartridge correlated magnet and the corresponding manifold correlated magnet in the form of magnetic repulsion, and that other magnetic communication is not precluded. For example, in one or more embodiments, a shear force could be introduced as the filter cartridge is installed in the manifold, such that the manifold magnet is caused to move in a radial, or alternatively, lateral direction with respect to the filter cartridge magnet as the filter cartridge is moved into the INSTALLED-LOCKED position. Such radial or lateral movement could also activate a limit switch to open a valve, as in the embodiments shown in the Figures.

In such an embodiment, each of the filter and manifold magnets comprises at least one correlated magnet (or an array of correlated magnets), where the polarity transitions of each of the magnets are aligned such that a net shear force is generated between the magnets when the filter cartridge is inserted within the manifold sump housing and moved into an alignment position, allowing for direct or indirect actuation of downstream system functionality via mechanical actuation of simple machines.

Claim 1:
A filtration system comprising:
a filter manifold (<NUM>) including:
a sump (<NUM>); and
an electronic switch assembly (<NUM>) comprising a switch (<NUM>) actuable between open and closed positions, the switch assembly radially disposed with respect to the sump;
a filter cartridge (<NUM>) including:
a filter media (<NUM>);
first and second end caps (<NUM>, <NUM>) sealed to the filter media; and
a body (<NUM>) disposed between the first and second end caps and surrounding the filter media;
the filtration system characterized by:
a correlated magnet (<NUM>) operably coupled to the switch assembly and comprising 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 plurality of magnetic field emission sources; and
a complementary or paired correlated magnet (<NUM>) radially disposed on one of the first or second end caps proximate an outside surface of the filter cartridge body;
wherein the correlated magnets (<NUM>, <NUM>) are interconnected via magnetic communication upon insertion of the filter cartridge (<NUM>) into the sump (<NUM>), and upon movement of the filter cartridge into an alignment position, the correlated magnet of the filter manifold (<NUM>) translates transversely with respect to a longitudinal axis of the sump as a result of the magnetic communication to contact an actuator (<NUM>) to activate the switch (<NUM>).