Patent ID: 12186686

DETAILED DESCRIPTION

Referring to the figures generally, various embodiments disclosed herein relate to a filtration system with a filter element that includes a dual lip seal (e.g., a dual lip seal member) that functions as an anti-drain seal. The dual lip seal member prevents fluid (e.g., fuel) being filtered from flowing back to a fluid storage tank (e.g., a fuel tank) through a drain in the filter housing when the filter element is in an installed position within the filter housing. Stated differently, the dual lip seal member prevents the dirty (e.g., yet to be filtered) fluid traveling through the inlet from flowing into the fluid storage tank. Further, the configuration of the dual lip seal member with the filter housing allows fluid to flow back to the fluid storage tank when the filter element is being removed from the filter housing (e.g., during a filter change service). Additionally, the dual lip seal member prevents fuel on the dirty side (e.g., inlet) of the filter element from entering a water sump of the filtration system, thereby eliminating the need for a separate seal member. Non-compatible filter elements without the dual lip seal member will permit fluid to return to the fluid tank when the non-compatible filter element is installed in the filtration system. Since the fuel returns to the tank when the engine is off, the lack of fuel will cause a hard engine start when the engine is being restarted. Accordingly, the dual lip seal member also functions as an engine integrity protection mechanism, helping to ensure that an installed filter element is genuine (i.e., authorized, Original Equipment Manufacturer (“OEM”) approved, etc.). Thus, the dual lip seal member performs multiple functions (anti-drain back to tank functions, draining functions, and engine integrity protection functions), thereby reducing the cost over traditional filter elements that require three separate components for each of the functions.

Referring toFIG.1, a cross-sectional view of a filtration system100that includes a filter element104with a dual lip seal member102is shown, according to an example embodiment. The filtration system includes a filter element104, a complementary housing106, and a filter mounting head103. The filter element104is installed in an interior compartment of a housing106in an installed position (i.e., in an operational position that permits filtering of the fluid). In the installed or operational position, the filter element104is connected to a filter mounting head (e.g., as described above) and the housing106is also attached to the filter mounting head103(e.g., via a threaded connection in arrangements where the housing106is a spin-on housing). The filter element104includes a dual lip seal member102that forms a radial seal between the filtration system housing106and the filter element104, thereby preventing fluid from bypassing the filter element104. Generally, when the filter element104is received in the installed position within the housing106(i.e., the filtration system100is assembled), the dual lip seal member102forms a seal between the housing106and the filter element104. The dual lip seal member102prevents the fluid from exiting the housing106through the drain passage118. As will be appreciated, if an improper filter element (i.e., a non-authorized or non-genuine filter element) is installed in a filtration system100, or if the proper filter element is installed incorrectly, the dual lip seal member102of the filter element104may not form a proper seal, and fluid may bypass the filter element104causing damage to downstream components or improper operation of the filtration system100or other components.

The filter element104includes a first endplate108, a second endplate110, filter media112, and the dual lip seal member102. The filter element104may be a cylindrical filter element with similarly shaped components. The filter media112includes an inner clean (e.g., filtered fuel) side116and an outer dirty (e.g. unfiltered fuel) side114. Accordingly, the filter element104is an outside-in flow filter element. In an alternative arrangement, the filter element104is an inside-out flow filter element having an inner dirty side114and an outer clean side116. Fluid to be filtered passes from the dirty side114of the filter media112to the clean side of the filter media112. The filter media112may include any of paper-based filter media, fiber-based filter media, foam-based filter media, or the like. The filter media112is disposed between the first endplate108and the second endplate110.

As shown inFIG.1, the first endplate108is coupled to a first, top end of the filter media112. The first endplate108may include a plurality of retention tabs to secure the filter element104to a filter mounting head of the filtration system100when the filter element104is installed in the filtration system100. For example, the retention tabs may form a snap-fit connection with the filter mounting head103of the filtration system100as the filter element104is installed in the filtration system100. The retention tabs removably secure the filter element104to the mounting head during removal of the housing106of the filtration system100, thereby permitting residual fluid in the housing to drain past the dual lip seal member102back into a fluid storage tank.

The filter element104further includes a second endplate110coupled to a second, bottom end of the filter media112. In some embodiments, the second endplate110includes a central opening. The central opening is sized and shaped to receive a component of a filtration system (e.g., a standpipe) when the filter element104is installed in an operating position within the filtration system. In other embodiments, the central opening is in fluid communication with a water sump. The first endplate108may also include a central opening. The central opening may route fluid and air to a component (e.g., to an internal combustion engine). The central opening may be configured to be in fluid communication with a center housing portion126of the housing106.

The filter element104includes a dual lip seal member102. The dual lip seal member102is configured as an anti-drain dual lip seal member. The dual lip seal member102includes a central opening120, a first protrusion122, and a second protrusion124. The dual lip seal member102comprises a cylindrical seal member with the first protrusion122and second protrusion124being disposed around the outer surface of the seal member102. The dual lip seal member102is disposed adjacent to the drain passage118in the housing106that is in fluid communication with the fluid storage tank (not shown). The dual seal member may be formed concentrically (e.g., having a common center) with the filtration system100or eccentrically (e.g., not having a common center) with the filtration system100(as shown below inFIGS.4A-4B). The dual lip seal member102is coupled to the second endplate110. In some embodiments, the dual lip seal member102is disposed around an outer surface of the second endplate110, the outer surface extending axially away from a bottom surface of the second endplate110away from the first endplate108. In some embodiments, the dual lip seal member102and the second endplate110may be manufactured as a single, integrated piece (e.g., via an over molding or heat staking process). In other embodiments, the second endplate110includes a retaining member, such that a snap-fit connection is formed between the retaining member and central opening120of the dual lip seal member102. The snap-fit connection removably secures the dual lip seal member102to the second endplate110. The central opening120of the dual lip seal member102is aligned with a central opening that is configured to allow a component (e.g., the standpipe) to be received through the central opening120of the dual lip seal member102.

The first protrusion122and the second protrusion124provide a radial seal with both the top and bottom side of the second endplate110. Beneficially in a particular embodiment, the dual lip seal member102includes two different lip seal diameters, as the first protrusion122has a first diameter and the second protrusion124has a second diameter. Accordingly, the diameters of the first protrusion122and the second protrusion124may be adjusted to provide ease of installation of the filter element104into the housing106. This ensures that the assembly of the filter element104and housing106is successful only when the filter element104and housing106are properly aligned (e.g., sealed). In some embodiments, the first diameter and the second diameter may be substantially similar. In other embodiments, the first diameter and the second diameter are different diameters.

As shown inFIGS.1and2, the dual lip seal member102includes a first protrusion122and a second protrusion124comprising a generally sideways ‘v’-shape, with the center130of the dual lip seal (e.g., the indention of the tip of the ‘v’ shape) being adjacent to the drain passage118. The first protrusion122and the second protrusion124extend around the outer surface around the dual lip seal member102. In some embodiments, the first protrusion122extends at a substantially 45-degree angle above a horizontal axis and the second protrusion extends at a substantially 45-degree angle below the horizontal axis, where the horizontal axis is parallel to the horizontal surface of the second endplate110. While the dual lip seal member102is shown having two protrusions in a generally sideways ‘v’-shape, a wide variety of configurations may be implemented including variations in the shape of the dual lip seal member102, size of dual lip seal member102, and number of protrusions of the dual lip seal member102. The dual lip seal member102is configured to have a shape, length, width, and number of elements that is specifically tailored to interface with an inner surface of the housing106. For example, the dual lip seal member102may comprise two separate O-rings, multiple lips, or other various shapes and configurations involving one or more lips and O-rings. This ensures that the assembly of the filter element104and housing106is successful only when the filter element104and housing106are properly aligned (e.g., sealed) and ensure engine integrity (e.g., genuine filter element104).

Referring toFIG.2, a cross-sectional view of the dual lip seal member102of the filtration system100ofFIG.1is shown.FIG.2shows the area of the filter element104near the second endplate110. The first protrusion122of the dual lip seal member102presses against a first portion202of an inner surface of the housing106and the second protrusion124of the dual lip seal member102presses against a lower, second portion204of the inner surface of the housing106. The drain passage118is located between the first protrusion122and the second protrusion124and adjacent the base formed by the first protrusion122and second protrusion124. Thus, the first protrusion122and the second protrusion124create a one-way valve, allowing the fluid to enter the housing106and preventing the fluid from returning back to the fluid storage tank. Accordingly, the dual lip seal member102prevents fluid to be filtered from exiting through a drain passage118located in the housing106while the filter element104is received in the installed position within the housing106. In such arrangements, the drain passage118connects the housing106to a fluid storage tank (e.g., the fuel tank of a vehicle powered by the internal combustion engine). Accordingly, the dual lip seal member102functions as an anti-drain back to the storage tank when the filter element104is installed in the housing106(e.g., between filter service operations).

FIG.3shows a close-up cross-sectional view of the dual lip seal member102interacting with the housing106when the filter element104is received in the installed position within the housing106. As shown inFIG.3, the dual lip seal member includes the first protrusion122and the second protrusion124. The first protrusion122and the second protrusion124may include flexing features or flanges to provide sealing between the housing106and the filter element104. The flexing features allow the first and/or second protrusions (122,124) of the dual lip seal member102to flex with respect to the main body of the dual lip seal member102. Accordingly, the flexing features can assist in creating the dual lip seal member between the first protrusion122and the housing106and the second protrusion124and the housing106. The flexing features may comprise grooves or cuts in the dual lip seal member102positioned at the joint between each of the first protrusion122and the second protrusion124and the main body of the dual lip seal member102. The flexing features also permit the dual lip seal member102to flex during full fluid flow, which reduces restriction and potential damage to the dual lip seal member102(e.g., reduces the risk of permanent deformation of the dual lip seal member102). In some embodiments, one or both of the first protrusion122and the second protrusion124include a first node302and a second node304(generally in the location shown inFIG.3). The inclusion of the first node302and the second node304on either one of the first protrusion122and second protrusion124creates a tighter seal between the dual lip seal member102and the inner surfaces (202,204) of the housing106.

Accordingly, when the filter element104is received in the installed position within the filtration system (i.e., within the housing106when both the housing106and the filter element104are secured to the filter mounting head103), the dual lip seal member102forms a radially directed seal between the housing106and the first protrusion122and the second protrusion124and the housing106. The dual lip seal member102prevents the fluid from exiting the housing106through the drain passage118. During servicing of the filter element104(e.g., during filter element replacement) by a technician, the technician first removes the housing106from the filter mounting head103. In doing so, the housing106is displaced relative to the filter element104.

As mentioned above, the dual lip seal member102provides clean servicing (e.g., when the dirty fuel is drained to the tank). By way of example, the housing106is removed (e.g., spun off) from a filter mounting head and the filter element104remains attached to the filter mounting head103through the retention tabs (e.g., as discussed above with respect toFIG.1). Accordingly, the housing106slides with respect to the dual lip seal member102. The housing106includes a variable inner diameter. When the filter element104is in the installed position, the first protrusion122and the second protrusion124of the dual lip seal member102form a dual lip seal against a first portion202and second portion204, respectively, of the housing106. When the housing106is displaced from the filter element104during removal of the housing106(e.g., during a filter replacement service), the first protrusion122and the second protrusion124slide to a third and fourth portion of the housing. The third and fourth portions have a larger diameter than the first portion202and second portion204. The third and fourth portions may include vertical ribs that displace the first protrusion122and the second protrusion124from the surface of the third and fourth portions thereby eliminating the dual seal between the dual lip seal member102and the housing106. The vertical ribs prevent the first protrusion122and the second protrusion124from being pressed against the surface of the third and fourth portions by the weight of the residual fluid. As will be appreciated, because there is no dual lip seal member102, fluid within the housing106can bypass the dual lip seal member102for draining out of the housing106through the drain passage118. Accordingly, the filter element104can be serviced without spilling or wasting residual fluid in the housing106.

Referring toFIG.4A, a perspective view of a filter element404that includes an eccentrically (e.g., not sharing a common center) oriented dual lip seal member402on an endplate410, according to another example embodiment. As will be appreciated, the eccentric filter element404is substantially similar to the concentric filter element104ofFIGS.1-3. Accordingly, the eccentric filter element404provides substantially the same benefits and features as the concentric filter element104. As shown inFIG.4A, the filter element404further includes a protruding member408to facilitate installation into the complementary housing406.FIG.4Bshows a perspective view of a housing406that is complementary to the filter element ofFIG.4A, according to an example embodiment.

It should be noted that any use of the term “exemplary” herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Additionally, features from particular embodiments may be combined with features from other embodiments as would be understood by one of ordinary skill in the art. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.