In accordance with exemplary embodiments of the present invention, a filter and method of making a filter is disclosed. In an exemplary embodiment the filter will comprise an outer housing and an end plate secured to the outer housing, the end plate being configured to have a plurality of inlet openings and at least one outlet opening, wherein a fluid path therethrough is defined and filter media is disposed in the fluid path.
In one non-limiting exemplary embodiment, the filter media comprises a plurality of layers of media formed by a pair of non-woven materials secured to each other wherein one of the non-woven materials is formed to have a plurality of corrugations and the other is a planar member welded to the layer having a plurality of corrugations and thereafter the two layers are wrapped around each other in order to provide a larger amount of filter surface area. Non-limiting examples of non-woven media include but are not limited to synthetic and cellulose based non-woven medias.
Reference is made to the following U.S. Pat. Nos. 6,673,136; 5,820,646; 4,410,427; and 4,589,983, the contents of which are incorporated herein by reference thereto.
Referring to
As illustrated filter 10 comprises a housing 12 having an end plate 14 secured to one end of the housing. End plate 14 has a plurality of inlet openings 16 and at least one outlet opening 18. As illustrated outlet opening 18 is configured to threadingly engage a threaded spud with a plurality of threads disposed in an inner surface of the outlet opening.
In accordance with an exemplary embodiment and secured to a portion 24 of the end plate is an end disk collector 26. End disk collector 26 is configured to have a neck portion 28 fluidly sealed to an outer periphery 30 of the outlet opening. In accordance with an exemplary embodiment, neck portion has a length sufficient to define a gap 32 between a shield portion 34 of the end disk collector and a portion of the end plate, which includes the inlet openings.
Depending away from shield portion 34 is a wall portion 36, which in an exemplary embodiment defines a fluid path 38 between an outer surface of the wall portion and an inner surface 42 of the housing.
Accordingly, a fluid path defined by arrows 50 is provided. As shown, a fluid enters the filter through the inlet openings passes though gaps 32 and 38 and a filter media 52 secured to the end disk collector.
Accordingly, the end disk collector and the filter media are configured to provide a flow path through the filter wherein fluid entering through openings 16 must be filtered by the media before exiting through opening 18.
In one non-limiting exemplary embodiment, the filter media is formed by the teachings of U.S. provisional patent application Ser. No. 11/533,649 filed Sep. 20, 2006, the contents of which are incorporated herein by reference thereto.
In this embodiment, the media provides high contaminant capacity per packing volume available. In accordance with the teachings of the aforementioned provisional patent application, a non-woven media is used to provide a top or first sheet that is formed into a corrugated layer, and then the first sheet is attached to another flat sheet of the non-woven media and then this two sheet layer is wrapped around itself, which provides a greater amount of media that can be fitted into a given packaging space thus giving greater filtering capacity of the media.
In one non-limiting exemplary embodiment the top sheet or first sheet containing the corrugations is formed to have the corrugations by a thermoforming process of a synthetic non-woven media. Alternatively, and if a cellulose based media is used, an embossing process could be used to form the corrugations and other means of sealing the two layers may be used other than sonic welding (e.g., adhesives, hot melt adhesives, etc.). Regardless of the material used and the process for forming the corrugations the corrugations would be formed prior to the attachment of the lower or second flat sheet of media. The forming of the corrugations should be tapered gradually to pinch down to a flat portion on one side of the sheet to enable the attachment by welding of the lower flat sheet. The two sheets can be bonded together on one edge using adhesive or in an exemplary embodiment a continuous sonic weld.
Once the two sheets are attached together forming a long continuous roll of paper the media can be wrapped around itself in a spiral pattern. During this wrapping process, a bead of adhesive will be applied on the edge opposite the flat edge of the two layers in order to secure the layers to each other as well as provide a sealing means in order to provide a plurality of fluid paths wherein fluid passing therethrough is filtered by the media. By having alternative ends of the corrugations on each subsequent layer sealed, a flow path is created which utilizes the entire media area. In accordance with an exemplary embodiment, the final shape of the media could be round, elliptical, oval or any number of the regular configurations.
Referring now to
Referring now to
In accordance with an exemplary embodiment a sonic welding horn 126 is lowered down onto second layer 124 and sonically welds a lower surface 128 of channels 120 to second layer 124 by compressing layers 110 and 124 between a contact surface 130 of welding horn 126 and the gears of roll 114.
Once first layer 110 is secured to second layer 124 a sheet of filter media 132 is formed with a plurality of channels each having an inlet flow opening 134 and a closed or outlet end 136. The closed end is also formed by sonically welding the two layers together. As illustrated in
In order to form the final configuration of a filter constructed in accordance with an exemplary embodiment, a strip of adhesive 138 is applied to an upper surface 140 of first layer 110 after the same has been secured to second layer 124. A non-limiting example of adhesive 138 is a rubber and epoxy sealant or any other equivalent adhesive capable of securing the layers together as well as providing a fluid barrier. Thereafter, the sheet of filter media is wrapped around itself such that second layer 124 is adhered to the adhesive disposed upon the upper surface of the first layer.
Referring now to
Accordingly and in accordance with exemplary embodiments of the present invention a high capacity honeycomb style media is employed in an oil, fuel or coolant or any other type of filter wherein the filtering capacity of the filter is increased.
In another alternative exemplary embodiment and for an oil filter, the media is wrapped around a solid centertube 125 having a hollow path therethrough (e.g., open on its ends but solid walls) and then the media is sealed to the inside of the housing thus, forcing the fluid through the media to the bottom of the can/housing wherein there is gap or area 127 for the filtered fluid to pass back up through the opening on the bottom of the centertube to the outlet opening on the top of the centertube. This embodiment is illustrated in
In accordance with an alternative exemplary embodiment and referring now to
As discussed, above the filter media may comprises a plurality of layers of media formed by a layers of non-woven materials secured to each other wherein one of the non-woven materials is formed to have a plurality of corrugations and the other is a planar member welded to the layer having a plurality of corrugations and thereafter the two layers are wrapped around each other in order to provide a larger amount of filter surface area.
Referring to
As illustrated, filter 210 comprises a housing 212 having an end plate 214 secured to one end of the housing. End plate 214 has a plurality of inlet openings 216 and at least one outlet opening 218. As illustrated, outlet opening 218 is configured to threadingly engage a threaded spud 220 with a plurality of threads 222 disposed in an inner surface of the outlet opening.
In accordance with an exemplary embodiment and secured to a portion 224 of the end plate is an inner sleeve 226. Inner sleeve 226 is configured to have a neck portion 228 fluidly sealed to an outer periphery 230 of the outlet opening. In accordance with an exemplary embodiment, neck portion has a length sufficient to define a gap 232 between a shield portion 234 of the inner sleeve and a portion of the end plate, which includes the inlet openings.
Depending away from shield portion 234 is a wall portion 236, which in an exemplary embodiment defines a fluid path 238 between an outer surface 240 of the wall portion and an inner surface 242 of the housing.
In accordance with an exemplary embodiment wall portion 236 terminates with a plurality of tab portions 244 at a distal end from the end of the inner sleeve secured to the threaded spud. In accordance with an exemplary embodiment the tab portions 244 define a plurality of openings 246 or fluid paths therethrough. In accordance with an exemplary embodiment, tabs 244 extend to and contact an end portion 248 of housing 212. Accordingly, a fluid path defined by arrows 250 is provided. As shown, a fluid enters the filter through the inlet openings passes though gaps 232 and 238, through openings 246 and into a filter media 252 disposed within an inner area 254 defined by inner sleeve 236.
Accordingly, inner sleeve defines an area for receipt of the filter media of the filter. In one non-limiting exemplary embodiment and as discussed above, the filter media is formed by the teachings of U.S. patent application Ser. No. 11/533,649 filed Sep. 20, 2006, the contents of which are incorporated herein by reference thereto.
In this embodiment, the media provides high contaminant capacity per packing volume available. In accordance with the teachings of the aforementioned provisional patent application, a non-woven media is used to provide a top or first sheet that is formed into a corrugated layer, and then the first sheet is attached to another flat sheet of the non-woven media and then this two sheet layer is wrapped around itself, which provides a greater amount of media that can be fitted into a given packaging space thus giving greater filtering capacity of the media.
In one non-limiting exemplary embodiment the top sheet or first sheet containing the corrugations is formed to have the corrugations by a thermoforming process of a synthetic non-woven media. Alternatively, and if a cellulose based media is used, an embossing process could be used to form the corrugations and other means of sealing the two layers may be used other than sonic welding (e.g., adhesives, hot melt adhesives, etc.). Regardless of the material used and the process for forming the corrugations the corrugations would be formed prior to the attachment of the lower or second flat sheet of media. The forming of the corrugations should be tapered gradually to pinch down to a flat portion on one side of the sheet to enable the attachment by welding of the lower flat sheet. The two sheets can be bonded together on one edge using adhesive or in an exemplary embodiment a continuous sonic weld.
Once the two sheets are attached together forming a long continuous roll of paper the media can be wrapped around itself in a spiral pattern. During this wrapping process, a bead of adhesive will be applied on the edge opposite the flat edge of the two layers in order to secure the layers to each other as well as provide a sealing means in order to provide a plurality of fluid paths wherein fluid passing therethrough is filtered by the media. By having alternative ends of the corrugations on each subsequent layer sealed, a flow path is created which utilizes the entire media area. In accordance with an exemplary embodiment, the final shape of the media could be round, elliptical, oval or any number of the regular configurations.
As described above, the filter media has a plurality of channels 254 wherein the channels are open or have an opening 258 on one side and closed or sealed by a sealant 256 on the other side in an alternating fashion thus, the media sealed in an alternating fashion defines a plurality of longitudinal channels wherein a plurality of inlet openings 258 are on one side and a plurality of outlet openings 258 are on the other side thus, fluid traveling through the filter media must pass through at least one layer of filter media in order to travel from the inlet to the outlet. Non limiting examples of the fluid path are shown by the arrows in
Referring now to
In accordance with an exemplary embodiment, a mounting portion 282 of the inner sleeve is received within the mounting flange 280 and a mounting portion 284 of the housing is also received within the mounting flange. In this embodiment, the neck portion or mounting portion is configured to sealingly engage the mounting flange and the housing has a feature that also engages the flange by for example a twist lock engagement thus sealing the filter to the flange wherein fluid flows into the filter, through the media and out the opening of the mounting portion.
In this embodiment, the shield portion 234 of the inner sleeve is received within the open end of the housing and a peripheral edge 235 of the shield portion defines a gap between the inner sleeve and an inner surface of the housing, the gap defining a fluid path between the inner sleeve and the inner surface of the housing.
In this embodiment, the inner sleeve and the filter media is easily inserted and removed from the housing, which provides for ease of replacement of the filter media. Accordingly, only the inner sleeve and the filter media is replaced, wherein the housing is reusable. Alternatively, the inner sleeve is also reusable in the event the filter media is capable of being removed and replaced from the inner sleeve. Also, the tab members of the inner sleeve are configured to have features 286 configured to engage features 288 of the housing thus providing a “snap-fit” engagement of the inner sleeve to the housing.
In one embodiment, mounting portion 282 has a pair of O-rings 290 that provide a means for sealing mounting portion 282 to flange 280. Likewise, the housing may also have a sealing feature such as O-rings or other equivalent members to provide a fluid seal between the housing and the flange. As in the embodiment of
In an alternative exemplary embodiment and as illustrated in
Accordingly and in accordance with exemplary embodiments of the present invention the inner sleeve of
The inner sleeve serves as a means with which to house/contain filtration media, preferably a high capacity honeycomb style media. Of course, other types of media are contemplated to be within the scope of exemplary embodiments of the present invention. Additional functions include: direct flow from the filter inlet through the media and funneling to the outlet; potentially eliminate other components such as retainer springs, filter cartridges end disks, center tubes, necessary spacers, grommets etc.
The inner sleeve itself can be a machined, molded or formed from a material that will provide reasonable structural strength and ease of manufacture, one non-limiting example is a plastic (e.g., nylon 6-6).
Inside the inner sleeve filtration media can be housed/contained such that an effective seal is created between the clean and dirty side of the filtration media which will allow the fluid to flow through the media. This seal may be accomplished in a number of ways including adhesives disposed between the media and the inner sleeve, infrared (IR) type welds or other welds and over molding of the sleeve about the filtration media.
While the invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
The present application claims the benefit of U.S. Provisional Patent Applications, Ser. Nos. 60/823,601 filed Aug. 25, 2006 and 60/840,219 filed Aug. 25, 2006, the contents each of which are incorporated herein by reference thereto.
Number | Date | Country | |
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60823601 | Aug 2006 | US | |
60840219 | Aug 2006 | US |