FIELD
The invention relates to filters.
BACKGROUND
Various filters are known in the art for filtering fluid as it passes through a fluid path. Filters include, in part, filter media which removes impurities from a fluid, such as, for example, oil or fuel that passes through filter media.
In most applications, either the filter or the filter media associated therewith must be periodically replaced to reduce the potential of developing unacceptably high impedance in the fluid path flow restriction.
While known filters have proven to be acceptable for various applications, such conventional filters are nevertheless susceptible to improvements that may enhance their overall performance and cost. Therefore, a need exists to develop improved filters that advance the art.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1A is an assembled, side partial cross-sectional view of a filter assembly in accordance with an exemplary embodiment of the invention;
FIG. 1B is an exploded, side cross-sectional view of the filter assembly of FIG. 1A;
FIG. 2A is a partial perspective, exploded view of an end cap and filter media of the filter assembly of FIGS. 1A-1B arranged above a mold tool component;
FIG. 2B is another partial perspective view of the portion of the end cap and filter media of FIG. 2A arranged adjacent the mold tool component of FIG. 2A;
FIG. 2C is a partial perspective, assembled view of a portion of the filter assembly of FIG. 2A including the endcap, filter media and a seal member arranged above the mold tool component of FIG. 2A;
FIG. 3A is a cross-sectional view of an endcap according to line 3A-3A of FIG. 2A in accordance with an exemplary embodiment of the invention;
FIG. 3B is an enlarged cross-sectional view of the endcap according to line 3B of FIG. 3A;
FIG. 4 is a cross-sectional view of a seal member of the filter assembly of FIGS. 1A-1B in accordance with an exemplary embodiment of the invention;
FIG. 4B is an enlarged cross-sectional view of the endcap according to line 4B of FIG. 4A;
FIG. 5 is a cross-sectional view of a mold tool component according to line 5-5 of FIG. 2A in accordance with an exemplary embodiment of the invention;
FIG. 6A illustrates a cross-sectional view of the endcap of FIG. 3A arranged adjacent the mold tool component of FIG. 5 in accordance with an exemplary embodiment of the invention;
FIG. 6B illustrates a cross-sectional view of the endcap arranged adjacent the mold tool component of FIG. 6A with a material being deposited over a portion of the endcap and the mold tool component in accordance with an exemplary embodiment of the invention;
FIG. 6C illustrates a cross-sectional view of the endcap arranged adjacent the mold tool component with the material deposited over the portion of the endcap and the mold tool component of FIG. 6B for forming a seal member in accordance with an exemplary embodiment of the invention;
FIG. 7A is a partial cross-sectional view of filter media of FIGS. 1A-2A arranged above the mold tool component including the material forming the seal member of FIG. 6C in accordance with an exemplary embodiment of the invention;
FIG. 7B is a cross-sectional view according to line 7B-7B of FIG. 2B including a portion of the filter media arranged in the material forming the seal member of FIG. 7A in accordance with an exemplary embodiment of the invention; and
FIG. 7C is a cross-sectional view according to line 7C-7C of FIG. 2C including a portion of the filter assembly including the filter media connected to the endcap by way of the material forming the seal member being removed from the mold tool component in accordance with an exemplary embodiment of the invention.
DETAILED DESCRIPTION
The Figures illustrate exemplary embodiments of a filter endcap with integral seal, a filter assembly and methods for manufacturing the same in accordance with embodiments of the invention, and, based on the foregoing, it is to be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should be given the broadest meaning by one of ordinary skill in the art.
Referring to FIGS. 1A-1B, a filter assembly is shown generally at 10 in accordance with an exemplary embodiment of the invention. The filter assembly 10 includes filter media 12, a first or upper endcap cap 14a, a second a lower endcap 14b and a seal member 16.
As will be explained in the following disclosure, the first or upper endcap cap 14a and the seal member 16 may form a sub-assembly 100 (see, e.g., FIG. 1B, 6C and 7A) of the filter assembly 10. Subsequent attachment of the filter media 12 to the sub-assembly 100 may form a portion 10a of the filter assembly 10 (see, e.g., FIGS. 1B, 2B-2C, 7A-7C). Referring to FIG. 1B, the second or lower endcap 14b may be attached to the portion 10a (by way of e.g., attaching material, A, such as, for example, an adhesive, potting compound, or the like) for forming the filter assembly 10.
Referring to FIGS. 1A-1B, the filter media 12 may include a body 18. The body 18 includes an outer surface 20, an inner surface 22, a first or upper end surface 24 and a second or lower end surface 26. The body 18 may include any desirable geometry or shape such as, for example, a ring shape, a cylindrical shape, a tube shape or the like.
The inner surface 22 forms a passage 28 extending through the body 18. The first or upper end surface 24 forms a first or upper opening 30a in the body 18. The second or lower end surface 26 forms a second or lower opening 32a in the body 18. The first or upper opening 30a and the second or lower opening 32a each provide access to the passage 28.
The second or lower endcap 14b may include a body 34 connected to an outer circumferential lip 36 and an inner circumferential lip 38. The body 34 includes a top surface 40 and a bottom surface 42. The outer circumferential lip 36 includes an outer surface 44 and an inner surface 46. The inner circumferential lip 38 includes an outer surface 48 and an inner surface 50. The outer surface 48 of the inner circumferential lip 38 of the second or lower endcap 14b forms an opening 32b.
The second or lower opening 32a in the body 18 of filter media 12 and the opening 32b of the second or lower endcap 14b may be one-in-the same in that both openings 32a, 32b provide access to the passage 28 extending through the body 18 of filter media 12. Accordingly, the openings 32a, 32b may be collectively referred to as a lower opening 32 (see, e.g., FIG. 1A).
The top surface 40 of the body 34 of the second or lower endcap 14b may be disposed substantially adjacent and connected to the second or lower end surface 26 of the filter media 12. The top surface 40 of the body 34 of the second or lower endcap 14b may be connected to the second or lower end surface 26 of the filter media 12 with any desirable attaching material, A, such as, for example, an adhesive, potting compound or the like.
The inner surface 46 of the outer circumferential lip 36 of the second or lower endcap 14b may be in a spaced-apart relationship with the outer surface 20 of the filter media 12. Alternatively, the inner surface 46 of the outer circumferential lip 36 of the second or lower endcap 14b may be in an adjacent relationship with the outer surface 20 of the filter media 12.
The inner surface 50 of the inner circumferential lip 38 of the second or lower endcap 14b may be in a spaced-apart relationship with the inner surface 22 of the filter media 12. Alternatively, the inner surface 50 of the inner circumferential lip 38 of the second or lower endcap 14b may be in an adjacent relationship with the inner surface 22 of the filter media 12.
Referring to FIGS. 1A-1B and 3A, the first or upper endcap 14a is shown. FIGS. 1A-1B may be described as being a “right-side-up” view of the first or upper endcap 14a whereas FIG. 3A may be described as being an “up-side-down” view of the first or upper endcap 14a. Accordingly, when words such as, for example, “upper,” “top” or “bottom” are used to describe features of the first or upper endcap 14a, the “right-side-up” view of FIGS. 1A-1B is utilized as a frame of reference for describing features of the first or upper endcap 14a; however, when FIG. 3A is referenced, the use of the words “upper,” “top” and “bottom” (from describing FIGS. 1A-1B) are maintained for consistency. Thus, based on the foregoing, it is reminded that the nomenclature used herein is simply for convenience and the terms (e.g., “upper,” “top,” “bottom” and the like) used to describe the invention should be given the broadest meaning by one of ordinary skill in the art.
Referring to FIGS. 1A-1B and 3A, the first or upper endcap 14a may include a body 52 connected to an outer circumferential lip 54 and an inner circumferential lip 56. The body 52 includes a top surface 58 and a bottom surface 60. The outer circumferential lip 54 includes an outer surface 62 and an inner surface 64.
Referring also to FIG. 3B, the inner circumferential lip 56 includes an inner surface 66 and an outer surface 68. The outer surface 68 of the inner circumferential lip 54 of the first or upper endcap 14a forms an upper opening 30b.
The first or upper opening 30a in the body 18 of the filter media 12 and the opening 30b of the first or upper endcap 14a may be one-in-the same in that both openings 30a, 30b provide access to the passage 28 extending through the body 18. Accordingly, the openings 30a, 30b may be collectively referred to as an upper opening 30 (see, e.g., FIG. 1A).
The inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a may be in a spaced-apart relationship with the outer surface 20 of the filter media 12. Alternatively, the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a may be in an adjacent relationship with the outer surface 20 of the filter media 12.
The inner surface 66 of the inner circumferential lip 56 of the first or upper endcap 14a may be in a spaced-apart relationship with the inner surface 22 of the filter media 12. Alternatively, the inner surface 66 of the inner circumferential lip 56 of the first or upper endcap 14a may be in an adjacent relationship with the inner surface 22 of the filter media 12.
Referring to FIG. 3B, a first or upper portion 56a of the inner circumferential lip 56 may extend away from and beyond the top surface 58 of the body 52 of the first or upper endcap 14a. A second or lower portion 56b of the inner circumferential lip 56 may extend away from and beyond the bottom surface 60 of the body 52 of the first or upper endcap 14a.
As will be described in the following disclosure at FIG. 6A, the first or upper portion 56a of the inner circumferential lip 56 may form a male portion or locating rib having a top surface portion 70 (see, e.g., FIG. 3B) that interfaces with a mold tool component (see, e.g., 200 of FIGS. 2A-2C, 5). The male portion or locating rib 56a interfaces with a female portion, groove or recess (see, e.g., 204) formed by the mold tool component 200. Accordingly, upon arranging the male portion or locating rib 56a formed by the inner circumferential lip 56 within a female portion or recess 204 formed in the mold tool component 200, the first or upper endcap 14a may be controllably-positioned (e.g., centrally positioned) upon the mold tool component 200 in order to, for example, ensure accurate repeatability of a formation (e.g., an over-molding) of plurality of sub-assemblies 100 including the seal member 16 over-molded to/upon the first or upper endcap 14a.
Further, as will be described in the following disclosure, the second or lower portion 56b of the inner circumferential lip 56 may form barb or tang that extends into the seal member 16 (as shown in, e.g., FIGS. 1A, 1B, 6C and 7A-7C). After the seal member 16 is formed (see, e.g., FIGS. 6C-7C) over the first or upper endcap 14a, the barb or tang 56b may engage the seal member 16 as a result of direct, physical contact of the barb or tang 56b with the seal member 16. Accordingly, upon the seal member 16 curing (i.e., transitioning from a substantially liquid or semi-solid state to a substantially solid state), the seal member 16 may not only said to be chemically bonded with the first or upper endcap 14a, but, also, the seal member 16 may be said to be frictionally connected to the first or upper endcap 14a as a result of the physical connection of the barb or tang 56b extending into the seal member 16.
Accordingly, unlike the connection of top surface 40 of the body 34 of the second or lower endcap 14b to the filter media 12 with an attaching material, A, such as, for example, a potting compound or adhesive, the bottom surface 60 of the body 52 of the first or upper endcap 14a may be connected to the filter media 12 during the formation (e.g., over-molding) of the seal member 16. As a result, the use of an attaching material, A, such as, for example, a potting compound or adhesive to connect the first or upper endcap 14a with the filter media 12 may be obviated because the upper endcap 14a may exploit and take advantage of the tacky, non-hardened, liquid, semi-solid or molten state of material, M (see, e.g., FIGS. 5B-6B), comprising the seal member 16 such that the material, M, forming the seal member 16 may be utilized to attach the first or upper endcap 14a to the filter media 12 (see, e.g., FIGS. 6A-6B).
Referring to FIGS. 1A-1B and 4A, the seal member 16 may include a body 72 connected to a circumferential lip 74. The body 72 includes a top surface 76, a bottom surface 78 and an outer side surface 80 connecting the top surface 76 to the bottom surface 78. The circumferential lip 74 includes an outer surface 82 and an inner surface 84.
The top surface 76 includes a female portion or recess 86. The female portion or recess 86 may substantially correspond to the shape of and receive the barb or tang 56b of the inner circumferential lip 56 of the first or upper endcap 14a.
Referring to FIG. 4A, a first portion 76a of the top surface 76 of the body 72 of the seal member 16 may be disposed adjacent the bottom surface 60 of the body 52 of the first or upper endcap 14a. A remaining or second portion 76b of the top surface 76 of the body 72 of the seal member 16 is not disposed adjacent any portion of the first or upper endcap 14a (as seen in, e.g., FIGS. 1A-1B), but, rather, is exposed to atmosphere. The second portion 76b of the top surface 76 of the body 72 of the seal member 16 is proximate to and extends away from the first portion 76a and tapers arcuately to form the outer surface 82 of the circumferential lip 74 of the seal member 16. Referring to FIGS. 1A-1B, the outer side surface 80 of the body 72 of the seal member 16 may be disposed adjacent to the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a.
The inner surface 84 of the circumferential lip 74 of the seal member 16 forms a passage 88. The passage 88 formed by the inner surface 84 of the circumferential lip 74 of the seal member 16 is in fluid communication with the passage 28 formed by the inner surface 22 of the body 18 by way of the first or upper opening 30.
Referring to FIGS. 1A-1B and 4A-4B, the inner surface 84 of the of the circumferential lip 74 of the seal member 16 may include a first radial surface portion 84a, a second radial surface portion 84b and an axial ledge surface portion 84c connecting the first radial surface portion 84a to the second radial surface portion 84b. The first radial surface portion 84a of the inner surface 84 forms the passage 88 of the circumferential lip 74 of the seal member 16 to include a first diameter, D88-1. The second radial surface portion 84b of the inner surface 84 forms the passage 88 of the circumferential lip 74 of the seal member 16 to include a second diameter, D88-2. The second diameter, D88-2, of the passage 88 of the circumferential lip 74 of the seal member 16 is approximately the same as, but slightly less than the first diameter, D88-1, of the passage 88 of the circumferential lip 74 of the seal member 16.
The second diameter, D88-2, of the passage 88 formed by the second radial surface portion 84b of the inner surface 84 of the circumferential lip 74 of the seal member 16 may be approximately equal to be less than a member, SP (see, e.g., FIG. 4A), that is to be inserted through the passage 88 formed by the inner surface 84 of the circumferential lip 74 of the seal member 16. In an implementation, the member, SP, may include a standpipe; accordingly, the seal member 16 may be referred to as a “standpipe seal.”
Referring to FIG. 4A, the body 72 of the seal member 16 may include a thickness, T72. The thickness, T72, may extend between the top surface 76 and the bottom surface 78 of the seal member 16. The thickness, T72, of the body 72 of the seal member 16 may be approximately equal to but slightly less than a length, L54 (see, e.g., FIG. 3A), of the outer circumferential lip 54 of the first or upper endcap 14a.
Referring to FIGS. 1A-1B, a portion 12a of the body 18 of the filter media 12 may extend into at least a portion of, or, substantially all of the thickness, T72, of the body 72 of the seal member 16. The portion 12a of the body 18 of the filter media 12 may include a portion, L12A (see, e.g., FIG. 1B), of a length, L12 (see, e.g., FIG. 1B), of the body 18 of the filter media 12; accordingly the portion, L12A, of the length, L12, of the body 18 of the filter media 12 may be approximately equal to the thickness, T72, of the body 72 of the seal member 16. The portion, L12A, of the length, L12, of the body 18 of the filter media 12 is approximately equal to about the length, L54, of the outer circumferential lip 54 of the first or upper endcap 14a. Referring to FIGS. 7B-7C, the portion 12a of the body of the filer media 12 may be extended into the body 72 of the seal member 16 prior to curing (i.e., transitioning from a substantially liquid state to a substantially solid state) of the material, M, that forms the seal member 16.
Referring to FIGS. 2A and 5, a mold tool component is shown generally at 200 in accordance with an exemplary embodiment of the invention. Referring to FIG. 5, the mold tool component 200 includes a surface 202 having a first surface portion 202a and a second surface portion 202b.
As seen in FIG. 6A, the first surface portion 202a may provide a support surface for supporting one or more surfaces of the first or upper endcap 14a that is/are disposed adjacent the first surface portion 202a. The one or more surfaces of the first or upper endcap 14a that is/are disposed adjacent the first surface portion 202a may include the top surface 58 of the body 52 and one or more of the outer surface 66, the inner surface 68 and the top surface portion 70 of the first or upper portion 56a of the inner circumferential lip 56.
Referring to FIG. 6B, the second surface portion 202b may provide a surface that receives material, M, for forming one or more surface portions of the seal member 16. The one or more surface portions of the seal member 16 that are formed by the second surface portion 202b may include the second portion 76b of the top surface 76 of the body 72 of the seal member 16 and the outer surface 82 and the inner surface 84 (including the first radial surface portion 84a, the second radial surface portion 84b and the axial ledge surface portion 84c) of the circumferential lip 74 of the seal member 16.
Referring to FIG. 6A, the remaining surface portions of the seal member 16 that are not formed by the second surface portion 202b may be formed by one or more surface portions of the first or upper endcap 14a. The remaining surface portions of the seal member 16 formed by one or more surface portions of the first or upper endcap 14a may include the first portion 76a of the top surface 76 of the body 72 of the seal member 16 (disposed adjacent the bottom surface 60 of the body 52 of the first or upper endcap 14a) and the outer side surface 80 of the body 72 of the seal member 16 (disposed adjacent to the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a). Accordingly, the bottom surface 60 of the body 52 of the first or upper endcap 14a and the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a may cooperate with the second surface portion 202b of the mold tool component 200 in order to form or provide a molding surface for receiving the material, M, and that forms the seal member 16.
Referring to FIGS. 5 and 6A, the first surface portion 202a may form a female portion or recess 204. As described above, the female portion or recess 204 corresponds to the male portion or locating rib 56a of the first or upper endcap 14a for assisting in the positioning (e.g., a central positioning) of the first or upper endcap 14a upon the mold tool component 200 in order to, for example, ensure accurate repeatability of a formation of a plurality of sub-assemblies 100 including a seal member 16 over-molded with that of an first or upper endcap 14a.
The second surface portion 202b may form a cavity 206. The cavity 206 includes a surface geometry (e.g., a circumferential or ring-shaped trough including a wall portion that flares or tapers radially-outwardly) for receiving a volume of the material, M, for forming the one or more surface portions of the seal member 16 including, for example, the second portion 76b of the top surface 76 of the body 72 of the seal member 16 and the outer surface 82 and the inner surface 84 (including the first radial surface portion 84a, the second radial surface portion 84b and the axial ledge surface portion 84c) of the circumferential lip 74 of the seal member 16.
Referring to FIGS. 6A-6C, a method for forming the sub-assembly 100 is described in accordance with an embodiment of the invention. Referring also to FIGS. 6A-7C, a method for forming a portion 10a of the filter assembly 10 including the sub-assembly 100 and the filer media 12 is described in accordance with an embodiment of the invention.
As seen in FIG. 6A, the first or upper endcap 14a may be disposed adjacent the first surface portion 202a of the surface 202 of the mold tool component 200. The disposing of the first or upper endcap 14a adjacent the first surface portion 202a of the surface 202 of the mold tool component 200 may include the registering of the male portion or locating rib 56a of the first or upper endcap 14a within the female portion or recess 204 of the first surface portion 202a of the surface 202 of the mold tool component 200.
Referring to FIG. 6B, after arranging the first or upper endcap 14a adjacent the first surface portion 202a of the mold tool component 200, an extruder 208 may deposit an amount of the material, M, upon the second surface portion 202b of the mold tool component 200 and the bottom surface 60 of the body 52 of the first or upper endcap 14a and the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a. The extruder 208 may be in communication with a supply, hopper or reservoir 210 that contains the material, M. The material, M, may include any desirable material, such as for example, a poly material.
The extruder 208 may be in communication with a controller 212 for de/actuating a valve (not shown) associated with the extruder 208 in order to permit or deny flow of the material, M, from the reservoir 210, through the extruder 208 and upon the second surface portion 202b of the mold tool component 200 and the bottom surface 60 of the body 52 of the first or upper endcap 14a and the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a.
As seen in FIG. 6B, the material, M, is deposited in a substantially liquid or semi-solid form. Upon flowing the material, M, the material, M conforms to a molding surface geometry defined by, for example, the second surface portion 202b of the mold tool component 200 and the bottom surface 60 of the body 52 of the first or upper endcap 14a and the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a.
Referring to FIG. 6C, once a volume of the material, M, has been deposited upon the second surface portion 202b of the mold tool component 200 and the bottom surface 60 of the body 52 of the first or upper endcap 14a and the inner surface 64 of the outer circumferential lip 54 of the first or upper endcap 14a, the flowing of the material, M, from the extruder 208 may cease. The ceasing of the flowing of the material, M, from the extruder 208 may be conducted in response to a signal sent from the controller 212 to the extruder 208.
Referring to FIG. 6C, upon solidification of the material, M (as a result of, e.g., curing of the material, M), the seal member 16 may be formed and may chemically bond to the first or upper endcap 14a in order to form the sub-assembly 100. The sub-assembly 100 may be removed from the mold tool component 200, if desired, and subsequently attached to filter media, such as for example, the filter media 12, by way of, for example, an adhesive, potting compound or the like. However, the liquid or semi-solid state of the material, M, may be advantageously exploited in order to utilize the material, M, that forms the seal member 16 as an attachment medium for joining the first or upper endcap 14a to the filter media 12 for forming the portion 10a of the filter assembly 10.
Prior to, during or after the depositing of the material, M, as described at FIGS. 6A-6C, the filter media 12 may be arranged upon one or more of the first or upper endcap 14a and the material, M. Referring to FIGS. 7A-7B, in an embodiment, prior to curing of the material, M, the portion 12a of the body 18 of the filter media 12 may be arranged upon and inserted into the thickness, T72, of the material, M, that forms the seal member 16.
Upon inserting the filter media 12 into the thickness, T72, of the material, M, the material, M, may be permitted to flow into an impregnate the portion 12a of the body 18 of the filter media 12. Subsequently, the material, M, may cure, and, as a result, the material, M, may form the seal member 16 while also being utilized to chemically bond the filter media 12 as well as to the first or upper endcap 14a. Upon the material, M, being cured, the filter media 12 along with the seal member 16 that has been integrally formed with (e.g. over-molded or molded-over) the first or upper endcap 14a are removed (see, e.g., FIG. 7C) from the mold tool component 200.
The connection of the filter media 12, the first or upper endcap 14a and the seal member 16 described at FIGS. 7A-7C may result in the formation of a portion 10a of the filter assembly 10. Upon subsequently attaching the second or lower endcap 14b to the portion 10a, the filter assembly 10 may be said to be formed. However, in an embodiment, the second or lower endcap 14b may be attached to the filter media 12 prior to attaching the filter media 12 to the sub-assembly 100; accordingly if the second or lower endcap 14b is previously attached to the filter media 12, upon attaching the filter media 12 to the sub-assembly 100, the filter assembly 10 may be said to be formed.
The present invention has been described with reference to certain exemplary embodiments thereof. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.
Patent Application
20130032521
