1. Field of the Invention
The present invention relates to filters, particularly non-metallic filter assemblies.
2. Description of the Related Art
Vehicle filtration systems, such as air filters, oil filters and fuel filters, commonly include replaceable, disposable filter assemblies. Oil and fuel filter assemblies, in particular, often comprise a substantial number of metal parts that must be assembled. For example, replaceable spin-on oil filter assemblies, generally, include a metal canister having an open end and a closed end, a filter element assembly disposed within the metal canister, and a metal case bottom assembly seamed to the open end of the canister.
The canister is typically made from sheet metal and often includes gripping portions pressed into the closed end of the can. The filter element assembly typically includes a pleated paper element or media arranged in a cylindrical shape with its vertical ends joined together by a metal clip. Each of the horizontal ends of the cylindrically arranged media are affixed to a metal end cap using an adhesive such as plastisol, which is typically cured in an oven. A separate center tube, which is typically metallic, is captured between the metal end caps and within a central aperture provided by the pleated paper element.
The case bottom assembly ordinarily includes a retainer plate and a cover plate, both comprised of sheet metal, and which are welded or clinched together. The cover is tapped to create a threaded outlet hole for mounting the filter assembly on, and communicating oil through the hollow engine stud. Inlet holes are also stamped or drilled into the cover plate. The retainer plate is seamed to the opened of the canister.
The spin-on oil filter assembly often includes additional metal components, such as an element guide for positioning the element assembly within the canister, and a pressure relief valve for bypassing the element when it becomes clogged. Finally, the filter assembly, particularly the canister, is typically painted and labeled, which involves metal surface pretreatment, painting and curing. Recycling of these metal-containing filters can be expensive because it requires collection, handling and treatment of the used filters.
Recent attempts have been made to reduce or eliminate the metal parts of a spin-on oil filter. For example, prior art non-metallic filter assemblies have employed the same number of components thereby failing to take advantage of the benefits provided by the non-metallic material. Separate center tubes are still employed, and element guides are often still used to locate the filter element assembly to a desired position. As a result, manufacturing efficiency has not been improved appreciably. Prior art non-metallic filter assemblies have not been commercially successful, and therefore, a need remains for a filter assembly that has no metallic parts, thereby reducing the cost of manufacture and assembly.
The present invention provides a non-metallic filter assembly that includes a non-metallic canister having a closed end, an open end, and defining a hollow. A non-metallic bottom assembly is mounted on the open end of the canister, and a non-metallic filter element assembly is arranged within the hollow of the canister. The filter element assembly includes a pleated media having a first end and a second end. In one example, the pleated media is sealed at each of the first and second ends extending along an interior surface of each of the first and second ends. The non-metallic bottom assembly includes an integrated center tube that extends through a central aperture of the filter element assembly. A non-metallic bypass valve is arranged at a free end of the center tube.
The closed end curves inward into the hollow and includes a plurality of radially extending, spaced-apart flanges projecting into the hollow. A non-metallic bottom assembly is mounted on the open end of the canister and a non-metallic element assembly is disposed within the hollow of the canister. In one example, the second end is supported by and abuts the plurality of flanges, and the free end of the center tube is arranged interiorly of the flanges so that the flanges extend radially outward relative to the free end. The curved, closed end and flanges form sediment collection pockets.
The present invention further provides a method for producing a non-metallic filter assembly including the step of molding a non-metallic canister having a concave closed end, an open end, and defining a hollow. The closed end defines a plurality of radially extending, spaced-apart flanges projecting into the hollow. The method also includes the steps of pleating an element media and sealing both a first end and a second end of the media. A non-metallic bottom assembly is provided having a thread portion and an integrally formed center tube extending therefrom. The element media is mounted about the center tube of the bottom assembly. The bottom assembly is secured onto the open end of the canister such that the center tube and element assembly are disposed within the canister.
The above-mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
a-6d are illustrations of the steps of producing the pleated media of an element assembly according to one embodiment of the present invention; and
a-7c are illustrations of the steps of producing the pleated media of an element assembly according to another embodiment of the present invention.
The embodiments hereinafter disclosed are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following description. Rather the embodiments are chosen and described so that others skilled in the art may utilize its teachings.
Canister 12 includes closed end 20 and cylindrical wall 22, which together define hollow 24. Canister 12 may be molded to include a plurality of gripping depressions 30 defined in cylindrical wall 22 near closed end 20. To provide added strength to the canister 12, closed end 20 may optionally have a concave shape that curves inward into hollow 24, which provides dimensionally stability to the closed end 20 under pressure. Closed end 20 also has a plurality of radially extending, spaced apart flanges or ribs 26 that protrude into hollow 24. As best illustrated in
Referring now to
Plate portion 32 further includes radial support ribs 50 defined on the exterior surface of plate portion 32. Ribs 50 reinforce plate portion 32 and provide added strength to prevent bending or deflection of plate portion 32 to better ensure dimensional stability so that a good seal is maintained. Bottom assembly 16 also includes circumferentially extending exterior groove 40 defined on the exterior surface of plate portion 32. Exterior groove 40 receives gasket 42, which seals oil filter assembly 10 to the engine. Alternatively, gasket 42 may be molded in place on plate portion 32 during the formation of bottom assembly 16. Bottom assembly 16 also includes circumferentially extending interior groove 44 defined on the interior surface of plate portion 32. Bottom assembly 16 is mounted on the open end 18 of canister 12 by fitting an open edge 19 of cylindrical wall 22 into interior groove 44 and sealingly fixing wall 22 within interior groove 44 using any suitable fixing means, such as spin welding, vibration welding or heat resistant adhesive. Such assembly process reduces the need for seaming equipment. Furthermore, bottom assembly 16 may be molded to include inlet holes 36, outlet hole 38, ribs 50, and grooves 40, 44, thereby eliminating the need for pressing, tapping and/or clinching.
Center tube 34 includes free end 46 opposite plate portion 32 and positioned adjacent closed end 20 of canister 12. When bottom assembly 16 is mounted on canister 12, center tube 34 extends into hollow 24 of canister 12 and free end 46 of center tube 34 fits within seat 28 of closed end 20. A step or stop flange 35 extends radially about center tube 34 near plate portion 32 and provides a supporting surface for filter element assembly 14. A non-metallic anti-drain back valve (not shown for clarity) may be supported near center tube 34 near the plate portion 32 to prevent dirty oil from flowing past the inlet holes 36.
The free end 46 is a received by the flanges 26, which locate the center tube 34, thereby eliminating the need for the prior art element guide.
Bottom assembly 16 also includes a non-metallic bypass valve 48 mounted in the free end 46 of center tube 34, as seen in
Turning now to
As shown in
As shown in
While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.