Filter assembly with top-ribbed inner filter element

Abstract

A filter assembly includes a housing, an external filter element, and an internal filter element. The external filter element is positioned within the housing and includes an external filter media. The internal filter element is positioned within the external filter element and includes an internal filter media, a media support structure, an internal top plate, and an internal bottom plate. The internal top plate includes a top rib that extends continuously around a portion of the top surface of the internal top plate.

Description

[0001] This application is a divisional application of the invention patent filed on March 19, 2018, with application number 201880018960.7 and invention title "Filter assembly with internal filter element with top rib".

[0002] Cross-referencing of related patent applications

[0003] This application claims priority and benefit to U.S. Provisional Patent Application No. 62 / 473,687, filed March 20, 2017, the entire contents of which are incorporated herein by reference. Technical Field

[0004] This invention generally relates to filter assemblies used in internal combustion engines and the like. Background Technology

[0005] Filter assemblies can be used to filter a variety of different fluids. For fluid filtration, many conventional filter assemblies include an external filter element and an internal filter element. The internal filter element is located within the external filter element. The internal filter element may have an internal top plate with legs extending vertically in the longitudinal direction of the internal filter element and in a direction perpendicular to the top surface of the internal top plate. The legs may be spaced apart from each other so that they do not extend continuously around a portion of the internal top plate.

[0006] In such an arrangement, numerous problems arise when installing the internal filter element within the external filter element, making installation difficult. For example, when the internal filter element is pushed and rotated through the interior of the external element by an operator or pressure equipment, the internal filter element may not follow the longitudinal axis of the external filter element, but may instead be angled relative to the longitudinal axis of the external filter element in various different directions within the external filter element during installation. This can cause the legs on the internal top plate to improperly contact various parts of the external filter element and may become stuck within the external filter element.

[0007] As an example of incorrect contact, instead of extending around the check valve retainer, the legs may "bump" and bottom out on the check valve retainer on the outer top plate of the outer filter element, or become stuck on the check valve retainer on the outer top plate of the outer filter element, preventing the inner filter element from being fully inserted into the outer filter element. Additionally, the legs on the inner top plate of the inner filter element may get stuck or clamped onto various other components of the outer filter element, such as the center tube and / or coalescing wrapper. Furthermore, the legs on the inner top plate of the inner filter element may clamp portions of the coalescing wrapper of the outer filter element during installation, creating holes in the coalescing wrapper and damaging the outer filter element, thus negatively impacting the filtration performance and fuel-water separation efficiency of the filter assembly.

[0008] Each time the internal filter element gets stuck on the external filter element, the operator may have to remove the internal filter element from the external filter element and begin the installation process. The internal filter element typically cannot be installed inside the external filter element in one go; instead, it may require multiple readjustments or repositionings during installation (potentially damaging the external filter element each time) until the internal filter element is correctly installed inside the external filter element. This installation process increases product assembly cycle time, which increases labor and administrative costs, and therefore increases product cost. Therefore, additional time, effort, and money are required to correctly install the internal filter element within the external filter element of a conventional filter assembly. Summary of the Invention

[0009] Various embodiments provide a filter assembly including a housing, an external filter element, and an internal filter element. The external filter element is positioned within the housing and includes an external filter media. The internal filter element is positioned within the external filter element and includes an internal filter media, a media support structure, an internal top plate, and an internal bottom plate. The internal top plate includes a top rib that extends continuously around a portion of the top surface of the internal top plate. The top rib guides the internal filter element into and within the external filter element during assembly.

[0010] Various other embodiments provide an internal filter element that can be positioned within an external filter element of a filter assembly. The internal filter element includes an internal filter medium, a media support structure, an internal top plate, and an internal bottom plate. The internal top plate includes a top rib that extends continuously around a portion of the top surface of the internal top plate. The top rib guides the internal filter element into and within the external filter element during assembly.

[0011] Various other embodiments provide methods for assembling filter assemblies. The method includes positioning an internal filter element, comprising an internal filter medium, below the external filter medium of an external filter element; inserting a top rib of an internal top plate of the internal filter element; subsequently inserting the internal filter medium of the internal filter element into the external filter medium of the external filter element; and attaching an internal bottom plate of the internal filter element to the external bottom plate of the external filter element. The top rib of the internal top plate of the internal filter element extends continuously around a portion of the top surface of the internal top plate.

[0012] These and other features (including, but not limited to, retaining and / or observing features) and the organization and manner of their operation will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which the same elements have the same reference numerals in the several drawings described below. Attached Figure Description

[0013] Figure 1A This is a perspective view of a filter assembly according to one embodiment.

[0014] Figure 1B yes Figure 1A A top perspective view of the lower part of the housing of the filter assembly.

[0015] Figure 1C yes Figure 1A A top view of the lower part of the housing of the filter assembly.

[0016] Figure 2A This is a side view of a filter component according to one embodiment.

[0017] Figure 2B yes Figure 2A Sectional view of section 2B-2B.

[0018] Figure 2C yes Figure 2A Another sectional view.

[0019] Figure 3A This is a perspective view of an external filter element according to one embodiment.

[0020] Figure 3B yes Figure 3A A side view of the external filter element, wherein the internal filter element is installed inside the external filter element.

[0021] Figure 3C yes Figure 3A Top view of the external filter element.

[0022] Figure 4A yes Figure 3A Top perspective view of the outer bottom plate of the external filter element.

[0023] Figure 4B yes Figure 4A A bottom perspective view of the outer bottom plate.

[0024] Figure 4C yes Figure 4A A sectional view of the outer bottom plate.

[0025] Figure 5A This is a perspective view of an internal filter element according to one embodiment.

[0026] Figure 5B yes Figure 5A Front view of the internal filter element.

[0027] Figure 5C yes Figure 5A A cross-sectional view of the internal filter element.

[0028] Figure 5D This is a cross-sectional view of an internal filter element according to another embodiment.

[0029] Figure 6A yes Figure 5A Top perspective view of the internal top plate of the internal filter element.

[0030] Figure 6B yes Figure 6A Top perspective view of the interior top panel.

[0031] Figure 6C yes Figure 6A A bottom view of the interior top plate.

[0032] Figure 6D yes Figure 6A Top view of the interior top plate.

[0033] Figure 6E yes Figure 6A Side view of the interior top plate.

[0034] Figure 6F yes Figure 6D Sectional view of section 6F-6F.

[0035] Figure 7A yes Figure 5A A cross-sectional view of a portion of the internal filter element.

[0036] Figure 7B yes Figure 5A A cross-sectional view of a portion of the internal filter element.

[0037] Figure 8A This is a perspective view showing the alignment of an internal filter element and an external filter element according to one embodiment.

[0038] Figure 8B The internal filter element was moved to Figure 8A A cross-sectional view of the external filter element.

[0039] Figure 8C yes Figure 3B Sectional view of section 8C-8C.

[0040] Figures 9A-9D This is a cross-sectional view of an internal filter element installed within an external filter element according to one embodiment.

[0041] Figures 10A-10C It is based on Figures 9A-9D The illustrated embodiment shows a cross-sectional view of an internal filter element installed within an external filter element.

[0042] Figure 11A-11C This is a cross-sectional view of an internal filter element installed within an external filter element, according to another embodiment.

[0043] Figures 12A-12C It is based on Figure 11A-11C The illustrated embodiment shows a cross-sectional view of an internal filter element installed within an external filter element.

[0044] Figure 13 This is a cross-sectional view of a portion of an internal filter element installed within an external filter element. Detailed Implementation

[0045] Referring generally to the accompanying drawings, the various embodiments disclosed herein relate to filter assemblies including a filter housing, an outer filter element, and an inner filter element. The inner filter element is positioned within the outer filter element and includes an inner top plate with top ribs. The top ribs of the inner filter element facilitate proper installation of the inner filter element into the outer filter element, ensuring a high-quality filter assembly and also reducing manufacturing cycle time and production and assembly time, thereby lowering product costs.

[0046] Filter components

[0047] Filter assembly 20 (e.g.) Figure 1A-2C The filter assembly 20 (shown in the diagram) is configured to filter fluid and includes a filter housing 22, an external filter element 30, and an internal filter element 130. The filter assembly 20 can be used for liquid filtration, such as for fuel and / or water filtration. Therefore, the fluid can be, in particular, a liquid, such as fuel and / or water.

[0048] The filter assembly 20 can have a variety of different filtration configurations. For example, the filter assembly 20 can be a filter-in-filter design or an advanced filter water separator (FWS). The filter assembly 20 can be designed to work in conjunction with a top-loading housing.

[0049] Filter housing

[0050] The housing 22 is configured to surround and house the outer filter element 30 and the inner filter element 130. The housing 22 includes an upper portion 24 and a lower portion 26, which are configured to attach to each other surrounding the outer filter element 30. Figure 2B and 2C As shown, the external filter element 30 is positioned inside the filter housing 22, and the internal filter element 130 is positioned inside the external filter element 30.

[0051] like Figure 2B-2C As shown, the lower portion 26 of the housing 22 includes a riser 27 that seals against the internal filter element 130, as further described herein. Figure 1B-1C As shown, the lower portion 26 of housing 22 also includes an engine integrity protection (“EIP”) critical component 29, which is configured to operate when an external filter element is installed within housing 22 (e.g., Figure 2B (As shown) corresponds to the tab 82 of the external filter element 30, as further described herein.

[0052] External filter element

[0053] An external filter element 30 may be positioned within the housing 22 and includes an external filter medium 32 configured to filter fluid. For example... Figure 8C As shown, the longitudinal axis 38 of the external filter element 30 extends through the middle of the external filter element 30 in the longitudinal direction.

[0054] like Figure 8C As shown, the external filter element 30 includes a central tube 34 that extends substantially along the length of the external filter element 30 within the internal central region of the external filter medium 32. The external filter element 30 also includes a coalescing medium or encapsulation 36 that surrounds the outside of the central tube 34 of the external filter element 30 and extends within the internal central region of the external filter medium 32.

[0055] The external filter element 30 also includes an external top cap or end plate 50 and an external bottom cap or end plate 70 located at the top and bottom of the external filter medium 32, the central tube 34 and the coalescing envelope 36, respectively.

[0056] like Figure 3A and 8CAs shown, the outer top plate 50 includes a check valve 52 and a corresponding check valve retainer 54, which holds the check valve 52 at the center of the outer top plate 50. The end 55 of the check valve retainer 54 extends into the inner central region of the outer filter medium 32 located within the outer filter element 30 (e.g., Figure 8C (As shown).

[0057] The outer bottom plate 70 can be attached to the rest of the outer filter element 30 (e.g., Figure 8A , 9A (as shown in 10A) or can be detached from the rest of the external filter element 30 (and can be attached to the rest of the external filter element 30) (as shown in 10A). Figure 11A and 12A As shown), this depends on the desired installation process (as further described herein). Figures 4A-4C As shown, the outer bottom plate 70 includes a top surface 72 and a bottom surface 76 on opposite sides. Figure 8C As shown, the top surface 72 faces the external filter medium 32 (and optionally is directly adjacent to the external filter medium 32), and the bottom surface 76 faces away from the external filter medium 32.

[0058] The outer bottom plate 70 includes an upper flange forming a top skirt 74 that extends from the top surface 72 toward the outer filter medium 32. The outer bottom plate 70 also includes a lower flange forming a bottom throat 78 that extends from the bottom surface 76 (in the opposite direction to the top skirt 74) away from the outer filter medium 32. The top skirt 74 extends continuously in a circular manner from the top surface 72, and the bottom throat 78 extends continuously in a circular manner from the bottom surface 76.

[0059] The top skirt 74 and the bottom throat 78 together define an aperture 79 that extends through the outer bottom plate 70 to allow fluid to enter and exit the outer filter element 30. For example, as further described herein, the inner filter element 130 can be inserted into the outer filter element 30 through the aperture 79.

[0060] like Figure 4B-4C As shown, the outer bottom plate 70 includes keys, micron-locking features, or tabs 82 on its bottom surface 76. (As shown...) Figure 2B As shown, the tab 82 corresponds to and interlocks with the EIP critical component 29 on the lower part 26 of the housing 22 to ensure that the unique external filter element 30 is properly positioned within the housing 22. The dimensions of the tab 82 correspond to the filter micron rating of the EIP critical component 29 on the housing 22 to ensure proper assembly of the external filter element 30 and the housing 22.

[0061] The tab 82 is positioned on the bottom surface 76 of the outer bottom end plate 70, adjacent to and abutting the outer side of the bottom throat 78. To accommodate the tab 82, the bottom throat 78 is not centered on the outer bottom end plate 70 (however, the top skirt 74 is centered on the outer bottom end plate 70). Therefore, the top skirt 74 and the bottom throat 78 are not concentric or coaxial, and are not aligned with each other, as... Figure 4C As shown. The offset between the top skirt 74 and the bottom throat 78 is shown in the side view of the outer filter element 30 (i.e., in a cross-section taken through the tab 82, for example, as shown). Figure 9D and 11C (As shown). However, when the cross-section is taken along a plane perpendicular to the side view of the outer filter element 30, the top skirt 74 and the bottom throat 78 are not offset, for example, as... Figure 10C and 12C As shown. According to one embodiment, the top skirt 74 and the bottom throat 78 are offset by approximately 2.64 millimeters (mm) to accommodate the tab 82.

[0062] The inner diameter of the top skirt 74 is larger than the inner diameter of the bottom throat 78. The difference between the inner diameters of the top skirt 74 and the bottom throat 78 (and the offset between the top skirt 74 and the bottom throat 78) forms an O-ring rest flange or bracket or flange 75 on the top surface 72 within the outer bottom end plate 70, such as... Figure 4A and 4C As shown. The flange 75 extends between the top skirt 74 and the bottom throat 78. (As illustrated...) Figure 8C As shown and further described herein, after the internal filter element 130 is installed into the external filter element 30, the legs 172 of the internal filter element 130 rest on the resting flange 75.

[0063] Internal filter element

[0064] The internal filter element 130 can be positioned within or inside the external filter element 30. For example... Figure 5C and 8C As shown, the longitudinal axis 138 of the internal filter element 130 extends through the middle of the internal filter element 130 in the longitudinal direction.

[0065] like Figures 5A-5DAs shown, the internal filter element 130 includes an internal filter medium 132 and a media support structure 134. The internal filter medium 132 is also configured to filter fluid. According to one embodiment, the internal filter medium 132 may include a hydrophobic screen and may include a filter medium having any suitable pore size, such as 2-3 micrometers. The internal filter medium cage or media support structure 134 extends along a portion of the length of the internal filter element 130 and is configured to support and retain the internal filter medium 132. The media support structure 134 may be made of various materials, such as plastic.

[0066] according to Figures 5A-5C In one embodiment shown, the internal filter medium 132 is overmolded into the media support structure 134, such that the internal filter medium 132 and the media support structure 134 form a single, integral structure that cannot be separated from each other without damage. According to... Figure 5D In another embodiment shown, the internal filter medium 132 and the media support structure 134 can be separate components that together form a multi-component structure, such as a three-piece structure. For example, the internal filter medium 132 and the media support structure 134 can be manually potted with an adhesive (e.g., epoxy resin).

[0067] like Figures 5A-5D As shown, the internal filter element 130 also includes an internal top end plate 150 and an internal bottom end plate 170 located at the top and bottom of the internal filter medium 132 and the media support structure 134, respectively. For assembling the internal filter element 130, the internal top end plate 150 can be pressed into the media support structure 134, pressed onto the top of the media support structure 134, or attached to the top of the media support structure 134, as shown. Figure 5C , 5D As shown in 7A and further described herein.

[0068] like Figures 6A-6F As shown, the internal top cover or end plate 150 includes a top surface 152 and a bottom surface 156 located on its opposite side. Figure 5C As shown, the top surface 152 faces away from the inner filter medium 132, and the bottom surface 156 faces the inner filter medium 132 (and optionally is directly adjacent to the inner filter medium 132).

[0069] The internal top plate 150 includes a top rib 154 extending upward from the top surface 152 of the internal top plate 150. The top rib 154 includes an inner surface 153 and an outer surface 155. The inner surface 153 is closer to the longitudinal axis 138 of the internal filter element 130. During assembly, the top rib 154 of the internal filter element 130 is first inserted into the external filter element 30, and then the remainder of the internal filter element 130 is inserted into the external filter element 30. When the internal filter element 130 is installed within the external filter element 30, the inner surface 153 of the top rib 154 is closer to the check valve retainer 54 (e.g., the outer surface 155 of the top rib 154) than the outer surface 155 of the top rib 154. Figure 13 (As shown).

[0070] The top rib 154 also includes a generally circular top portion 163 and a generally circular base portion 165. The top portion 163 is the portion of the top rib 154 furthest from the top surface 152. The base portion 165 is the portion closest to and adjacent to the top surface 152. The base portion 165 extends from the top surface 152.

[0071] The top rib 154 extends continuously (e.g., in 360°) around a portion of the top surface 152 of the inner top plate 150. For example, the top rib 154 extends approximately in a circle from the top surface 152 of the inner top plate 150. Therefore, when the inner filter element 130 is installed within the outer filter element 30, the top rib 154 extends at least completely around the end 55 of the check valve retainer 54 and a portion of the length of the check valve retainer 54 (e.g., ...). Figure 8C (As shown). According to one embodiment, the top rib 154 has no discontinuities (e.g., recesses, notches, cuts, openings, holes, etc.) and is substantially smooth around its circumference (including along the top portion 163, the base portion 165, and the central portion between the top portion 163 and the base portion 165).

[0072] The top rib 154 is shaped similarly to a partially hollow cone on the top surface 152 of the inner top plate 150, such that the inner diameter at the base portion 165 of the top rib 154 is smaller than the inner diameter at the top portion 163 of the top rib 154. For example, the base portion 165 of the top rib 154 extends outward and upward from the top surface 152 of the inner top plate 150 to the top portion 163 of the top rib 154 in a circular manner. In other words, the top rib 154 tapers inward and downward from the top portion 163 of the top rib 154 to the base portion 165 of the top rib 154.

[0073] The top rib 154 extends from the top surface 152 of the inner top plate 150 (i.e., from the base portion 165 to the top portion 163) at a constant and non-zero angle relative to the top surface 152 and relative to the longitudinal axis 138 of the inner filter element 130. Therefore, the base portion 165 of the top rib 154 extends from the top surface 152 of the inner top plate 150 at a non-perpendicular angle (to the longitudinal axis 138) in a generally straight line to the top portion 163 of the top rib 154 (to the top surface 153).

[0074] According to one embodiment, the top rib 154 extends from the top surface 152 at an angle of approximately 123°, ±3° (referring to the angle between the inner surface 153 of the top rib 154 and the top surface 152 of the inner top plate 150). The angle of the top rib 154 (and therefore the inner diameter of the top portion 163 of the top rib 154) can be varied according to the dimensions of the check valve 52 (and therefore the check valve retainer 54). For fitting around the check valve retainer 54, the inner diameter of the top portion 163 of the top rib 154 is larger than the outer diameter of the check valve retainer 54.

[0075] As further described herein, the top rib 154 is a self-guiding component on the inner top plate 150 that guides the inner filter element 130 into and within the outer filter element 30 during assembly, thereby facilitating the proper installation of the inner filter element 130 into the outer filter element 30. For example, the top rib 154 allows the inner filter element 130 to self-guide while the inner filter element 130 is being inserted into the outer filter element 30 (or while the outer filter element 30 is being placed on top of the inner filter).

[0076] like Figures 6A-6F As further shown, the inner top plate 150 also includes a bottom rib 158 that surrounds the bottom surface 156 of the inner top plate 150 and extends continuously (e.g., in 360°) from a portion of the inner top plate 150. For example, the bottom rib 158 extends approximately one circumference from the bottom surface 156 of the inner top plate 150. Figure 5C and 7A In the illustrated embodiment, when the inner top plate 150 is assembled with the medium support structure 134, the bottom rib 158 extends into the interior of the medium support structure 134, such that a portion of the inner top plate 150 (i.e., the bottom rib 158) is positioned within the medium support structure 134. According to Figure 5D In another embodiment shown, when the inner top plate 150 is assembled with the medium support structure 134, the bottom rib 158 extends around the outside of the medium support structure 134, such that a portion of the medium support structure 134 is positioned within the inner top plate 150 (i.e., within the bottom rib 158).

[0077] The bottom rib 158 of the internal top plate 150 can be attached to the media support structure 134 of the internal filter element 130. According to one embodiment, the bottom rib 158 of the internal top plate 150 and the media support structure 134 may have a plastic-to-plastic sealing interface or a plastic-to-plastic interference fit to attach them to each other. Therefore, as... Figure 6B , 6E As shown in -6F and 7A-7B, the internal top plate 150 includes a circumferential boss, lip, or protrusion 159 extending around the outer surface of the bottom rib 158. As... Figure 7A As shown, the media support structure 134 has a corresponding circumferential groove or notch 139 extending around the inner surface of the media support structure 134. To mount or attach the inner top plate 150 to the media support structure 134, the bottom rib 158 of the inner top plate 150 is inserted into the media support structure 134 until the protrusion 159 engages in the groove 139, thereby attaching (and optionally locking) the inner top plate 150 and the media support structure 134 together. It should be understood that, in alternative embodiments, the inner top plate 150 includes the groove 139, and the media support structure 134 includes the protrusion 159.

[0078] like Figures 5A-5D As shown, the inner bottom end cover or end plate 170 includes at least one leg 172, which extends from the bottom surface of the inner bottom end plate away from the internal filter medium 132 and is angled outward relative to the longitudinal axis 138 of the internal filter element 130 and downward relative to the bottom surface of the inner bottom end plate. For example, the inner bottom end plate 170 may include four legs 172. Figure 8C As shown, the legs 172 of the internal filter element 130 stabilize the internal filter element 130 relative to the external filter element 30 after installation by resting the legs 172 on the resting flange 75 within the top skirt 74 of the outer bottom plate 70 of the external filter element 30 during assembly. The legs 172 also center the internal filter element 130 relative to the top skirt 74. As further described herein, when the internal filter element 130 is installed within the external filter element 30, the legs 172 facilitate securing the internal filter element 130 within the external filter element 30.

[0079] like Figure 2B-2C As shown in 5A, 5C, and 5D, the internal bottom plate 170 includes a grommet 174 configured to seal against the riser 27 of the lower portion 26 of the housing 22 once the external filter element (with the internal filter element 130) is installed within the housing 22. Figure 2B-2CAs shown, riser 27 extends through hole 79 in outer bottom plate 70 of outer filter element 30 and through grommets 174 of inner filter element 130. Grommets 174 are positioned in the area surrounded by legs 172.

[0080] To explain why the top skirt 74 and bottom throat 78 of the outer bottom plate 70 of the outer filter element 30 are not concentric or coaxial and are not aligned with each other (as described above), the inner filter element 130 "floats" or can move slightly within the outer filter element 30 after the inner filter element 130 is installed into the outer filter element 30. This may be due, for example, that the inner diameter of the top skirt 74 is greater than the distance between the outer surfaces of the ends of the two opposing legs 172 (while the inner diameter of the bottom throat 78 is less than the distance between the outer surfaces of the ends of the two opposing legs 172, in order to hold the inner filter element 130 within the outer filter element 30). This configuration ensures that the inner filter element 130 can be aligned with the riser 27 (once the outer filter element 30 (with the inner filter element 130) is installed within the housing 22) and maintains concentricity between the inner filter element 130 and the riser 27, so as to create a proper and perfect seal between the inner filter element 130 and the riser 27. Furthermore, since the internal filter element 130 is aligned with the housing 22 via the riser 27 and the internal filter element 130 is aligned with the external filter element 30, the external filter element 30 is also aligned within the housing 22.

[0081] Installation of internal filter elements

[0082] Because the internal filter element 130 is separate from the external filter element 30 (rather than being potted together with the external filter element 30), the internal filter element 130 is configured to be installed within the external filter element 30, as... Figure 8A-12C As shown. Figure 8A-10C and Figure 11A-12C As shown, the internal filter element 130 can be installed in the external filter element 30 in various different ways, so the filter assembly 20 can be assembled in various different ways.

[0083] For assembling the filter assembly 20, the inner filter element 130 is positioned below the outer filter medium 32, the top rib 154 of the inner top plate 150 of the inner filter element 130 (and subsequently the inner filter medium 132 of the inner filter element 130) is inserted into the outer filter medium 32 of the outer filter element 30, and the inner bottom plate 170 of the inner filter element 130 is attached to the outer bottom plate 70 of the outer filter element 30. However, the exact order of the various processes and how the processes are performed may vary depending on the embodiments, as further described herein.

[0084] For example, Figures 8A-8C 9A-9D and 10A-10C each describe a method for mounting the internal filter element 130 within the external filter element 30, wherein the internal filter element 130 is pushed into the entire interior of the external filter element 30. The internal filter element 130 is first aligned with and positioned below the external filter element 30, as shown in Figures 9A-9D and 10A-10C. Figure 8A As shown. Figure 8B , 9A As shown in 10A, the internal filter element 130 (particularly the top rib 154 of the internal top plate 150) is inserted or moved, slid, or pushed by an operator or pressure device through the hole 79 of the external bottom plate 70 of the external filter element 30 (when the external filter element 30 may optionally be held in place). When the internal bottom plate 170 of the internal filter element 130 moves through the hole 79 and the leg 172 begins to enter the external bottom plate 70 of the external filter element 30, the bottom throat 78 of the external bottom plate 70 is directed inward (towards the longitudinal axis 138 of the internal filter element 130 and in the direction of the arrow, as shown in 10A). Figure 9B and 10B (As shown) the leg 172 is bent, compressed, or pressed. Therefore, while the leg 172 of the internal filter element 130 is compressed inward during installation and assembly, the leg 172 moves through the bottom throat 78 of the hole 79 in the outer bottom plate 70 of the outer filter element 30 to assemble the internal filter element 130 through the outer bottom plate 70 of the outer filter element 30 and facilitate installation, as shown. Figure 9C As shown.

[0085] The inner filter element 130 is pressed into the outer filter element 30 until the leg 172 of the inner bottom end plate 170 is within and engaged with the top skirt 74 of the outer bottom end plate 70 of the outer filter element 30. In this position (i.e., after the leg 172 has moved through the bottom throat 78 of the hole 79), the leg 172 automatically moves outward or expands into a relaxed state within the top skirt 74 of the hole 79 and on the top of the resting flange 75. Figure 9D and 10C(As shown), this allows the inner filter element 130 to remain mounted within the outer filter element 30. Thus, the inner filter element 130 (particularly the top rib 154) is fully inserted into the outer filter element 30, and after the outer bottom plate 30 is attached to the remainder of the outer filter element 30, the inner bottom plate 170 of the inner filter element 130 is attached to the outer bottom plate 70 of the outer filter element 30. Because the inner diameter of the hole 79 along the top skirt 74 is larger than the inner diameter along other portions of the hole 79 (e.g., the bottom throat 78), the top skirt 74 allows the legs 172 to extend outward from the longitudinal axis 138 of the inner filter element 130 in a relaxed state approximately at their original angle (relative to the longitudinal axis 138), and the legs 172 can abut the top skirt 74 of the outer bottom plate 70 and the resting flange 75. The resting flange 75 on the top surface 72 of the outer bottom plate 70 prevents the legs 172 (and the remainder of the inner filter element 130) from moving out of the outer filter element 30. Therefore, in this relaxed state and position, the internal filter element 130 is fully pushed through the external bottom plate 70, and then positioned and fully installed inside the external filter element 30.

[0086] Figure 11A-11C Each of 12A-12C describes an alternative configuration in which the internal filter element 130 can be mounted within the external filter element 30, wherein a portion of the external filter element 30 is pushed over the top of the internal filter element 130 and another portion of the external filter element 30 is pushed over the bottom of the internal filter element 130, such that the internal filter element 130 and the external filter element 30 are assembled from the inside out. More specifically, as... Figure 11A-11B As shown in 12A-12B, before and simultaneously with the insertion of the top rib 154 of the inner top plate 150 into the outer filter medium 32 of the outer filter element 30, the outer bottom plate 70 of the outer filter element 30 first separates from the rest of the outer filter element 30. Therefore, before the outer bottom plate 70 is attached to the rest of the outer filter element 30 (i.e., before the rest of the outer filter element 30 is attached) and before the inner filter element 130 (partially the top rib 154) is fully (or partially) inserted into the outer filter element 30, the inner bottom plate 170 of the inner filter element 130 is attached to, positioned on, mounted on, or encapsulated within the outer bottom plate 70 of the outer filter element 30, as... Figure 11A and 12AAs shown. According to one embodiment, the leg 172 can be inserted into the top skirt 74 through the top of the outer bottom plate 70, such that the inner filter element 130 does not move at all through the bottom throat 78 of the hole 79 (and at the same time, the outer bottom plate 70 is not attached to the rest of the outer filter element 30). According to another embodiment, the inner filter element 130 is inserted through the bottom throat 78 and the top skirt 74 to position the leg 172 within the top skirt 74, while the outer bottom plate 70 is not attached to the rest of the outer filter element 30. Once the inner bottom plate 170 of the inner filter element 130 is attached to the outer bottom plate 70 of the outer filter element 30, the leg 172 of the inner bottom plate 170 of the inner filter element 130 is positioned in a relaxed state on the outer bottom plate 70 within the top skirt 74 of the outer bottom plate 70 and rests on the resting flange 75 of the outer bottom plate 70 (as described above).

[0087] like Figure 11B and 12B As shown, after the inner bottom plate 170 of the inner filter element 130 is attached to the outer bottom plate 70 of the outer filter element 30, the inner filter element 130 is aligned with and positioned below the remainder of the outer filter element 30, and then the remainder of the outer filter element 30 (e.g., the outer filter medium 32, the central tube 34, the coalescing envelope 36, and the outer top plate 50) is pushed on top of the top rib 154 of the inner filter element 130, slid over or encapsulated above the top rib 154 of the inner filter element 130, and attached or encapsulated and sealed to the outer bottom plate 70 (while the inner filter element 130 (particularly the leg 172) and the outer bottom plate 70 remain connected to each other and can also optionally remain in place, and after the top rib 154 of the inner top plate 150 of the inner filter element 130 (and the inner filter medium 132) is inserted into the outer filter medium 32 of the outer filter element 30). Alternatively, the top rib 154 of the internal filter element 130 (with the outer bottom plate 70 attached to the inner bottom plate 170), followed by the internal filter medium 132, is inserted into the outer filter element 30. Once the entire outer filter element 30 is assembled onto the internal filter element 130, the internal filter element 130 is in place and installed within the outer filter element 30, as... Figure 11C and 12C As shown.

[0088] Once the internal filter element 130 is fully installed within the external filter element 30, the top rib 154 of the internal top plate of the internal filter element 130 completely surrounds the end 55 of the check valve retainer 54 and a portion of the length of the check valve retainer 54. At least a portion of the top rib 154 (e.g., the top portion 163 and at least a portion of the inner surface 153 of the top rib 154) overlaps with the end 55 of the check valve retainer 54 (and a portion of the length of the check valve retainer 54) along the longitudinal length direction of the filter assembly 20. A gap or interval exists between the inner surface 153 of the top rib 154 on the internal top plate 150 of the internal filter element 130 and the check valve retainer 54 on the external top plate 50 of the external filter element 30, such as... Figure 13 As shown. According to one embodiment, the gap can be approximately 5 mm.

[0089] Throughout the installation process (regardless of the method used), the top rib 154 helps guide and facilitate the correct installation of the inner filter element 130 within the outer filter element 30, protects the outer filter element 30 from damage during installation, and ensures the absence of defects or errors by allowing the inner filter element 130 to automatically and easily self-align within the outer filter element 30 during installation. Even if the longitudinal axis 138 of the inner filter element 130 is angled relative to the longitudinal axis 38 of the outer filter element 30 within the outer filter element 30 during installation, the top rib 154 ensures that the inner filter element 130 will not damage the outer filter element 30 and also properly realigns the inner filter element 130 within the outer filter element 30. For example, if the inner filter element 130 comes into contact with the interior of the outer filter element 30 during installation, the inner filter element 130 simply slides along the outer filter element 30 without being damaged (rather than stuck on or damaged) due to the construction of the top rib 154. During the assembly and installation of the internal filter element 130 within the external filter element 30, the top rib 154 serves as a "pokeyoke" within the filter assembly 20 to prevent unintentional errors.

[0090] Specifically, due to the construction of the top rib 154, the top rib 154 guides the remainder of the internal filter element 130 and prevents the internal filter element 130 from being squeezed onto or jammed by various parts of the external filter element 30. For example, the top rib 154 prevents the internal filter element 130 from getting stuck on the check valve retainer 54, the center tube 34, or the coalescing envelope 36 of the external filter element 30. As the internal filter element 130 gradually contacts the check valve retainer 54 of the outer top plate 50 of the external filter element 30, the angled inner surface 153 of the top rib 154 slides along the check valve retainer 54, causing the check valve retainer 54 to move from the top portion 163 of the top rib 154 to the base portion 165 of the top rib 154. This movement automatically realigns and recenters the longitudinal axis 138 of the internal filter element 130 to the longitudinal axis 38 of the external filter element 30, and maintains the concentricity between the top rib 154 and the check valve retainer 54 (e.g., Figure 8C (As shown). Because the top rib 154 extends continuously in an approximately circular shape, it also prevents the inner filter element 130 from getting stuck on the center tube 34 of the outer filter element 30 during installation. In addition, the top rib 154 prevents the inner filter element 130 from clamping any coalescing fodder 36 of the outer filter element 30 during installation.

[0091] Therefore, due to the top rib 154, the internal filter element 130 can be easily and more quickly installed inside the external filter element 30 in one attempt, and the internal filter element 130 automatically falls into the position inside the external filter element 30 as if the internal filter element 130 were installed inside the external filter element 30, which reduces manufacturing cycle time.

[0092] As used herein, the term "substantially" and similar terms are intended to have a broad meaning, consistent with common and accepted usage by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art who read this disclosure will understand that these terms are intended to allow that the scope of certain features described and claimed is not limited to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or irrelevant modifications or alterations to the described and claimed subject matter are considered to be within the scope of the invention as set forth in the appended claims.

[0093] The terms “connection”, “attachment”, etc., used herein mean that two components are connected to each other directly or indirectly. Such connection can be static (e.g., permanent) or movable (e.g., removable or releasable). Such connection can be achieved by two components or two components and any other intermediate components being integrally formed into a single unit, or by two components or two components and any other intermediate components being connected to each other.

[0094] References to element positions (e.g., "top", "bottom", etc.) herein are used only to describe the orientation of the various elements in the accompanying drawings. It should be noted that the orientation of the various elements may differ according to other exemplary embodiments, and these variations are intended to be covered by this disclosure.

[0095] It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments are described in detail in this disclosure, those skilled in the art will readily recognize that many modifications are possible without substantially departing from the novel teachings and advantages of the subject matter described herein (e.g., variations in the size, dimensions, structure, shape, and proportions of various elements, parameter values, mounting arrangements, use of materials, color, orientation, etc.). For example, an element shown as integrally formed may be composed of multiple parts or elements, the positions of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. According to alternative embodiments, the order or sequence of any process or method steps may be changed or reordered. Other substitutions, modifications, alterations, and omissions may also be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of the invention.

Claims

1. A filter assembly characterized by, comprising: an outer filter element, the outer filter element comprising: an outer filter media; a first end plate disposed on a first end of the outer filter media, the first end plate defining a check valve retainer extending toward the outer filter media, the check valve retainer configured to retain a check valve; a second end plate disposed on a second end of the outer filter media opposite the first end; a throat extending axially away from the outer filter media from the second end plate, a central axis of the throat being radially offset from a longitudinal axis of the filter assembly; and at least one keying structure disposed on the second end plate and abutting an outer surface of the throat, the keying structure configured to engage a key feature of a housing in which the filter assembly is installed; and an inner filter element disposed within the outer filter element, the inner filter element comprising: an inner filter media; and an inner first end plate coupled to a first end of the inner filter media proximate the first end plate of the outer filter element, the inner first end plate comprising a circumferential rib extending from the inner first end plate toward the first end plate, the circumferential rib lacking a flow passage along an axial length thereof from a top surface of the inner first end plate to a top of the circumferential rib furthest from the top surface, the circumferential rib extending continuously around a portion of the top surface of the inner first end plate by 360° such that at least a portion of the circumferential rib is disposed circumferentially around the check valve retainer.

2. The filter assembly of claim 1, wherein, the keying structure comprises a tab disposed on a surface of the second end plate.

3. The filter assembly of claim 2, wherein, the tab extends radially from a base of the throat.

4. The filter assembly of claim 2, wherein, the tab comprises a rectangular protrusion.

5. The filter assembly of any one of claims 1-4, wherein, the second end plate defines an opening from an inner peripheral surface of which the throat extends.

6. The filter assembly of any one of claims 1-4, wherein, the throat defines a groove on a radially outer surface thereof and further comprises an O-ring disposed in the groove.

7. The filter assembly of any one of claims 1-4, wherein, the second end plate comprises a skirt extending axially from the second end plate toward the outer filter media.

8. The filter assembly of claim 7, wherein, the skirt is not concentric with the throat.

9. The filter assembly of claim 7, wherein, an inner diameter of the skirt is greater than an inner diameter of the throat.

10. The filter assembly of claim 9, wherein, the second end plate comprises a flange extending between the skirt and the throat.

11. The filter assembly of any of claims 1-4, wherein: a central passage is defined and extends axially through the outer filter media, and the inner filter media is disposed within the central passage.

12. The filter assembly of claim 11, wherein, the inner filter media is coupled to a media support structure disposed in the central passage.

13. The filter assembly of claim 12, wherein, further comprising an inner second plate coupled to a second end of the inner filter media opposite the first end of the inner filter media.

14. The filter assembly of any one of claims 1-4, wherein, further comprising a center tube extending along a length of the outer filter media within an inner central region of the outer filter media.

15. The filter assembly of claim 14, wherein, further comprising a wrap disposed within the inner central region and coupled to the center tube.

16. A method of assembling a filter assembly, characterized by, comprising: A housing for a filter assembly is provided, the housing having a first portion and a second portion configured to couple to one another to define an internal volume for receiving the filter assembly, the second portion defining a critical feature; A filter assembly is provided, the filter assembly comprising: an outer filter element comprising: an outer filter media, a first end plate disposed on a first end of the outer filter media, the first end plate defining a check valve holder extending toward the outer filter media, the check valve holder configured to retain a check valve, a second end plate disposed on a second end of the outer filter media opposite the first end, a throat extending axially from the second end plate away from the outer filter media, a central axis of the throat being radially offset from a longitudinal axis of the filter assembly, and at least one keying structure disposed on the second end plate and abutting an outer surface of the throat; and an inner filter element disposed within a central passage of the outer filter element, the inner filter element comprising: an inner filter media; and an inner first end plate coupled to a first end of the inner filter media proximate the first end plate of the outer filter element, the inner first end plate comprising a circumferential rib extending from the inner first end plate toward the first end plate, the circumferential rib lacking a flow passage along an axial length thereof from a top surface of the inner first end plate to a top of the circumferential rib furthest from the top surface, the circumferential rib extending continuously around a portion of the top surface of the inner first end plate by 360° such that at least a portion of the circumferential rib is disposed circumferentially around the check valve holder; and installing the filter assembly within the housing such that the keying structure engages the critical feature of the housing. The keying structure comprises a tab disposed on a surface of the second end plate.

17. The method of claim 16, wherein, The second end plate defines an opening from an inner peripheral surface of which the throat extends.

18. The method of any one of claims 16-17, wherein, The second end plate defines an opening from an inner peripheral surface of which the throat extends.

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