Multistage filter with hydrophobic filter screen

Abstract

A filter element includes a first filter media defining a central passage. An end cap is disposed on one end of the filter media, the end cap defining an outlet for cleaning fluid to exit the filter media. A second filter media is disposed radially inward of the first filter media, the second filter media configured to coalesce water. A hydrophobic screen is disposed across the outlet defined in the end cap.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and benefit to U.S. Provisional Application No. 63 / 127,447, filed December 18, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to filtration systems for filtering fluids such as fuels.

[0004] background

[0005] Internal combustion engines typically burn a mixture of fuel (e.g., diesel, gasoline, natural gas, etc.) and air. Before entering the engine, the fuel usually passes through a filter element to remove particulate matter (e.g., dust, metal particles, debris, etc.), and in some cases, water is also separated from the fuel. Such fuel-water separator filter assemblies typically separate water at the outer diameter of the filter element, and the separated water accumulates in a reservoir located below the filter element. In some cases, water may still remain in the clean fuel after passing through various water separation layers, which is undesirable.

[0006] Overview

[0007] The embodiments described herein generally relate to fuel-water separator filter assemblies, and particularly to filter assemblies comprising multiple layers of filter media, hydrophobic screens, and / or filter elements, wherein the hydrophobic screens are configured to span an outlet defined in a filter media end cap, and the filter elements have tapered filter media tubes.

[0008] In some embodiments, the filter element includes a first filter medium defining a central channel. An end cap is disposed at one end of the filter medium, defining an outlet for cleaning fluid to exit the filter medium. A second filter medium is disposed radially inside the first filter medium, the second filter medium being configured to coalesce water. A hydrophobic filter screen is configured to span the outlet defined in the end cap.

[0009] In some embodiments, the filter element further includes a sealing member disposed within the outlet and defining a passage through the sealing member, wherein the hydrophobic filter screen is disposed at the upstream end of the sealing member.

[0010] In some embodiments, the hydrophobic filter is coupled to the upstream end of the sealing member.

[0011] In some embodiments, the sealing member includes a circumferential slot defined on the radially inner surface of the sealing member, with the outer peripheral edge of the hydrophobic filter located within the circumferential slot.

[0012] In some embodiments, the sealing member includes: a sealing member body disposed within the central channel of the first filter medium and defining the upstream end of the sealing member; a sealing member downstream of the sealing member body, the sealing member downstream having a larger cross-sectional width than the upstream end; a sealing member intermediate portion connecting the sealing member body to the sealing member downstream portion; and an end cap sealing portion including a circumferential wall extending axially from the sealing member intermediate portion toward the upstream end of the sealing member, such that a radial space is formed between the sealing member body and the end cap sealing portion.

[0013] In some embodiments, the end cap defines an end cap outlet, and an end cap flange extends axially from the inner peripheral edge of the end cap outlet into the central channel of the first filter medium. The radially inner surface of the end cap flange is disposed around and contacts the radially outer surface of the end cap sealing portion to form a radial seal between the radially inner surface of the end cap flange and the radially outer surface of the end cap sealing portion.

[0014] In some embodiments, the end cap sealing portion includes an end cap sealing portion lug extending radially outward from the end cap sealing portion, and a first axial end of the end cap flange is disposed on an axial surface of the end cap sealing portion lug away from the upstream end and contacts the axial surface of the end cap sealing portion lug.

[0015] In some embodiments, the axial surface of the downstream portion of the sealing member near the end cap is configured to: contact the axial surface of the end cap near the downstream portion of the sealing member and form an axial seal with the axial surface of the end cap; or contact the radially inner surface of the end cap flange and form an axial seal with the radially inner surface of the end cap flange.

[0016] Radial seal.

[0017] In some embodiments, the sealing member further includes a plurality of arms extending radially outward from the outer surface of a downstream portion of the sealing member.

[0018] In some embodiments, the sealing member further includes a sealing member ring disposed circumferentially around the downstream portion of the sealing member and coupled to an axial end of each of the plurality of arms remote from the downstream portion of the sealing member.

[0019] In some embodiments, the sealing member further includes a plurality of spacer pins extending axially away from the upstream end of the sealing member ring.

[0020] In some embodiments, the spacer pin is disposed at the location where the plurality of arms of the sealing member ring are connected to the sealing member ring.

[0021] In some embodiments, the second filter medium includes: a first layer configured to coalesce water; and a second layer downstream of the first layer, the second layer being a hydrophobic layer.

[0022] In some embodiments, the second filter medium includes a filter medium tube having a tapered profile along the longitudinal axis of the filter element.

[0023] In some embodiments, a filter assembly includes: a housing defining an internal volume; a filter element disposed within the internal volume; and a nut plate coupled to a first end of the housing, the first end of the housing being adjacent to an end of the first filter medium having the end cap disposed thereon, the nut plate defining a central opening and a nut plate flange extending axially from an inner periphery of the central opening toward the sealing member, wherein the nut plate flange extends into a downstream portion of the sealing member such that a radially outer surface of the nut plate flange contacts a radially inner surface of the downstream portion of the sealing member to form a radial seal between the radially outer surface of the nut plate flange and the radially inner surface of the downstream portion of the sealing member.

[0024] In some embodiments, a sealing member is provided for forming a seal between a filter element and a filter head. The sealing member includes a sealing member body configured to be disposed within a central channel of the filter medium of the filter element, the sealing member body defining an upstream end of the sealing member. A downstream portion of the sealing member is located downstream of the sealing member body and has a larger cross-sectional width than the upstream end. An intermediate portion of the sealing member connects the sealing member body to the downstream portion of the sealing member. The sealing member also includes an end cap sealing portion including a circumferential wall extending axially from the intermediate portion of the sealing member toward the upstream end of the sealing member, such that a radial space is formed between the sealing member body and the end cap sealing portion.

[0025] In some embodiments, the end cap of the filter element defines an end cap outlet, an end cap flange extends axially from the inner peripheral edge of the end cap outlet into the central channel of the filter medium; and the end cap sealing portion is configured to be disposed together with the central channel of the filter medium such that when the sealing member is coupled to the end cap, the radially inner surface of the end cap flange surrounds and contacts the radially outer surface of the end cap sealing portion to form a radial seal between the radially inner surface of the end cap flange and the radially outer surface of the end cap sealing portion.

[0026] In some embodiments, the end cap sealing portion includes an end cap sealing portion lug extending radially outward from the end cap sealing portion, and a first axial end of the end cap flange is configured to be disposed on an axial surface of the end cap sealing portion lug away from the upstream end and to contact the axial surface of the end cap sealing portion lug when the sealing member is coupled to the end cap.

[0027] In some embodiments, the sealing member further includes a plurality of arms extending radially outward from the outer surface of a downstream portion of the sealing member.

[0028] In some embodiments, the sealing member further includes a sealing member ring disposed circumferentially around the downstream portion of the sealing member and coupled to an axial end of each of the plurality of arms remote from the downstream portion of the sealing member.

[0029] In some embodiments, the sealing member further includes a plurality of spacer pins extending axially away from the upstream end of the sealing member ring.

[0030] In some embodiments, the spacer pin is disposed at the location where the plurality of arms of the sealing member ring are connected to the sealing member ring.

[0031] In some embodiments, the filter element includes a first filter medium defining a central channel. A filter medium tube is disposed within the central channel, the filter medium tube having a tapered profile along the longitudinal axis of the filter element, and an end cap is disposed at one end of the first filter medium, the end cap defining an outlet for cleaning fluid to exit the filter element.

[0032] In some embodiments, the method of forming a filter element includes: stacking a top filter media layer on at least one bottom media layer; connecting vertical points along the length of the top and bottom filter media layers to form a filter media; and winding the filter media into a filter media tube to form pillow-shaped protrusions on the inner or outer surface of the filter media tube.

[0033] It should be understood that all combinations of the foregoing concepts and other concepts discussed in more detail below (assuming such concepts are not inconsistent with each other) are contemplated as part of the inventive subject matter disclosed herein. In particular, all combinations of the claimed subject matter appearing in this disclosure are contemplated as part of the inventive subject matter disclosed herein. Brief description of the attached diagram

[0035] The foregoing and other features of this disclosure will become more fully apparent from the following description taken in conjunction with the accompanying drawings and the appended claims. It should be understood that these drawings depict only a few embodiments according to this disclosure and should therefore not be construed as limiting the scope of this disclosure, which will be described in further specific description and detail using the drawings.

[0036] Figure 1 This is a cross-sectional view of a filter element according to an embodiment.

[0037] Figure 2 yes Figure 1 Part of the filter element ( Figure 1 The side cross-sectional view (indicated by arrow A in the figure).

[0038] Figure 3A Is included Figure 1 The bottom perspective view of the first end cap of the filter element, which has a hydrophobic filter screen disposed across the outlet of the first end cap.

[0039] Figure 3B yes Figure 3A Side view of the end cap and hydrophobic filter screen.

[0040] Figure 4 This is a cross-sectional view of the filter assembly according to an embodiment.

[0041] Figure 5 Included according to a particular embodiment Figure 4 A cross-sectional view of the sealing component in the filter assembly.

[0042] Figure 6 This is a side view of the conical filter media tube according to an embodiment.

[0043] Figure 7A A rectangular filter medium sheet according to an embodiment is shown, and Figure 7B A filter media tube is shown where a rectangular filter media sheet is folded into a uniform cross-section.

[0044] Figure 8A A rectangular filter medium sheet according to an embodiment is shown, and Figure 8B The image shows a rectangular filter media sheet folded into a conical filter media tube.

[0045] Figure 8C yes Figure 8B Side perspective view of the filter media tube.

[0046] Figure 9 This is a perspective view of an assembly tool according to an embodiment, used to facilitate the insertion of a tapered filter media tube into a central tube disposed within the filter media.

[0047] Figures 10A-10B Is it by Figure 9 The assembly tool prevents the tapered filter media tube from being fully inserted into the central tube. Figure 10C This is a perspective view of a conical filter media tube inserted into the center tube with the correct orientation (without...). Figure 9 (The assembly tools interfere); and Figure 10D It is a perspective view of the filter medium set in the assembly tool, the filter medium having a central tube and a tapered filter medium tube inserted into the filter medium in the correct orientation facilitated by the assembly tool.

[0048] Figure 11 This is a side view of the conical filter media tube according to an embodiment.

[0049] Figure 12 This is a side perspective view of a central tube according to an embodiment, which is tapered in its inner diameter and straight-walled in its outer diameter, with an end cap attached to the central tube.

[0050] Figure 13 An internal view of the filter media tube with a pillow-shaped protrusion is shown after the central tube is inserted.

[0051] Figures 14-15 The various steps in a method for forming a conical filter media tube to increase the uniformity of the pillow-shaped protrusions of the conical filter media tube according to an embodiment are shown.

[0052] Figure 16 This is a perspective view of a sealing member in a filter assembly according to another embodiment.

[0053] Figure 17 It includes Figure 16 A side cross-sectional view of a portion of the filter assembly containing the sealing component.

[0054] In the following detailed description, reference is made to the accompanying drawings. In the drawings, like reference numerals generally identify like parts unless the context otherwise indicates. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that aspects of this disclosure generally described herein and illustrated in the drawings can be arranged, substituted, combined, and designed in a variety of different configurations, all of which are expressly contemplated and constitute a part of this disclosure.

[0055] Detailed description

[0056] The embodiments described herein generally relate to fuel-water separator filter assemblies, and more particularly to filter assemblies comprising multiple layers of filter media, hydrophobic screens, and / or filter elements, wherein the hydrophobic screens are configured to span an outlet defined in a filter media end cap, and the filter elements have tapered filter media tubes.

[0057] The embodiments of the filter elements described herein can provide various benefits, including, for example: (1) providing improved water separation efficiency (up to 99%) in various embodiments; (2) allowing easy integration with existing filter elements; and (3) improving water separation efficiency without significantly increasing manufacturing complexity or manufacturing costs.

[0058] It should be understood that while the various embodiments of the filter elements and filter assemblies described herein are described as fuel-water separators configured to separate water from fuel, it should be understood that the concepts described herein can be used to filter and separate water from any fluid, such as lubricants, air, air-fuel mixtures, etc.

[0059] Figure 1 This is a side cross-sectional view of a filter element 130 according to an embodiment. The filter element 130 includes a first filter medium 132, which defines a longitudinal axis A around the filter element 130. LA central channel 131. A central tube 138 is disposed within the central channel 131. A first filter medium 132 is a radial flow filter element configured to filter fuel as it flows radially from the outer radial surface of the first filter medium 132 and passes through the first filter medium 132, the fuel entering the central channel 131 (e.g., via a plurality of openings defined in the central tube 138) becoming filtered fuel. In some embodiments, the first filter medium 132 may include a pleated filter medium. In other embodiments, the first filter medium 132 may include a straw media, a grooved media, a tetrahedral media, a corrugated media, a depth filter media, or any other suitable filter medium. In some embodiments, the first filter medium 132 may be configured to coalesce and separate water from the fuel as it passes through the first filter medium 132.

[0060] The second filter medium 134 is disposed radially inside the central tube 138. The second filter medium 134 can be configured to coalesce water droplets. In some embodiments, the second filter medium 134 can be a dual-layer filter medium comprising a first layer configured to coalesce water and a second layer radially disposed downstream of the first layer and configured to strip water. The water stripping layer can also be made as a layer separating inward from the second filter medium 134. The second layer can be a hydrophobic layer configured to further separate or strip water that may remain in the fuel after passing through the first layer. In some embodiments, the second filter medium 134 can include a filter medium tube, for example, a coalescing tube disposed within a central channel 131 radially inside the central tube 138, or in other embodiments, a coalescing tube disposed between the first filter medium 132 and the central tube 138. The coalescing tube can form the first layer of the second filter medium 134 and further coalesce water droplets to make the droplets larger and heavier. A hydrophobic layer or any other water separation layer is attached to the upstream layer of the second filter medium 134, for example, to the inner surface of the first layer, and forms the second layer of the second filter medium 134. The second layer separates or strips agglomerated water droplets from the clean fuel that has passed through the first layer of the first filter medium 132 and the second filter medium 134. The separated water flows downwards towards the bottom of the filter element 130 under the influence of gravity, and the separated water can be collected in a water reservoir of the filter housing, in which the filter element 130 is disposed.

[0061] like Figure 1As shown, a plurality of orifices 135 may be defined at the bottom end of the second filter medium 134 (e.g., the lower end of the second filter medium 134 relative to gravity). The plurality of orifices 135 may be defined in one or both of the first and second layers of the second filter medium 134. Water that has separated from the fuel after passing through the second filter medium 134 (e.g., coalescing through the first layer and / or stripping from the fuel stream through the second layer) flows down the surface of the second filter medium 134 and through the plurality of orifices 135, thereby falling into a water reservoir (from which water may be discharged).

[0062] A first end cap 142 is disposed on the top end of the first filter medium 132, and a second end cap 144 is disposed on the bottom end of the first filter medium 132 opposite to the top end. The first end cap 142 defines an outlet for cleaning fluid to exit the filter element 130. In some embodiments, the first and second layers of coalescing tubes forming the second filter medium 134 are joined to each other at their respective axial ends. The top end of the coalescing tube may be encapsulated (i.e., bonded or fused) into the first end cap 142, and the bottom end of the coalescing tube may be encapsulated into the second end cap 144. During the manufacture of the filter element 130 for sealing the first and second layers, the axial edges of the coalescing tubes forming the second filter medium 134 may be covered with a potting compound.

[0063] A hydrophobic filter 136 is configured to span an outlet defined in a first end cap 142. Clean fuel, filtered by the first filter medium 132 and the second filter medium 134, flows into the central channel 131 and then exits the filter element 130 through the outlet defined in the first end cap 142. A small amount of water may still be present in the fuel. The hydrophobic filter 136 acts as a final stage filter to remove any remaining water droplets from the fuel as it passes through the outlet. This further improves the water separation efficiency of the filter element 130 and allows the filter element 130 to have a water separation efficiency of up to 99%.

[0064] The hydrophobic filter 136 can be made of any suitable material. In some embodiments, the hydrophobic filter 136 can be formed of a polymer (e.g., polyester or nylon). In other embodiments, the hydrophobic filter 136 can be formed of stainless steel coated with a hydrophobic material. In some embodiments, the hydrophobic filter can have a pore size in the range of 10 micrometers to 150 micrometers. In a particular embodiment, the pore size of the hydrophobic filter 136 can be in the range of about 55 micrometers to about 105 micrometers (inclusive).

[0065] The hydrophobic filter 136 may have an open area of ​​15% to 60% (inclusive). In some embodiments, the hydrophobic filter 136 has a pore size of 105 micrometers and an open area of ​​33% or 52%. In other embodiments, the hydrophobic filter has a pore size of 55 micrometers and an open area of ​​31%. In still other embodiments, the hydrophobic filter 136 has a pore size of 18 micrometers and an open area of ​​18%. The pore size of the hydrophobic filter 136 may be specified such that the hydrophobic filter will not be clogged by any particles that may pass through the first filter medium 132 and the second filter medium 134. In some embodiments, the hydrophobic filter 136 may be formed of braided yarn. In other embodiments, the hydrophobic filter 136 may be formed of a perforated material (e.g., perforated sheet, polymer, plastic, or metal (e.g., stainless steel)).

[0066] Now also referencing Figures 2-3B The sealing member 150 is disposed in the outlet defined by the first end cap 142. The sealing member 150 may include a gasket configured to receive the filter head (e.g., when the filter element 130 is coupled to the filter head). Figure 4 The inlet of the filter head 204. A sealing member 150 defines a channel through which the filter passes. A hydrophobic filter screen 136 is disposed on the upstream end 151 of the sealing member 150. (As...) Figures 2-3B As shown, to secure the hydrophobic filter 136 to the upstream end 151 of the sealing member 150, the hydrophobic filter 136 can be disposed on the surface of the first end cap 142 configured to be close to the first filter medium 132, such that a portion of the hydrophobic filter 136 overlaps with the upstream end 151 of the sealing member 150. The first filter medium 132 is then attached to the surface of the first end cap 142, such that the hydrophobic filter 136 is inserted and thus secured between the first end cap 142 and the first filter medium 132. A portion of the hydrophobic filter 136 remains disposed on the upstream end 151 of the sealing member 150 and serves as the final water stripping layer of the filter element 130.

[0067] In some embodiments, a hydrophobic filter may be attached to the upstream end of the sealing member (e.g., integrated with the sealing member). For example, Figure 4 A cross-section of a filter assembly 200 according to an embodiment is shown. The filter assembly 200 includes a housing 201, a filter element 230, an adapter 248, and an adapter sealing member 246 positioned around the adapter 248. It should be understood that, although Figure 4 The accompanying drawings show a hydrophobic filter connected to the upstream end of the sealing member, but in other embodiments, the hydrophobic filter may be connected to the downstream end of the sealing member. All such embodiments should be understood to be included in this disclosure.

[0068] The housing 201 defines the internal volume, and the filter element 230 is located along the longitudinal axis A of the housing 201. L The filter assembly 200 is disposed within an internal volume. A nut plate 260 is attached to the top of the housing 201. The nut plate 260 defines a central opening that can be used as an outlet for filtered fuel exiting the housing 201. For example, when the filter assembly 200 is attached to the filter head 204, the filter head inlet 205 of the filter head 204 can be inserted through the central opening defined by the nut plate 260. An orifice 262 may also be defined in the nut plate 260 around the central opening for conveying unfiltered fuel into the housing 201 surrounding the filter element 230. A filter head sealing member 206 (e.g., an O-ring or washer) is disposed at the top of the housing 201 and is configured to form an axial seal and / or a radial seal with the filter head 204 when the filter assembly 200 is attached to the filter head 204.

[0069] Adapter 248 is coupled to the bottom end of housing 201 opposite to the top end. Adapter 248 may include an annular structure comprising a plurality of threads 249 defined on its radially inner surface. The plurality of threads 249 are configured to engage with corresponding threads of water reservoir 270 to allow water reservoir 270 to be coupled to the bottom end of housing 201 via adapter 248. Water separated from fuel after passing through filter element 230 enters water reservoir 270 through adapter 248 and can be collected in water reservoir 270 for later discharge.

[0070] Filter element 230 includes a first filter medium 132, a second filter medium 134, a central tube 138, a first end cap 142, and a second end cap 144, as described above with respect to filter element 130. However, unlike filter element 130, filter element 230 includes a sealing member 250 disposed in an outlet defined in the first end cap 142. Sealing member 250 defines a channel through which filter head inlet 205 is inserted when filter element 230 is coupled to filter head 204. Unlike sealing member 150, hydrophobic filter screen 236 is coupled to the upstream end 251 of sealing member 250, for example, by overmolding into sealing member 250. In some embodiments, hydrophobic filter screen 236 is integrally formed with sealing member 250, for example, in a molding process used to form sealing member 250. In other embodiments, hydrophobic filter screen 236 may be bonded to upstream end 251 by adhesive, melt bonding, welding, or any other suitable joining process.

[0071] An adapter sealing member 246 is disposed around the adapter 248 and forms an axial seal with the second end cap 144. The adapter sealing member 246 may include a gasket having a rectangular cross-section. In other embodiments, the adapter sealing member 246 may include an O-ring. The adapter sealing member 246 may be configured to form an axial seal and / or a radial seal with the housing 201. For example, the top surface of the adapter sealing member 246 near the second end cap 144 abuts the second end cap 144 to form an axial seal therewith, and may also form a radial seal with the housing 201. In this way, the adapter sealing member 246 forms a seal between the housing 201 and the filter element 230, without being disposed in or held by the housing 201 or the filter element 230. Alignment and positioning of the adapter sealing member 246 are instead achieved by the adapter 248. Furthermore, the adapter sealing member 246 may have a simple design that is easy to manufacture and reduces manufacturing and installation costs.

[0072] like Figure 4 As shown, a sealing member 250 is disposed between the first end cap 142 and the nut plate 260, providing a seal between the central channel 131 of the filter element 130 and the central opening of the nut plate 260. For example, a first portion of the sealing member 250 may be disposed within the inner rim of an outlet defined in the first end cap 142, the inner rim being coaxial with the central channel 131 of the first filter medium 132. A second portion of the sealing member 250 surrounds the central opening of the nut plate 260, such that the sealing member 250 forms a conduit connecting the central channel 131 to the central opening, and forms a seal between the central channel and the central opening.

[0073] A biasing member 264 (e.g., a coil spring, Bass spring, etc.) is operatively coupled to the second end cap 144. For example, the biasing member 264 may be disposed between the nut plate 260 and the first end cap 142. The biasing member 264 applies a biasing force on the first end cap 142, pushing the filter element 230 toward the adapter seal member 246, thereby causing the first end cap 142 to press against the adapter seal member 246. Furthermore, the biasing force also pushes the adapter seal member 246 toward the housing 201, which enhances the seal between the housing 201 and the second end cap 144 through the adapter seal member 246.

[0074] As previously described, holes 135 or perforations may be present near the bottom end of the filter media tube forming the second filter media 134 to drain coalesced water. The size of the holes 135 may be so small that it is difficult to discern which end of the filter media tube is the bottom when it is inserted into the central tube (e.g., central tube 138). This can lead to an incorrect orientation where the holes 135 are located at the top instead of the bottom. To address this alignment problem, in some embodiments the filter media tube may be tapered. For example, according to an embodiment, Figure 6 This is a side view of the conical filter media tube 334. (Example) Figure 6 As shown, the bottom end 337 of the filter media tube 334, which has a plurality of holes 335 defined in its vicinity, has a larger cross-sectional width (e.g., diameter) than the top end 339 of the filter media tube 334 opposite to the bottom end 337. The plurality of holes 335 may be located on the inner diameter of the filter media tube 334 closer to the larger bottom end 337. Therefore, based on the difference in cross-section between the top end 339 and the bottom end 337, a user can distinguish the top end 339 from the bottom end 337. In other embodiments, the top end 339 may have a larger cross-sectional width than the bottom end 337 of the filter media tube 334, and the plurality of holes 335 may be defined at the smaller bottom end 337.

[0075] The top end 339 is smaller than the bottom end 337, or vice versa, allowing the conical filter media tube 334 to be inserted into the central tube with a non-uniform or conical cross-section only in one direction, i.e., the top end 339 with the smaller cross-section is inserted into the central tube first.

[0076] Figure 7A A rectangular filter medium sheet according to an embodiment is shown, and Figure 7B A filter media tube is shown where a rectangular filter media sheet is folded into a uniform cross-section. Similarly, Figure 8A A rectangular filter medium sheet according to an embodiment is shown, and Figure 8B The image shows a rectangular filter media sheet folded into a conical filter media tube. Figure 8C yes Figure 7B A side perspective view of the filter media tube. A slight overlap exists when rectangular filter media sheets are folded to form a tapered filter media tube. However, the maximum overlap width can be relatively small (e.g., less than 20 mm), and its impact on the overall filtration efficiency or porosity of the filter media tube is negligible.

[0077] Figure 9This is a perspective view of an assembly tool 380 according to an embodiment for facilitating the insertion of a tapered filter media tube 334 into a central tube of a filter element. The central tube may have a uniform cross-section, may be hourglass-shaped, and / or have any other shape or cross-section that allows the tapered filter media tube 334 to be inserted therein from any axial direction (e.g., a tapered shape with a sufficiently large diameter to allow the tapered filter media tube 334 to be inserted therein in any orientation). The assembly tool 380 includes an assembly cylinder 382 having a first portion having a first cross-sectional width (e.g., diameter) and a second portion coupled to the first portion. The second portion has a smaller cross-section (e.g., diameter) than the first portion, such that the assembly cylinder 382 tapers gradually from the first portion to the second portion. The first portion may be disposed in an assembly cap 384.

[0078] The assembly cylinder 382 prevents the conical filter media tube from being inserted inverted into the central tube because, although one end of the filter media tube with a smaller cross-section can be inserted into the second part of the assembly cylinder 382, ​​it will interfere with the first part of the assembly cylinder 382 with a larger cross-sectional width, thereby preventing the conical filter media tube from being further inserted toward the assembly cover 384.

[0079] Figures 10A-10C According to the embodiment, the assembly tool 380 is used to... Figure 6 Various images of a conical filter media tube 334 inserted into a central tube 338 (e.g., a uniform cross-section or an hourglass-shaped central tube). For example... Figures 10A-10B As shown, if the filter media tube 334 is inserted into the central tube 338 with an incorrect orientation (e.g., inserting the tip 339 with a smaller cross-section first), there will be interference with the assembly cylinder 382. Figure 10A The interference at the maximum diameter is shown, and Figure 10B Interference is shown at the minimum diameter of the top 339 of the filter media tube 334, which has a smaller cross-section, thus preventing the filter media tube 334 from being fully inserted into the central tube 338. Instead, Figure 10CThe filter media tube 334 is shown inserted into the central tube 338 with the correct orientation, wherein the filter media tube 334 does not interfere with the assembly cylinder 382 and slides on the second and first portions of the assembly cylinder 382 to fully engage within the central tube 338. In some embodiments, visual markings may be provided on the filter media tube 334 to allow a user to distinguish the bottom end 337 from the top end 339 of the tapered filter media tube 334. In some embodiments, the tapered central tube, including the tightly engaged tapered filter media tube 334, may also be used with the assembly tool 380 to ensure that the tapered central tube and the tapered filter media tube 334 assembly are correctly oriented when forming the filter element. In such an embodiment, if the tapered central tube and the tapered filter media tube 334 are not correctly oriented, both the tapered central tube and the tapered filter media tube will be pushed upward relative to the filter media 332, i.e., ejected from the filter media.

[0080] In some embodiments, the central tube may also have a tapered profile. For example, according to an embodiment, Figure 11 This is a side view of the conical filter media tube 434, and Figure 12 This is a side perspective view of a tapered central tube 438 configured to receive a tapered filter media tube in only one direction. The bottom end 441 of the central tube 438 has a larger cross-section than the top end 443 of the central tube 438, corresponding to the bottom end 437 of the filter media tube 434, and the top end 443 of the central tube 438 corresponds to the top end 439 of the filter media tube 434. Therefore, the central tube 438 becomes a pass / fail gauge that allows the filter media tube 434 to be inserted only in the correct orientation. As previously mentioned, visual markings may be present on the filter media tube 434 to aid in orientation.

[0081] Figure 12 Also shown is a top end cap 442 connected to the top end 443 of the central tube 438 according to an embodiment, and a bottom end cap 444 connected to the bottom end 441 of the central tube 438. The bottom end cap 444 has a larger diameter bottom end cap inner rim 447 connected to the inner surface of the bottom end 441 of the central tube 438 than the diameter of the top end cap inner rim 445 of the top end cap 442 connected to the inner surface of the top end 443 of the central tube 438.

[0082] In some embodiments, a pillow-shaped protrusion may appear in the filter media tube during insertion into the central tube. For example, Figure 13 An internal view of a filter media tube with a pillow-shaped protrusion after the central tube has been inserted is shown. It may be desirable to obtain a uniform pillow-shaped protrusion around the inner circumference. Figures 14-15Various processes in a method 600 for forming a filter media tube according to an embodiment are shown to increase the uniformity of the pillow-shaped protrusions of the filter media tube.

[0083] Method 600 includes layering the media in step 1, for example, stacking a top media layer on top of a bottom media layer. In step 2, vertical points are joined along the length of the media layers (e.g., by ultrasonic welding, adhesive, bonding, etc.). The distance between the joined areas can vary based on the total length of the layers. The joined areas do not necessarily cover the full height of the filter media tube. Dimension Y can vary with the total height of the filter media tube or as needed.

[0084] In step 3, the joined media layers are rolled into a filter media tube. Two alternatives can be used. For example, an alternative is shown in step 3A, where the top layer is flat when the joining occurs. This allows a pillow-shaped protrusion to form naturally on the inner diameter of the filter media tube due to the difference in circumference between the outer and inner layers. Another alternative is shown in step 3B, where the defined space between the top layer and the joining area is joined to form the pillow-shaped protrusion, and the joining layer is rolled into a filter media tube such that a pillow-shaped protrusion is formed on the outer diameter of the filter media tube.

[0085] Figure 16 This is a perspective view of a sealing member 550 that can be used in a filter assembly (e.g., filter assembly 100) according to yet another embodiment. Figure 17 This is a side cross-sectional view of a portion of a filter assembly 500, including a sealing member 550, which is coupled to a filter head 204. The sealing member 550 includes a sealing member body 551 defining a longitudinal channel configured to receive an inlet 205 of the filter head 204. A hydrophobic filter screen 536 is coupled to an upstream end of the sealing member body 551. The hydrophobic filter screen 536 may be substantially similar to the hydrophobic filter screens 136 or 236 described earlier herein. In some embodiments, a circumferential slot 555 may be defined on an inner surface of the sealing member body 551, and an outer peripheral edge of the hydrophobic filter screen 536 may be inserted into the circumferential slot 555 to secure the hydrophobic filter screen 536 to the upstream end of the sealing member body 551. In other embodiments, the hydrophobic filter screen 536 may be embedded in the upstream end of the sealing member body 551 (e.g., overmolded into the upstream end of the sealing member body 551).

[0086] The sealing member body 551 includes a sealing member downstream portion 556 having a cross-sectional width (e.g., diameter) larger than the upstream end of the sealing member body 551. A plurality of arms 557 extend radially outward from the outer surface of the sealing member downstream portion 556. A sealing member ring 559 is circumferentially disposed around the sealing member downstream portion 556 and is coupled to an axial end of each of the plurality of arms 557 remote from the sealing member downstream portion 556. A plurality of spacer pins 558 extend from the sealing member ring 559 axially away from the upstream end of the sealing member body 551. The spacer pins are positioned at the locations where the plurality of arms 557 of the sealing member ring 559 are coupled to the sealing member ring 559.

[0087] The sealing member 550 also includes an end cap sealing portion 552, which is configured to interact with the filter element (e.g., as per the description of the filter element). Figure 17 The end cap of the described filter element 530 forms a seal. The end cap sealing portion 552 includes a circumferential wall extending axially from a middle portion 561 of the sealing member toward the upstream end of the sealing member 550, the middle portion 561 connecting the sealing member body 551 to a downstream portion 556 of the sealing member, such that a space 554 is formed between the sealing member body 551 and the end cap sealing portion 552. The length of the end cap sealing portion 552 is less than the length of the sealing member body 551, such that the end cap sealing portion 552 extends only partially toward the upstream end.

[0088] Figure 17 A side cross-section of a filter assembly 500 according to an embodiment is shown. The filter assembly 500 includes a housing 501, a filter element 530 including a sealing member 550, and a nut plate 560. The housing 501 may be substantially similar to housing 201 and defines an internal volume, with the filter element 530 along the longitudinal axis A of the housing 501. L It is located within this internal volume.

[0089] Housing 501 defines an internal volume, and filter element 530 is located along the longitudinal axis A of housing 501. L It is disposed within an internal volume. The filter element 530 includes a filter medium 532 defining a central channel 531 about a longitudinal axis A. L Extending in the axial direction. Filter medium 532 is a radial flow filter medium and may be substantially similar to filter medium 132 described earlier herein. A first end cap 542 is disposed on a first end (e.g., the top) of filter medium 532. The first end cap 542 defines an end cap outlet for the exit of cleaning fluid from filter element 530. A first end cap flange 543 extends downward from the inner peripheral edge of the end cap outlet of the first end cap 542 into the central channel 531 of filter medium 532.

[0090] A nut plate 560 is coupled to a first end (e.g., the top) of the housing 501, which is located near the first end of the filter medium 532. The nut plate 560 defines a central opening that can serve as an outlet for filtered fluid (e.g., filtered fuel) exiting the housing 501. For example, when the filter assembly 500 is coupled to the filter head 204, the filter element 530 can be coupled to the filter head 204, and the filter head inlet 205 of the filter head 204 can be inserted through the central opening defined by the nut plate 560. An orifice 562 may also be defined around the central opening via the nut plate 560 for conveying unfiltered fuel around the filter element 530 into the housing 501. A filter head sealing member 506 (e.g., an O-ring or washer) is disposed at the first end of the housing 501 and is configured to form an axial and / or radial seal with the filter head 204 when the filter assembly 500 is coupled to the filter head 204.

[0091] A sealing member 550 is disposed at a first end of the filter element 530 and configured to form a seal with the filter head inlet 205, the first end cap 542, and also with the nut plate 560. Further, the sealing member 550 is configured to pass through an outlet defined by the first end cap 542, such that the radially inner surface of the first end cap flange 543 surrounds and contacts the radially outer surface of the end cap sealing portion 552 of the sealing member 550, thereby forming a radial seal between the radially inner surface of the first end cap flange 543 and the radially outer surface of the end cap sealing portion 552. An end cap sealing portion lug 553 extends radially outward from the end cap sealing portion 552, and at least a portion of the first end cap flange is disposed radially inner to the outer radial edge of the end cap sealing portion lug 553. In some embodiments, the axial distance from the downstream portion 556 of the sealing member to the axial surface of the end cap sealing portion lug 553 away from the hydrophobic filter 536 corresponds to the length of the first end cap flange 543, such that the axial end of the first end cap flange 543 is disposed on and contacts the axial surface of the end cap sealing portion lug 553. In some embodiments, the axial surface of the downstream portion 556 of the sealing member near the first end cap 542 may also contact the first axial surface of the first end cap 542 away from the filter medium 532 and / or the radially inner surface of the first end cap flange 543 to form an axial seal and / or a radial seal.

[0092] Multiple arms 557 and a sealing member ring 559 are disposed on a first axial surface of the first end cap 542. A spacer pin 558 can contact the axial surface of a nut plate 560 adjacent to the first axial surface of the first end cap 542 to maintain a gap between the nut plate 560 and the first end cap 542. A nut plate flange 563 extends axially from the inner periphery of the central opening of the nut plate 560 toward the sealing member 550. The nut plate flange 563 extends into the downstream portion 556 of the sealing member such that the radially outer surface of the nut plate flange 563 contacts the radially inner surface of the downstream portion 556 of the sealing member, thereby forming a radial seal between the radially outer surface of the nut plate flange 563 and the radially inner surface of the downstream portion 556 of the sealing member.

[0093] The filter head inlet 205 extends into the sealing member body 551 such that the radially outer surface of the filter head 204 contacts at least a portion of the radially inner surface of the sealing member body 551 (e.g., due to the interference fit between the radially outer surface of the filter head 204 and the radially inner surface of the sealing member body 551), thereby forming a radial seal between the sealing member body 551 and the filter head inlet 205. A portion of the filter head inlet 205 may also contact the intermediate portion 561 of the sealing member and form an axial seal and / or a radial seal with the intermediate portion 561 of the sealing member. For example, the inner surface of the intermediate portion 561 of the sealing member may be shaped to conform to the shape of at least a portion of the filter head inlet 205 in order to form an axial seal and / or a radial seal with at least a portion of the filter head inlet 205.

[0094] As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” include plural indicators. Thus, for example, the term “a component” is intended to mean a single component or a combination of components, and “a material” is intended to mean one or more materials or a combination thereof.

[0095] As used herein, the terms “about” and “approximately” generally mean adding or subtracting 10% of a specified value. For example, about 0.5 would include 0.45 and 0.55, about 10 would include 9 to 11, and about 1000 would include 900 to 1100.

[0096] As used herein, the term "connection" refers to the direct or indirect linking of two components to each other. Such a connection can be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such a connection can be achieved by the integral formation of two components or two components and any additional intermediate components into a single whole, or by the attachment of two components or two components and any additional intermediate components to each other.

[0097] It is important to note that the structures and arrangements of the various exemplary embodiments are merely illustrative. While only a few embodiments are described in detail in this disclosure, those skilled in the art will readily recognize that many modifications (e.g., variations in the size, dimensions, structure, shape and proportion of various elements, values ​​of parameters, mounting arrangements, use of materials, color, orientation, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter described herein. Furthermore, it should be understood that features from one embodiment disclosed herein can be combined with features from other embodiments disclosed herein, as will be understood by those skilled in the art. Other substitutions, modifications, variations, and omissions may also be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of this application.

[0098] While this specification contains many specific implementation details, these should not be construed as applicable to any specific implementation.

[0099] The embodiments may be interpreted as limiting the scope of the claims, but rather as a description of features specific to particular implementations of particular embodiments. Certain features described in the context of individual implementations may also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation may also be implemented individually or in any suitable sub-combination in multiple implementations. Furthermore, although features may be described above as functioning in certain combinations, or even originally claimed as such, in some cases one or more features from the claimed combination may be removed from that combination, and the claimed combination may refer to a sub-combination or a variation of a sub-combination.

Claims

1. A filter element, comprising: A first filter medium, the first filter medium defining a central channel; An end cap is disposed at one end of the first filter medium, the end cap defines an outlet for cleaning fluid to exit the filter element, and the end cap includes an end cap flange; A sealing member disposed within the outlet, such that the radially inner surface of the end cap flange contacts the radially outer surface of the sealing member to form a radial seal between the radially inner surface of the end cap flange and the radially outer surface of the sealing member; A second filter medium is disposed radially inside the first filter medium, and the second filter medium is configured to coalesce water. as well as A hydrophobic filter screen, the hydrophobic filter screen being configured to span the outlet defined in the end cap. The sealing component includes: A sealing member body, the sealing member body being disposed within the central channel of the first filter medium and defining the upstream end of the sealing member; The downstream portion of the sealing member is located downstream of the main body of the sealing member and has a larger cross-sectional width than the upstream end. A middle portion of a sealing member, the middle portion of which connects the main body of the sealing member to a downstream portion of the sealing member; and An end cap sealing portion includes a circumferential wall extending axially from the middle portion of the sealing member toward the upstream end of the sealing member, such that a radial space is formed between the sealing member body and the end cap sealing portion.

2. The filter element according to claim 1, wherein: The sealing member defines a channel through which the sealing member passes. The hydrophobic filter screen is disposed on the upstream end of the sealing member.

3. The filter element according to claim 2, wherein, The hydrophobic filter is connected to the upstream end of the sealing member.

4. The filter element according to claim 2, wherein, The sealing member includes a circumferential slot defined on the radial inner surface of the sealing member, and the outer peripheral edge of the hydrophobic filter is located within the circumferential slot.

5. The filter element according to claim 1, wherein, The central tube is disposed within the central channel, and the second filter medium is disposed radially inside the central tube.

6. The filter element according to claim 1, wherein: The end cap defines the end cap outlet. The end cap flange extends axially from the inner peripheral edge of the end cap outlet into the central channel of the first filter medium, and The radial inner surface of the end cap flange is disposed around the radial outer surface of the end cap sealing portion.

7. The filter element according to claim 6, wherein: The end cap sealing portion includes an end cap sealing portion lug extending radially outward from the end cap sealing portion, and The first axial end of the end cap flange is disposed on the axial surface of the end cap sealing portion lug, which is away from the upstream end, and is in contact with the axial surface of the end cap sealing portion lug.

8. The filter element according to claim 6, wherein, The axial surface of the downstream portion of the sealing member near the end cap is configured to: contact the axial surface of the end cap near the downstream portion of the sealing member and form an axial seal with the axial surface of the end cap; or contact the radial inner surface of the end cap flange and form a radial seal with the radial inner surface of the end cap flange.

9. The filter element according to claim 1, wherein, The sealing member also includes a plurality of arms extending radially outward from the outer surface of the downstream portion of the sealing member.

10. The filter element according to claim 9, wherein, The sealing member further includes a sealing member ring disposed circumferentially around the downstream portion of the sealing member and connected to an axial end of each of the plurality of arms away from the downstream portion of the sealing member.

11. The filter element according to claim 10, wherein, The sealing member further includes a plurality of spacer pins extending axially away from the upstream end of the sealing member ring.

12. The filter element according to claim 11, wherein, The spacer pin is disposed at the position where the plurality of arms of the sealing member ring are connected to the sealing member ring.

13. The filter element according to any one of claims 1-12, wherein, The second filter medium includes: The first layer, configured as coalesced water; and Downstream of the first layer is a second layer, which is a hydrophobic layer.

14. The filter element according to any one of claims 1-12, wherein, The second filter medium includes a filter medium tube having a tapered profile along the longitudinal axis of the filter element.

15. A filter assembly, comprising: A housing that defines an internal volume; The filter element according to any one of claims 1-12, wherein the filter element is disposed within the internal volume; as well as A nut plate is connected to a first end of the housing, the first end of the housing being close to the end of the first filter medium on which the end cap is disposed. The nut plate defines a central opening and a nut plate flange, the nut plate flange extending axially from the inner periphery of the central opening of the nut plate toward the sealing member. The nut plate flange extends into the downstream portion of the sealing member, such that the radially outer surface of the nut plate flange contacts the radially inner surface of the downstream portion of the sealing member, thereby forming a radial seal between the radially outer surface of the nut plate flange and the radially inner surface of the downstream portion of the sealing member.

16. A filter element, comprising: A first filter medium, the first filter medium defining a central channel; An end cap is disposed at one end of the first filter medium, and the end cap defines an outlet for cleaning fluid to exit the filter element; A second filter medium is disposed radially inside the first filter medium, and the second filter medium is configured to coalesce water. and A hydrophobic filter screen, the hydrophobic filter screen being disposed across the outlet defined in the end cap; as well as A sealing member, disposed within the outlet and defining a channel passing through the sealing member, a hydrophobic filter screen disposed at the upstream end of the sealing member, the sealing member comprising: A sealing member body, the sealing member body being disposed within the central channel of the first filter medium and defining the upstream end of the sealing member; The downstream portion of the sealing member is located downstream of the main body of the sealing member and has a larger cross-sectional width than the upstream end. The middle portion of the sealing member connects the main body of the sealing member to the downstream portion of the sealing member. An end cap sealing portion, the end cap sealing portion including a circumferential wall extending axially from the middle portion of the sealing member toward the upstream end of the sealing member, such that a radial space is formed between the sealing member body and the end cap sealing portion; and Multiple arms extend radially outward from the outer surface of the downstream portion of the sealing member.

17. The filter element according to claim 16, wherein, The sealing member further includes a sealing member ring disposed circumferentially around the downstream portion of the sealing member and connected to an axial end of each of the plurality of arms away from the downstream portion of the sealing member.

18. The filter element according to claim 17, wherein, The sealing member further includes a plurality of spacer pins extending axially away from the upstream end of the sealing member ring.

19. The filter element according to claim 18, wherein, The spacer pin is disposed at the position where the plurality of arms of the sealing member ring are connected to the sealing member ring.

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