Integral filter endcap, mold, and seal

Abstract

To provide a filter element, integrated seal member or canister filter system capable of providing sealing redundancy while also simplifying assembly.SOLUTION: An integrated seal member (300a) includes an at least partially annular body defining a longitudinal axis (216a), a radial direction (218a), and a circumferential direction (217). The at least partially annular body includes a top annular mounting portion (324c), a sealing portion (302a) including at least one top sealing feature (343) and at least one bottom sealing feature (336), and a connecting portion (318a) that extends at least radially outwardly from the top annular mounting portion (324c) to the sealing portion (302a).SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates generally to canister-type filter systems that use replaceable filter elements having an axially intermediate radially outer sealing member (e.g., O-ring) interposed between the base of the filter system and the canister. More specifically, the present disclosure relates to filter elements used with filter systems that replace a separate seal with a sealing member integrated with the filter element. [Background technology]

[0002] Liquid filter systems are known for filtering various fluids, such as gas, oil, and diesel fuel, to remove contaminants from these fluids. For example, in diesel engines, fuel line filters are used to separate water and debris from the fuel. Various seals are provided to prevent leaks. For example, canister-type filter systems often include an upper seal disposed between the filter element and the base, a lower seal disposed between the filter element and the canister (sometimes called the housing), and an axially intermediate radially outer seal, such as an O-ring, disposed between the base and the canister. It has been found that the use of such O-rings can sometimes result in small amounts of leakage.

[0003] U.S. Patent No. 9,970,394 B2 discloses a positioning structure for radially positioning an axial sealing gasket relative to the mounting and sealing flanges of the housing and base. The gasket can be axially secured to the mounting or sealing flanges of the housing and base. A wing nut is used to secure the housing to the base and provide the necessary sealing force. However, like an O-ring, this sealing gasket can leak. Summary of the Invention

[0004] A filter element according to one embodiment of the present disclosure includes an at least partially annular configuration and defines a longitudinal axis, a radial direction, and a circumferential direction. The filter element may include an annular filter media defining a central passage and a central tube disposed within the central passage of the annular filter media defining a central reservoir, the annular filter media surrounding the central tube and the central reservoir. An upper open end including an opening allowing fluid flow from the central reservoir to the exterior of the filter element may be joined to the center tube disposed along the longitudinal axis. A lower end (which may be open or closed) may be joined to the center tube opposite the upper open end disposed along the longitudinal axis. An integrated seal member may be attached to the filter element and may include a sealing portion disposed at least radially away from the annular filter media. The integrated seal member may further include a connecting portion extending at least radially away from the filter element to the sealing portion.

[0005] According to one embodiment of the present disclosure, an integrated seal member includes an at least partially annular body defining a longitudinal axis, a radial direction, and a circumferential direction. The at least partially annular body can include an upper annular mounting portion including an upper mounting ring having a bottom surface and a plurality of standoff tabs extending axially downward from the bottom surface, the upper mounting ring also at least partially defining a central aperture, the sealing portion including at least one upper sealing feature and at least one lower sealing feature, and the connecting portion extending at least radially outward from the upper annular mounting portion to the sealing portion.

[0006] A filter element according to one embodiment of the present disclosure includes an at least partially annular configuration and defines a longitudinal axis, a radial direction, and a circumferential direction. The filter element may include an annular filter media defining a central passage and a central tube disposed within the central passage of the annular filter media, the central tube defining a central reservoir, the annular filter media surrounding the central tube and the central reservoir. An upper open end including an opening allowing fluid flow from the central reservoir to the exterior of the filter element may be joined to the center tube disposed along the longitudinal axis. A lower end (which may be open or closed) may be joined to the center tube opposite the upper open end disposed along the longitudinal axis. An integrated seal member may be attached to the filter element and may include an upper annular mounting portion including an upper mounting ring and a radially inner annular wall defining a central aperture. A connecting portion including a radially outer skirt may further be provided. The upper mounting ring may include a continuous member lacking any through apertures in communication with the central aperture, the radially inner annular wall may also include a continuous member lacking any through apertures in communication with the central aperture, and in some embodiments, the radially outer skirt may further include a continuous member lacking any through apertures so that the integral seal member can function as a mold. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a cross-sectional front view of a filter assembly including a filter base, a canister, and a filter element including an integral seal member according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is an enlarged detailed view of the sealing portion of the integrated seal of FIG. 2 taken from rectangle 2-2 in FIG. 2, showing the sealing portion forming an upper sealing interface with the base and a lower sealing interface with the canister. [Figure 3] 3 is a perspective view of the filter element of FIG. 1 including the integral seal member removed from the filter assembly of FIG. 1. FIG. [Figure 4] FIG. 4 is a cross-sectional front view of the filter element having the integral seal member of FIG. [Figure 5] 5 is a perspective view of the integrated seal member removed from the filter element of FIG. 3. FIG. [Figure 6] FIG. 6 is a cross-sectional front view of the integrated seal member of FIG. [Figure 7] 7 is an enlarged detail view of the peripheral sealing portion of the integrated seal member of FIG. 6 taken from rectangle 7-7 of FIG. [Figure 8] FIG. 8 is a flowchart including the assembly method related to FIGS. [Figure 9] FIG. 9 is an enlarged cross-sectional front view of another filter assembly including an integrated seal member according to another embodiment of the present disclosure. [Figure 10] 10 is a bottom perspective view of the integrated seal member of FIG. 9. FIG. [Figure 11] FIG. 11 is a bottom view of the integrated seal member of FIG. [Figure 12] FIG. 12 is a cross-sectional front view of the integrated seal member of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used in the drawings to refer to the same or similar parts. In some cases, where reference numbers are shown herein, the drawings will designate the reference numbers as followed by an alphabetic letter, e.g., 100a, 100b, or as followed by a prime indicator, e.g., 100', 100''. The use of an alphabetic letter or prime immediately following a reference number should be understood to indicate that these features have similar shapes and similar functions, as is often the case when geometric shapes surround a symmetrical planar mirror image. For ease of explanation herein, alphabetic letters or primes are typically not included, but may be shown in the drawings to indicate duplication of features described herein.

[0009] First, a filter system will be described to provide the reader with the proper context to understand how various embodiments of the present disclosure may be used. It should be understood that the description is exemplary, not limiting. Any embodiment of the apparatus or method described herein may be used in conjunction with any filter system.

[0010] Next, filter elements that can include integrated seal members according to various embodiments are described. In some embodiments, the integrated seal members simplify assembly of the filter system while providing sealing redundancy to help prevent leaks and allowing contaminated fluids to pass through apertures in the connections of the integrated seal member so that the contaminated fluid can reach the annular filter media for filtration. Then, the integrated seal members are described, which can be provided as replacement parts or as components for manufacturing filter elements.

[0011] FIG. 1 illustrates a canister filter system 100 that may use a filter element 200 and an integrated seal member 300 according to various embodiments of the present disclosure.

[0012] The canister filter system 100 may include a base 102, a canister 104, and a filter element 200 with an integral seal member 300. The canister filter system 100 may be used to filter fluids such as diesel, gasoline, or other liquid fuels, lubricating oil, hydraulic fluid for hydraulic power systems, transmission fluid, or in some cases, intake air for an engine. The canister filter system 100 may also be used as a fuel / water separating filter. The canister filter system 100 having the features described herein may be adapted by one skilled in the art to serve many different purposes and be suitable for many other applications.

[0013] The base 102 includes an inlet passage 106 for fluid to enter the canister filter system 100 and an outlet passage 108 for fluid to exit the canister filter system 100. Clips (not shown) may be provided to attach the canister 104 to the base 102. Other attachment structures may be used, such as screws, various fasteners, etc.

[0014] The canister 104 includes an upper open end 112 and a lower open end 114, as shown in FIG. 1, or in other embodiments of the present disclosure, includes a lower closed end.

[0015] The filter element 200 can take many different forms to suit a particular application. In the illustrated embodiment, the filter element 200 is well suited for filtering fuel or lubricating oil. The filter element 200 can include an annular filter media 202 circumferentially surrounding a central reservoir 204 defined by a center tube 206. The axial ends of the annular filter media 202 are shown sealed by upper and lower end caps 208, 212.

[0016] The upper end cap 208 may define an open axial end of the filter element 200. The upper end cap 208 is said to be "open" because it includes an opening 210 through which fluid can pass.

[0017] Meanwhile, the lower end cap 212 defines the axially open end of the filter element 200. The lower end cap 212 is said to be "open" because it allows for insertion of the pedestal 110 into the center tube 206 or the like.

[0018] The upper end cap 208 and the lower end cap 212 may each be joined to the center tube 206 by welding, gluing, molding, etc. Alternatively, some or all of the center tube 206, the upper end cap 208, and the lower end cap 212 may be constructed as a single piece. Conversely, the lower end cap 212 and / or the upper end cap 208 may be separate pieces from the center tube 206, etc. Further details of the closure structure of the bottom of the canister filter system 100 and the filter element 200 are provided later in this specification.

[0019] In operation, fluid to be filtered enters the inlet passageway 106 and flows into the annular cavity 118 between the canister 104 and the annular filter media 202. The fluid then enters and passes through the filter media 202 and then enters the central tube 206 through the perforations 214 shown in FIG.

[0020] The fluid then exits the central tube 206 through the upper end cap 208 and opening 210 and enters the outlet passageway 108. Sealing structures at the top and bottom of the filter element 200 help define fluid channels into and out of the annular filter media 202, preventing any fluid from bypassing the annular filter media 202 by flowing directly into the outlet passageway 108. To that end, sealing features (e.g., rounded, pointed, flattened, etc.) may be provided, as will be described in more detail later in this specification. Additionally, it may be desirable to form a chamber (e.g., a water bowl in a fuel / water separator, a drain reservoir, etc.) between the bottom of the filter element and the bottom of the canister. Therefore, a pedestal may provide a positioning feature. Other configurations of the filter element 200 are possible in other embodiments of the present disclosure.

[0021] 1 and 2, a canister filter system 100 according to various embodiments of the present disclosure including an integrated seal member 300 will be described.

[0022] 1 , canister filter system 100 may include a filter element 200 that includes an at least partially cylindrical structure (or annular structure, such that the various surfaces of the filter element and integral seal member may be circumferentially coincident surfaces of revolution) and defines a longitudinal axis 216, a circumferential direction 217, and a radial direction 218. Filter element 200 may include an annular filter media 202 that defines a central passageway 219, and a central tube 206 that is disposed within central passageway 219 of annular filter media 202 and defines a central reservoir 204. Thus, annular filter media 202 surrounds center tube 206 and central reservoir 204.

[0023] 1, filter element 200 may further include an open top end 220 joined to central tube 206 disposed along longitudinal axis 216. Open top end 220 includes opening 210 that allows fluid to flow from central reservoir 204 to the exterior of filter element 200 (which may also allow for insertion of upper pedestal 110a).

[0024] Similarly, the filter element 200 may include a lower open end 222 joined to the center tube 206 opposite an upper open end 220 also disposed along the longitudinal axis 216, such that the lower open end 222 allows for insertion of the lower pedestal 110.

[0025] The canister filter system 100 may further include a canister 104 including an open top end 112 and an open bottom end 114 relative to a longitudinal axis 216, and a lower pedestal 110 that rests on the open bottom end 114 of the cartridge filter 104. In other embodiments of the present disclosure, this may not be the case. For example, in Figure 1, the pedestal 110 is integrally molded with the canister 104.

[0026] 1 and 2, it can be seen that the canister 104 includes a sealing flange 120 disposed adjacent to the upper open end 112 of the canister 104 (sometimes referred to as a housing), and the base 102 includes a downwardly facing sealing groove 122 (sometimes referred to as a seal-receiving groove) disposed adjacent to the lower open end 114 of the base 102. The integrated seal member 300 may be attached to the filter element 200 and may include a sealing portion 302 disposed within the sealing groove 122 of the base 102 and in contact with the sealing flange 120 of the canister 104.

[0027] As best shown in FIG. 2 , the sealing groove 122 of the base 102 includes an at least partially rectangular contour 124 or an at least partially trapezoidal contour 126 in a plane containing the radial direction 218 and the longitudinal axis 216 (i.e., the cross section of FIG. 2 ). More specifically, the at least partially rectangular contour 124 may be defined by an upper annular surface 128 perpendicular to the longitudinal axis 216 and a radially outer cylindrical surface 130 extending from the upper annular surface 120. Meanwhile, the at least partially trapezoidal contour 126 may be defined by an upper annular surface 128 perpendicular to the longitudinal axis 216 and a radially inner angled surface 132 (which is angled at a plane of approximately 5° with respect to the longitudinal axis 216 to provide lead-in during assembly; sometimes referred to as a conical surface) extending from the upper annular surface 128.

[0028] It can also be seen in Figure 2 that the sealing flange 120 of the canister 104 may extend axially upward and radially outward from the cylindrical wall 134 of the canister 104 (e.g., at an angle of about 20° relative to the radial direction in the plane of Figure 2). In other embodiments of the present disclosure, this may not be the case; that is, the canister may be otherwise arranged.

[0029] 1 , it can be seen that the sealing portion 302 may be disposed radially outward from the annular filter media 202 and axially below the open top end 220 of the filter element 200. In other embodiments, this may not be the case. For example, the sealing portion may also be axially located at the open top end, etc.

[0030] As best shown in FIG. 2, the sealing portion 302 may include a single upper sealing lobe 304 that contacts the upper annular surface 128 of the sealing groove 122 of the base 102 and a pair of lower sealing lobes 306 (providing sealing redundancy) that contact the sealing flange 120 of the canister 104.

[0031] Looking at sealing portion 302 in more detail, sealing portion 302 of integrated seal member 300 may include a radially inner angled surface 308 (sometimes referred to as a conical surface) extending downward from upper sealing lobe 304, a radially outer conical surface 310 extending downward from upper sealing lobe 304 (both surfaces 308 and 310 may provide a lead-in for assembly), a radially inner cylindrical surface 312 (sometimes referred to as a conical surface) extending downward from radially inner angled surface 308, and a radially outer cylindrical surface 314 extending downward from radially outer conical surface 310. The radially outer cylindrical surface 314 and the radially inner cylindrical surface 312 are configured to contact (e.g., by expanding in opposite radial directions) the radially outer cylindrical surface 130 of the sealing groove 122 and the radially inner angled surface 132 of the sealing groove 122, respectively, when the upper sealing lobe 304 is compressed (see arrow 136 for the amount of compression). This configuration may provide sealing redundancy.

[0032] 2 , base 102 includes a radially inner wall 138 that at least partially defines sealing groove 122 and includes a free end 140 that defines a radially inwardly and axially downwardly directed lower convex arc blend 142. Similarly, integrated seal member 300 includes a bridge portion 316 (bridging from connection portion 318 of integrated seal member 300 to sealing portion 302), which defines a bridge concave arc blend 320 that at least partially coincides with lower convex arc blend 142 of base 102.

[0033] The canister 104 may further include an outer locating wall 144 extending axially upward from the sealing flange 120, and the base 102 may further include a radially outer wall 146 that partially defines the sealing groove 122 and is configured to simultaneously contact the outer locating wall 144 and the sealing flange 120 of the canister 104. This configuration may prevent the sealing portion 302 of the integrated seal member 300 from being overly compressed.

[0034] 3 and 4, a filter element 200 that may be provided as a replacement part will now be described.

[0035] The filter element 200 may be configured as described herein above and may include an integrated seal member 300 attached to the filter element 200, the integrated seal member 300 including a sealing portion 302 radially spaced from the annular filter media 202 and axially disposed between the upper open end 220 and the lower open end 222 of the filter element.

[0036] Attachment can be achieved in a variety of ways. For example, the upper end cap 208 can be overmolded onto the center tube 206 and integrated seal member 300; the center tube 206, upper end cap 208, and integrated seal member 300 can be formed as a single piece of material; the integrated seal member 300 can be glued or welded to the upper end cap 208, which can then be glued or welded to the center tube 206, etc. To facilitate such attachment, the integrated seal member 300 can include an upper attachment ring 324 (see also FIG. 5 ) that is captured or held by the upper end cap 208, extending over the top and sides of the upper attachment ring 324. This structure 324 can also function as a “standoff tab” to offset the media when the end cap is overmolded so that the media is encapsulated.

[0037] As previously described herein, the integrated seal member 300 may further include a connecting portion 318 extending radially outward and axially downward from the upper open end 220 of the filter element 200. Additionally, the connecting portion 318 of the integrated seal member 300 may be open (see apertures 322) to allow a flow of dirty fluid through the integrated seal member 300 and into the annular filter media 202 for filtration. To that end, the connecting portion 318 includes a series of downwardly extending angled members 326 (so named because they form an angle of approximately 15° with respect to the longitudinal axis 216 in the cross-section of FIG. 4 ) and a plurality of cross-members 330 circumferentially connecting (forming a mesh) each of the series of downwardly extending angled members 326. Other configurations of the mesh are possible in other embodiments of the present disclosure. In some embodiments, the cross member 330 may be omitted.

[0038] 4, the sealing portion 302 of the unitary seal member 300 may include an upwardly pointing arrow portion 332 and an at least partially downwardly pointing undulating portion 334 (sometimes referred to as a lower undulating portion). Other configurations of the sealing portion 302 are possible in other embodiments of the present disclosure.

[0039] 5-7, an integrated seal member 300 will now be described which may be provided as a replacement part or component for manufacturing the filter element 200 described above.

[0040] 5 and 6 , the integrated seal member 300 may include an at least partially annular body 335 defining a longitudinal axis 337, a radial direction 339, and a circumferential direction 341. The at least partially annular body 335 may include an attachment portion 324a and a sealing portion 302 including at least one upper sealing feature 343 (which may have any suitable shape, including an arcuate shape, a flattened shape, a pointed shape, etc.) and at least one lower sealing feature 336 (which may have any suitable shape, such as a sealing bead having an arcuate shape, a flattened shape, a pointed shape, etc.). Additionally, the connecting portion 318 may extend radially outward (e.g., purely radially outward, substantially radially outward, radially outward and axially downward, etc.) from the attachment portion 324a to the sealing portion 302.

[0041] In some embodiments, the connecting portion 318 also extends axially downward from the mounting portion 324a, defining a grid pattern. The mounting portion 324a may further include a ring (e.g., an upper mounting ring 324 that is perpendicular to or defines the longitudinal axis 328).

[0042] The grid pattern may be at least partially formed by a plurality of members 338 extending radially outward and axially downward from ring 324 to sealing portion 302. Each of the plurality of members 338 may include a radially outward facing surface 340, and grooves 342 may be disposed on radially outward facing surface 340, without limitation.

[0043] 7, the at least one upper sealing feature 334 of the sealing portion 302 can include an upper convex arc sealing surface 344, and the at least one lower sealing feature 336 of the sealing portion 302 can include a lowermost convex arc sealing surface 346 and a radially outermost convex arc sealing surface 348. This surface 348 can be disposed radially outwardly adjacent the lowermost convex arc sealing surface 346 with a concave arc transition surface 350 sandwiched therebetween.

[0044] The upper convex arc sealing surface 344 may be at least partially radially interposed between the radially outermost convex arc sealing surface 348 and the lowermost convex arc sealing surface 346. The radially outermost convex arc sealing surface 348 may be at least partially axially disposed between the upper convex arc sealing surface 344 and the lowermost convex arc sealing surface 346. Such an arrangement may define a tangent line 352 that is tangent to both the lowermost convex arc sealing surface 346 and the radially outermost convex arc sealing surface 348, forming an acute angle 354 (which may coincide with the angle of the canister's sealing flange) with the radial direction 339 in a plane containing the radial direction 339 and the longitudinal axis 328 (i.e., the cross section in FIG. 7 ). Other embodiments of the present disclosure may not be so.

[0045] The integrated seal member may be made of any suitable material and manufacturing process, for example, injection molding using a urethane material with a durometer of 20 to 95 Shore A (e.g., 60 Shore A).

[0046] In other embodiments of the present disclosure, any of the above-described features, components, or assemblies may be arranged differently from those specifically shown and described herein.

[0047] The following describes another embodiment of a filter system 100a that is configured and operates similarly to the filter systems previously described herein with reference to Figures 1-7, except where contradictory or otherwise noted with reference to Figures 9-12.

[0048] As best shown in FIG. 9, the canister filter system 100a may include a canister 104a including an open upper end 112a including external threads 113, and an open or closed lower end disposed along a longitudinal axis 216a, similar to those previously described herein, and a sealing groove 122a disposed adjacent to the open upper end 112a.

[0049] The canister filter system 100a may include a base 102a defining an open upper end 148, a lower opening 150 including an internal threaded portion 152, and a downwardly facing sealing surface 154 axially disposed between the open upper end of the base 102a and the internal threaded portion 152. The downwardly facing sealing surface 154 may be flat or conical, as shown, for example, in FIG.

[0050] The filter element 200a may also include an integrated seal member 300a attached to the filter element 200a and having a sealing portion 302a that is positioned within the sealing groove 122a of the canister 104a and contacts the downwardly facing sealing surface 154 of the base 102a.

[0051] The sealing groove 122a of the canister 104a may comprise an at least partially rectangular contour or an at least partially trapezoidal contour in a plane containing the radial direction 218a and the longitudinal axis 216a (eg, the cross section in FIG. 9).

[0052] More specifically, this at least partially rectangular profile may be defined by a lower annular surface 156 perpendicular to the longitudinal axis and a radially outer cylindrical annular wall 158 extending from the lower annular surface 156. In other embodiments, the lower annular surface may be conical rather than planar, etc.

[0053] Similarly, this at least partially rectangular contour may be defined by a lower annular surface 156 perpendicular to the longitudinal axis 216 a and a radially inner cylindrical annular wall 160 extending from the lower annular surface 156 .

[0054] The radially outer cylindrical annular wall 158 may contact or nearly contact the base 102a (e.g., downward-facing sealing surface 154), and the radially inner cylindrical annular wall 160 may be spaced from the base 102a to form a gap 162. In other embodiments, the radially outer cylindrical annular wall 158 may not contact the base (a slight gap may be provided) to help prevent excessive compression of the sealing portion 302a, and the stop flange 172 may be located below the external threads 113 that contact the internal threads 152 of the base 102a (as actually shown in FIG. 9). In either case, the radially outer cylindrical annular wall may be taller than the radially inner cylindrical annular wall, etc.

[0055] The sealing portion 302a of the integrated seal member 300a is 2 and below the upper open end 220a of the filter element 200. The sealing portion 302a may be disposed axially. a single upper sealing lobe 304 that contacts the sealing surface 154 and a sealing groove in the canister; a pair of lower sealing lobes 306a contacting the lower annular surface 156 of the These lobes are arranged such that the lower lobe becomes the upper lobe and the upper lobe becomes the lower lobe. It may be flipped 180 degrees so that

[0056] The sealing portion 302a of the unitary seal member 300a includes a radially inner conical surface 308a extending downwardly from the upper sealing lobe 304, a radially outer conical surface 310 extending downwardly from the upper sealing lobe 304, a radially inner cylindrical surface 312a extending downwardly from the radially inner conical surface 308a, and a radially outer cylindrical surface 314a extending downwardly from the radially outer conical surface 310. The radially outer cylindrical surface 314a and the radially inner cylindrical surface 312a are configured to contact the radially outer and inner cylindrical annular walls 158, 160, respectively, of the sealing groove 122a when the upper sealing lobe 304 is compressed. Other configurations are possible in other embodiments of the present disclosure.

[0057] 9-12, it can be seen that the integrated seal member 300a further includes a plurality of circumferentially spaced flanges 316a that form a flow passage 356, each of the plurality of flanges 316a extending from the radially inner conical surface 308a through the gap 162.

[0058] Additionally, canister 104a and base 102a are radially spaced from filter element 200a, forming an annular cavity 118a therebetween. Each of a plurality of flanges 316a extends into annular cavity 118a, thereby providing a flow path in fluid communication with the annular cavity and allowing fluid to be filtered downward through the integral seal member to reach the annular filter media, where the fluid flows circumferentially around and through the media to be cleaned.

[0059] Filter element 200a may be provided as a replacement component for canister filter system 100a described above, and is constructed similarly or identically to filter element 200 described hereinabove with respect to Figures 1-7, except as may be inconsistent with or described in opposition to the following description with reference to Figures 9-12.

[0060] First, filter element 200a includes integrated seal member 300a attached to filter element 200a, including sealing portion 302a disposed at least radially away from annular filter media 202 and possibly axially between upper open end 220a and the lower end, and connecting portion 318a extending axially and radially away from filter element 200a to sealing portion 302a. Specifically, connecting portion 318a of integrated seal member 300a extends axially downward and radially outward from upper open end 220a of filter element 200a.

[0061] In other embodiments, it is contemplated that the sealing portion and connecting portion may be axially aligned with the upper or lower end of the filter element. Other configurations are also possible.

[0062] As previously described herein, connecting portion 318a of integrated seal member 300a at least partially defines a plurality of flow passages 356. More specifically, connecting portion 318a may include an axially extending skirt 358 defining a bottom 359 and a plurality of flange portions 316a extending axially downward and radially outward from bottom 359 of skirt 358 to sealing portion 302a to form the plurality of flow passages 356. The geometry of these passages may take the form of a plurality of circumferentially extending slits (see FIG. 11 ) defined circumferentially by a pair of flanges 316a and radially by sealing portion 302a and axially extending skirt 358.

[0063] In other embodiments, the flange may extend from other portions of the integral seal member, such as the mounting ring, the periphery of the skirt, etc.

[0064] 10-12, the unitary seal member 300a includes an upper mounting ring 324b that at least partially defines a central aperture 360, and a bottom surface 362. As shown in FIG.

[0065] As best shown in FIG. 12 , the sealing portion 302a of the integrated seal member 300a includes an upwardly pointing arrow portion 332a and an at least partially downwardly pointing undulating portion 334a. The integrated seal member 300a may further include an annular wall 364 extending downward from the upper mounting ring 324b and defining (at least partially) the central aperture 360. The annular wall 364 may include a radially inwardly facing surface 366 (e.g., a surface of revolution such as a cylindrical or conical surface) and a sealing bead 368 disposed on the radially inwardly facing surface 366. Additionally, a plurality of standoff tabs 370 may extend axially downward from the bottom surface 362 of the upper mounting ring 324b. This configuration allows the integrated seal member 300a to function as a potting material mold. Each of the plurality of standoffs includes a cylinder extending axially downward from the bottom surface of the upper mounting ring or a spirally extending rib connected to the bottom surface of the upper mounting ring. Of course, other embodiments may use other suitable shapes for the standoffs as needed or desired.

[0066] 10-12, another embodiment of an integrated seal member 300a that may be provided as a replacement part is described. The integrated seal member 300a may include an at least partially annular body defining a longitudinal axis 216a, a radial direction 218a, and a circumferential direction 217. The integrated seal member 300a may include an upper attachment ring 324b having a bottom surface 362 and an upper annular mounting portion 324c including a plurality of standoff tabs 370 extending axially downward from the bottom surface 362. The upper attachment ring 324b may also at least partially define a central aperture 360, while the sealing portion 302a includes at least one upper sealing feature 343 and at least one lower sealing feature 336. A connecting portion 318a may extend axially downward and radially outward from the upper annular mounting portion 324c to the sealing portion 302a.

[0067] Connecting portion 318a may include a radially outer skirt 358 extending axially downward from upper attachment ring 324b, and upper annular attachment portion 324c may further include a radially inner annular wall 364a extending axially downward from upper attachment ring 324b that at least partially defines central aperture 360. A sealing bead 368 may be disposed on radially inner annular wall 364a so as to face radially inward from and extend circumferentially from radially inner annular wall 364a. As previously described herein, connecting portion 318a may include a plurality of flanges 316a extending axially downward and radially outward from radially outer skirt 358 to sealing portion 302a.

[0068] 11 and 12, the at least one upper sealing feature 343 of sealing portion 302a may include an upper convex arc sealing surface 344. The at least one lower sealing feature 336 of sealing portion 302a includes a radially innermost convex arc sealing surface 372 and a radially outermost convex arc sealing surface 348a disposed radially outwardly adjacent radially innermost convex arc sealing surface 372 with concave arc transition surface 350a therebetween.

[0069] Additionally, upper convex arc sealing surface 344 is at least partially radially interposed between radially outermost convex arc sealing surface 348a and radially innermost convex arc sealing surface 372. Sealing portion 302a may also have a radially inner conical surface 308a extending from upper convex arc sealing surface 344, with a plurality of flanges 316a attached to radially inner conical surface 308a, although this may not be the case in other embodiments of the present disclosure.

[0070] The unitary seal member 300a may be configured to function as a mold. As such, the upper mounting ring 324b may lack any through apertures communicating with the central aperture 360, the radially outer skirt 358 lacks any through apertures, and the radially inner annular wall 364a lacks any through apertures communicating with the central aperture 360. This allows the unitary seal member 300a to include any potting material poured therein. The radially inner annular wall 364a may be disposed within the center tube 206, in which case a sealing bead 368 may be disposed within the central aperture 360 ​​that may contact the base annular wall (shown in FIG. 9 ).

[0071] 11 and 12, each of the plurality of flanges 316a includes a radially extending leg 374 and a bent portion 376 connecting the radially extending leg 374 to the radially outer skirt 358. The radially extending leg 374 may be connected to the radially inner conical surface 308a of the sealing portion 302a. In other embodiments of the present disclosure, the flanges may be configured differently and attached to the sealing portion in other ways.

[0072] 12, the radially innermost convex arcuate sealing surface 372 and the radially outermost convex arcuate sealing surface 348a may define a common tangent 378 that extends purely radially. In other embodiments of the present disclosure, this may not be the case.

[0073] The integrated seal member may be constructed of any suitable material and manufacturing process, for example, injection molding a urethane material having a durometer of 20 to 95 Shore A (e.g., 60 Shore A). In other embodiments, any suitable flexible material may be used, such as urethane, elastomer, rubber, foam, etc.

[0074] In other embodiments of the present disclosure, any of the above-described features, components, or assemblies may be arranged differently from those specifically shown and described herein. Industrial Applicability

[0075] Indeed, a filter element, integrated seal member, or canister filter system according to any embodiment disclosed herein may be obtained or provided in an original equipment manufacturer (OEM) or aftermarket context, and the various features described above may be used to provide sealing redundancy while simplifying assembly.

[0076] In the embodiment shown in Figures 1-7, the web version of the integral seal can be completely enclosed within the potted filter end cap, and the potting material can form a seal with the base to separate clean fluids from dirty fluids and vice versa.

[0077] On the other hand, the embodiment shown in Figures 9-12 provides a cup-type integrated seal intended to function as a potting material mold. Therefore, the potting material may be poured into this seal, which must chemically and physically bond with the potting material. Additionally, physical bonding aids, such as undercuts, can be provided between the end cap and the potting material. These undercuts are located on the inside of the end cap, where they interface with the potting material. The integrated seal also has an integrated sealing bead that contacts the base to separate clean fluids from dirty fluids.

[0078] The connection point between the sealing section and the flexible leg (also called the flange or bridge section) already accommodates moving the sealing section from the lower third to the upper third, moving the seal groove from the filter base to the filter housing (also called the canister).

[0079] In accordance with the above, the assembly methods of the canister filter systems shown in Figures 1-7 and 9-12 according to various embodiments of the present application can be adapted to provide sealing redundancy while allowing assembly in three or fewer steps, as shown in Figure 8.

[0080] Method 400 may include inserting the filter element into one of the base and the canister (step 402) until a seal contacts one of the base and the radially inner portion of the canister and until another seal contacts one of the base and the radially outer portion of the canister. For example, the seal contact at the radially inner portion of the base is shown as 402a in Figure 1, and the seal contact at the radially inner portion of the canister is shown as 402b in Figure 1. Similarly, the seal contact at the radially outer portion of the base is shown as 402c in Figure 1, and the seal contact at the radially outer portion of the canister is shown as 402d in Figure 1.

[0081] Next, the method may further include inserting the filter element into the other of the base and the canister until a seal contacts the other of the base and the radially inner portion of the canister, and until another seal contacts the other of the base and the radially outer portion of the canister (step 404).

[0082] For example, step 402 may involve inserting a filter element into a canister and simultaneously or substantially simultaneously creating sealing contacts 402b and 402d, while step 404 may involve inserting a filter element into a base and creating sealing contacts 402a and 402c, or vice versa, as shown in Figure 1. Steps 402 and 404 may be completed simultaneously or at different times.

[0083] The base and canister may be coupled together (step 406), such as via threads, clips, other fasteners, etc. Step 406 may be completed after steps 402 and 404, between steps 402 and 404, etc.

[0084] The method may also include steps 401 and 401a of Figure 8. Step 401 may include fabricating the filter element by fully encapsulating a seal within a potted filter end cap to form an integral seal, while step 401a may include fabricating the filter element by injecting a potting material into the seal and chemically and physically bonding the seal to the potting material.

[0085] It is further contemplated that the integrated seal member may be attached to the bottom of the filter element (e.g., the lower end cap) and extend along a portion of the bottom wall and / or side wall of the canister, terminating in a sealing portion adjacent the sealing flange of the canister.

[0086] It should be understood that the foregoing description provides examples of the disclosed assemblies and techniques. However, it is anticipated that other embodiments of the present disclosure may differ in detail from the foregoing examples. All references to the present disclosure or examples thereof are intended to refer to the specific examples described therein and are not intended to suggest any more general limitation of the scope of the disclosure. All language of distinction and disparagement regarding certain features is intended to indicate a lack of preference for those features, but is not intended to be wholly excluded from the scope of the disclosure unless otherwise stated.

[0087] Unless otherwise stated herein, recitation of ranges of values ​​herein is intended merely as a shorthand method of referring individually to each individual value falling within the range, and each individual value is incorporated herein as if it were individually set forth herein.

[0088] As will be apparent to those skilled in the art, various modifications and variations can be made in the embodiments of the apparatus and assembly methods described herein without departing from the scope or spirit of the invention. Other embodiments of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the various embodiments disclosed herein. For example, some devices may have configurations and functions different from those described herein, and certain steps of any methods may be omitted, performed in a different order than previously specifically mentioned, or in some cases performed simultaneously or in substeps. Furthermore, specific aspects or features of the various embodiments may be changed or modified to create further embodiments, and features and aspects of the various embodiments may be in addition to, or substituted for, other features or aspects of other embodiments to provide still further embodiments.

[0089] Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, this disclosure includes any combination of the above-described elements in all possible variations thereof unless otherwise indicated herein or clearly contradicted by context.

Claims

1. A filter element (200, 200a) comprising an at least partially annular configuration and defining a longitudinal axis (216a), a radial direction (218a), and a circumferential direction (217), an annular filter media (202) defining a central passageway (219); a central tube (206) having perforations (214) disposed within a central passage (219) of the annular filter media (202) defining a central reservoir (204), the central tube (206) surrounding the central tube (206) and the central reservoir (204); an upper end cap (208) defining an upper open end (220, 220a) joined to a central tube (206) disposed along a longitudinal axis (216a), the upper end cap (208) including an opening (210) that allows fluid flow from the central reservoir (204) to an exterior of the filter element (200, 200a); a lower end (222) joined to the central tube (206) opposite the upper open ends (220, 220a) disposed along the longitudinal axis (216a); a filter element (200, 200a) including an integrated seal member (300, 300a) attached to the filter element (200, 200a), the integrated seal member including a sealing portion (302, 302a) positioned radially away from the annular filter media (202), and a connecting portion (318, 318a) extending at least radially away from the filter element (200, 200a) to the sealing portion (302, 302a); a base (102) including an inlet passage (106) through which the fluid enters the canister filter system (100, 100a) and an outlet passage (108) through which the fluid exits the canister filter system (100, 100a), the base (102) being disposed to cover at least a portion of the filter element (200, 200a) along the longitudinal axis (216a); a canister (104) held by the base (102) and containing the filter element (200, 200a); an annular cavity (118) defined between the canister (104) and the annular filter media (202); Equipped with the connecting portion (318, 318a) of the integrated seal member (300, 300a) extends from an upper annular mounting portion (324, 324c) so as to be positioned axially downward and radially outward from the upper open end (220, 220a) of the filter element (200, 200a), so that the sealing portion (302, 302a) is positioned axially between the upper open end (220, 220a) and the lower end (222); the sealing portion (302, 302a), the connecting portion (318, 318a), and the upper annular mounting portion (324, 324c) are integrated together; The sealing portion (302, 302a) includes at least one upper sealing lobe (304) and at least one lower sealing lobe (306); the sealing portion (302, 302a) further includes a radially inner angular surface (308) extending downward and radially inward from the upper sealing lobe (304), a radially inner cylindrical surface (312) extending downward from the radially inner angular surface (308), a radially outer conical surface (310) extending downward and radially outward from the upper sealing lobe (304), and a radially outer cylindrical surface (314) extending downward from the radially outer conical surface (310); the connecting portion (318, 318a) of the integrated seal member (300, 300a) at least partially defines a plurality of flow paths (322, 356); the fluid flowing in from the inlet passage (106) passes through the plurality of flow paths (322, 356) of the connecting portion (318, 318a) of the integrated seal member (300, 300a) and flows into the annular cavity (118); The canister filter system (100, 100a) wherein the fluid entering the annular cavity (118) flows through the perforations (214), into the center tube (206), through the upper end cap (208) and the opening (210), out of the center tube (206), and out through the outlet passage (108).

2. 2. The canister filter system of claim 1, wherein the connecting portion includes a radially outer skirt defining a bottom and a plurality of flanges extending axially downward and radially outward from the bottom of the radially outer skirt to the sealing portion, such that the connecting portion forms a plurality of flow paths in the form of a plurality of circumferentially extending slits bounded radially by the sealing portion and the radially outer skirt.

3. 3. The canister filter system of claim 2, wherein the integrated seal member includes an upper mounting ring that at least partially defines a central aperture, and a bottom surface.

4. 4. The canister filter system of claim 3, wherein the sealing portion of the integrated seal member includes an upward arrow portion and an at least partially downward undulating portion, and further includes an annular wall extending downward from an upper mounting ring forming a central aperture, the annular wall including a radially inward facing surface and a sealing bead disposed on the radially inward facing surface, and a plurality of standoff tabs extending axially downward from the bottom surface of the upper mounting ring.

5. 5. An integrated seal member (300a) for use in the canister filter system (100a) of any one of claims 1 to 4, comprising an at least partially annular body defining a longitudinal axis (216a), a radial direction (218a), and a circumferential direction (217), the at least partially annular body comprising: an upper annular mounting portion (324c) including an upper mounting ring (324b) having a bottom surface (362) and a plurality of standoff tabs (370) extending axially downward from the bottom surface (362), the upper mounting ring (324b) also at least partially defining a central aperture (360); a sealing portion (302a) including at least one upper sealing feature (343) and at least one lower sealing feature (336); a radially inner conical surface (308a) extending downwardly and radially inwardly from said upper sealing feature (343); a radially inner cylindrical surface (312a) extending downwardly from said radially inner conical surface (308a); a radially outer conical surface (310) extending downwardly and radially outwardly from said upper sealing feature (343); and a radially outer cylindrical surface (314a) extending downwardly from said radially outer conical surface (310); a connecting portion (318a) extending at least radially outward from the upper annular mounting portion (324c) to the sealing portion (302a); the sealing portion (302a), the connecting portion (318a), and the upper annular mounting portion (324c) are integrated together; The unitary seal member (300a) includes a plurality of circumferentially spaced flanges (316a) that define a flow passage (356).

6. The connecting portion (318a) includes a radially outer skirt (358) extending axially downward from an upper attachment ring (324b), and the upper annular attachment portion (324c) further includes a radially inner annular wall (364a) extending axially downward from the upper attachment ring (324b) that at least partially defines a central aperture (360), the radially inner annular wall (364a) being spaced apart from the radially inner annular wall (364a) so as to face radially inward from and extend circumferentially therethrough. 64a), the integrated seal member being manufactured from any of a urethane, elastomer, rubber, and foam material, the upper mounting ring being devoid of any through apertures communicating with the central aperture, the radially outer skirt being devoid of any through apertures, and the radially inner annular wall being devoid of any through apertures.

7. 7. The integrated seal member of claim 6, wherein the connecting portion includes the plurality of flanges extending axially downward and radially outward from the radially outer skirt to the sealing portion, each of the plurality of standoff tabs includes a cylindrical body extending axially downward from a bottom surface of the upper mounting ring or a spirally extending rib attached to the bottom surface of the upper mounting ring, each of the plurality of flanges including a radially extending leg and a bent portion connecting the radially extending leg to the radially outer skirt, and wherein the integrated seal member is fabricated from urethane having a durometer of 20 to 95 Shore A such that the integrated seal member can be used as a potting mold.

8. The at least one upper sealing feature (343) of the sealing portion (302a) includes an upper convex arc sealing surface (344), and the at least one lower sealing feature (336) of the sealing portion (302a) includes a radially innermost convex arc sealing surface (372) and a radially outermost convex arc sealing surface (348a) disposed radially outwardly adjacent the radially innermost convex arc sealing surface (372) with a concave arc transition surface (350a) therebetween, the upper convex arc sealing surface (344) being at least partially radially 8. The integrated seal member (300a) of claim 7, wherein the sealing portion (302a) is radially interposed between an upper convex arc sealing surface (348a) and a radially innermost convex arc sealing surface (372), the sealing portion (302a) having the radially inner conical surface (308a) extending from the upper convex arc sealing surface (344), the plurality of flanges (316a) attached to the radially inner conical surface (308a), and the radially inner convex arc sealing surface (372) and the radially outermost convex arc sealing surface (348a) defining a common tangent (378) that extends purely radially.

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