Filter with efficiently sealed end
A filter element has a resiliently compressible end cap at a first axial end sealing the filter and providing sealed engagement with a flow tube.
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The invention relates to fluid filters, and more particularly to improved sealing of the filter media end.
The invention arose during continuing development efforts relating to filter elements having pleated filter media having a plurality of pleats in a closed loop, typically annular, for example as shown in U.S. Pat. Nos. 6,149,700, 6,261,334, 6,391,076, 6,398,832, all incorporated herein by reference. The closed loop pleated filter media has an outer perimeter defined by a plurality of outer pleat tips, and an inner perimeter defined by a plurality of inner pleat tips, and has a hollow interior extending along a given axis. Fluid flows axially in the hollow interior, before or after flow through the media, depending on whether the flow is inside-out or outside-in. The filter element has an open axial end providing an axial flow passage therethrough along the axis communicating with the hollow interior.
The present invention relates to improved sealing of the pleat ends at the open axial end of the filter element, including improvements in both the effectiveness of the sealing and manufacturing efficiency for cost reduction. The invention further relates to other filter media end sealing techniques.
Flow passage 56 extending along axis 40 circumscribes hollow interior 38 and has a flow perimeter 60 greater than inner perimeter 34 defined by inner pleat tips 36, as described in the incorporated '700 patent. Flow perimeter 60 is less than outer perimeter 30 defined by outer pleat tips 32. Inner perimeter 34 defines and bounds a first cross-sectional area. Flow perimeter 60 defines and bounds a second cross-sectional area. The second cross-sectional area is greater than the first cross-sectional area. Outer perimeter 30 defines and bounds a third cross-sectional area. The second cross-sectional area is less than the third cross-sectional area. Filter element 22 has first and second axial ends 62 and 64. Axial end 62 is open and provides axial flow passage 56 therethrough. An end cap 66 of soft resilient compressible material, such as foamed potted urethane, axially abuts the axial ends 68 of the pleats. End cap 66 has an inner perimeter 70 greater than inner perimeter 34 defined by inner pleat tips 36. End cap 66 partially covers the axial ends 68 of the pleats such that the laterally outward portions 72 of the axial ends 68 of the pleats 28 are covered by end cap 66 but not the laterally inward portions 74 of the axial ends 68 of the pleats, such that the laterally inward portions 74 of the axial ends of the pleats are uncovered and exposed at axial end 62 of filter element 22, FIG. 4.
In one embodiment, second axial end 64 of filter element 22 is closed. A second end cap 76,
End cap 66 has a sidewall 92 extending axially away from axial ends 68 of pleats 28 at axial end 62 of filter element 22. The sidewall has the noted inner perimeter 70, and has an outer perimeter 94. As noted above, inner perimeter 70 of sidewall 92 is greater than inner perimeter 34 of filter element 22 defined by inner pleat tips 36. Inner perimeter 70 of sidewall 92 of end cap 66 is less than outer perimeter 30 of filter element 22 defined by outer pleat tips 32. Outer perimeter 94 of sidewall 92 of end cap 66 is greater than outer perimeter 30 of filter element 22 defined by outer pleat tips 32. Flow tube 90 has an inner section 96 axially facing the axial ends 68 of pleats 28. Inner section 96 of flow tube 90 has an inner perimeter 98 and an outer perimeter 100. Outer perimeter 100 is greater than inner perimeter 70 of sidewall 92 of end cap 66, such that as filter element 22 at end cap 66 is axially slid rightwardly over inner section 96 of flow tube 90, end cap 66 is radially compressed to expand inner perimeter 70 along outer sidewall 100 of flow tube inner section 96 to effect the noted radial seal. Inner perimeter 70 of end cap 66 is preferably stepped, as shown at 71 in
An outer liner 102,
Pleats 28 have pairs of walls defining axially extending interior channels 106,
As noted, the method for molding end cap 66 onto pleated filter media 26 involves dipping axial ends 68 of the pleats into liquid castable material in trough 122 of mold 120, and engaging axial ends 68 of the pleats against dam 126 at a location between outer pleat tips 32 and inner pleat tips 36 such that dam 126 impedes flow of the liquid castable material laterally inwardly towards inner pleat tips 36. Trough 122 is provided and aligned such that it partially spans axial ends 68 of the pleats such that the laterally outward portions 72 of the axial ends of the pleats are covered by the liquid castable material during dipping, but not the laterally inward portions 74 of the axial ends of the pleats. Further in accordance with the described method, laterally inward flow of the liquid castable material is impeded along the axial ends of the pleats toward inner pleat tips 36 by providing and aligning dam 126 to engage axial ends 68 of the pleats between outer pleat tips 32 and inner pleat tips 36 such that laterally outward portions 72 of the axial ends of the pleats are covered by end cap 66, and laterally inward portions 74 of the axial ends of the pleats are uncovered by end cap 66 and are left exposed. Trough 122 and filler element 22 are aligned during the noted dipping such that outer perimeter 126 of trough 122 circumscribes outer perimeter 30 of the filter element defined by outer pleat tips 32, and inner perimeter 128 of trough 122 circumscribes inner perimeter 26 of the filter element defined by inner pleat tips 36.
The described filter construction was developed for air filters, though may be used for other fluids such as liquid. In the disclosed embodiment, fluid to be filtered flows laterally inwardly through the filter media from the outer perimeter to the inner perimeter and then flows axially in the hollow interior, such that flow passage 56 is an outlet flow passage. Alternatively, fluid to be filtered may flow axially in hollow interior 38 and then flow laterally outwardly through the filter media from the inner perimeter to the outer perimeter, in which case flow passage 56 is the inlet flow passage. In another alternative, fluid flow to or from axial end 64 of the filter element and through the media may be axial or a combination of axial and radial, for example as in the noted incorporated '076 patent. In other alternatives, metal end caps are used instead of urethane end caps, or various combinations of materials are used for the end caps. In further alternatives, outer section 90b,
During further development, it has been found that there are some applications where enhanced structural integrity is desired in the end cap area at 66, for example wet conditions, heavy load conditions, vibration, and the like. There are also circumstances where cost reduction is desired. There are also circumstances where even further sealing is desired.
In one embodiment, the filter element includes in combination the noted second end cap 76 at the second axial end 64 of the filter element at axial ends 78 of the pleats and covering inner and outer pleat tips 36 and 32 and spanning radially between inner and outer perimeters 34 and 30, and also spanning hollow interior 38 and closing the second axial end of the filter element. The filter element is preferably contained in the noted housing having an end wall 220 facing the first axial end of the filter element. Flow tube 202 is part of end wall 220.
Flow tube 202 engages end cap 200 at first, second and third engagement seals 218, 222 and 224, respectively, to provide triple scaling of end cap 200 to flow tube 202. Seals 218 and 224 are axial seals, and seal 222 is a radial seal. First inner portion 212 of flow tube 202 extends axially along step 204 and engages the step to form the noted second radial seal 222. Tubular portion 212 has the noted inner axial end 214 axially engaging end cap 200 at the noted second section 210 and forming the noted third axial seal 224. Flow tube 202 has the noted flange portion 216 extending radially from tubular 212 and axially spaced outwardly of inner axial end 214 and axially engaging end cap 200 at first section 208 and providing the noted first axial seal 218. Second radial seal 222 is axially between first and third axial seals 218 and 224.
As shown in comparing
It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims.
Claims
1. A filter element comprising pleated filter media having a plurality of pleats in a closed loop having an outer perimeter defined by a plurality of outer pleat tips, and an inner perimeter defined by a plurality of inner pleat tips, said loop having a hollow interior extending along a given axis, wherein fluid flows axially in said hollow interior, said filter element having first and second axial ends, said first axial end being open and providing an axial flow passage therethrough along said axis communicating with said hollow interior, a resiliently compressible first end cap at said first axial end covering said inner and outer pleat tips and spanning radially between said inner and outer perimeters, a flow tube communicating with said hollow interior and extending along said axial flow passage and engaging said end cap, wherein said flow tube at said engagement with said end cap has an inner perimeter greater than said inner perimeter defined by said inner pleat tips, and comprising in combination a second end cap at said second axial end of said filter element covering said inner and outer pleat tips and spanning radially between said inner and outer perimeters and also spanning said hollow interior and closing said second axial end of said filterelement.
2. The filter element according to claim 1 19 wherein said inner perimeter of said flow tube at said engagement with said first end cap is less than said outer perimeter defined by said outer pleat tips.
3. The filter element according to claim 2 1 wherein said first end cap has a first section extending radially inwardly from said outer perimeter defined by said outer pleat tips, and has a second section extending radially outwardly from said inner perimeter defined by said inner pleat tips, said first and second sections meeting at a junction defining a stepfacing radially toward and engaging said flow tube.
4. The filter element according to claim 3 20 wherein said step has a first axial length, said flow tube has a tubular portion extending axially along said step, said tubular portion having an inner axial end axially facing said first axial end of said filterelement, and said flow tube has a flange portion extending radially from said tubular portion and facing said first axial end of said filter element and axially spaced from said inner axial end of said tubular portion by a second axial length less than said first said axial length.
5. The filter element according to claim 3 wherein said first end cap has a first axial thickness at said first section at said outer perimeter defined by said outer pleat tips, a second axial thickness at said first section at said step, a third axial thickness at said second section at said step, and a fourth axial thickness at said second section at said inner perimeter defined by said inner pleat tips, and wherein said second axial thickness is greater than said third axial thickness.
6. The filter element according to claim 5 wherein said first axial thickness is greater than said fourth axial thickness.
7. The filter element according to claim 5 wherein said first axial thickness is less than said second axial thickness.
8. The filter element according to claim 5 wherein said third and fourth axial thicknesses are substantially the same.
9. The filter element according to claim 1 19 comprising a housing containing said filterelement, said housing having an end wall axially facing said first axial end of said filterelement, and wherein said flow tube is part of said end wall.
10. The filter element according to claim 1 wherein fluid flows laterally radially through said filter element media between said outer and inner perimeters, and flows axially in said hollow interior.
11. A filter element comprising a closed loop filter media member having a hollow interior extending along a given axis, wherein fluid flows axially in said hollow interior, said filter element having first and second axial ends, said first axial end being open and providing an axial flow passage therethrough along said axis communicating with said hollow interior, a resiliently compressible end cap at said first axial end, a flow tube communicating with said hollow interior and extending along said axial flow passage, said flow tube having a tubular portion engaging said end cap and forming a seal therewith, said tubular portion being cylindrical, said filter media member being non-cylindrical.
12. The filter element according to claim 11 wherein said filter media member is elliptical.
13. The filter element according to claim 11 wherein said end cap has a first section extending radially inwardly from an outer perimeter, and has a second section extending radially inwardly from said first section to an inner perimeter, said first and second sections meeting at a junction defining a step, said first section having said outer perimeter and having an inner perimeter at said step, said second section having an outer perimeter at said step and having said inner perimeter communicating with said hollow interior, said outer perimeter of said first section being non-cylindrical, said inner perimeter of said first section being cylindrical, said step being cylindrical, said outer perimeter of said second section being cylindrical.
14. The filter element according to claim 13 wherein said cylindrical tubular portion engages said end cap at said cylindrical step.
15. The filter element according to claim 13 further comprising a flow tube communicating with said hollow interior and extending along said axial flow passage, said flow tube having a tubular portion engaging said end cap and forming a seal therewith, said tubular portion being cylindrical, wherein said inner perimeter of said second section is non-cylindrical.
16. The filter element according to claim 13 wherein said filter media member and said outer perimeter of said first section of said end cap are elliptical and have a radially extending major axis and a radially extending minor axis, wherein the radial extension of said first section of said end cap along said major axis between said outer perimeter of said first section of said end cap and said step is greater than the radial extension of said first section of said end cap along said minor axis between said outer perimeter of said first section of said end cap and said step, and wherein the radial extension of said second section of said end cap along said minor axis between said step and said inner perimeter of said second section of said end cap is greater than the radial extension of said o second section of said end cap section along said major axis between said step and said inner perimeter of said second section of said end cap.
17. The filter element according to claim 11 wherein said filter media member comprises pleated filter media having a plurality of pleats in a closed loop having an outer perimeter defined by a plurality of outer pleat tips, and an inner perimeter defined by a plurality of inner pleat tips, said loop having said hollow interior extending along said given axis.
18. The filter of claim 1, wherein said first end cap is configured to receive a flow tube communicating with said hollow interior and extending along said axial flow passage and engaging said first end cap, wherein said flow tube at said engagement with said first end cap has an inner perimeter greater than said inner perimeter defined by said inner pleat tips.
19. The filter of claim 1, further comprising a flow tube communicating with said hollow interior and extending along said axial flow passage and engaging said first end cap, wherein said flow tube at said engagement with said first end cap has an inner perimeter greater than said inner perimeter defined by said inner pleat tips.
20. The filter of claim 3, further comprising a flow tube communicating with said hollow interior and extending along said axial flow passage and engaging said first end cap, wherein said flow tube at said engagement with said first end cap has an inner perimeter greater than said inner perimeter defined by said inner pleat tips, the first and second sections meeting at a junction defining a step facing radially toward and engaging the flow tube.
21. The filter of claim 11, the end cap at said first axial end configured to receive a flow tube communicating with said hollow interior and extending along said axial flow passage, said flow tube having a tubular portion engaging said end cap and forming a seal therewith, said tubular portion being cylindrical.
22. The filter of claim 11 further comprising a flow tube communicating with said hollow interior and extending along said axial flow passage, said flow tube having a tubular portion engaging said end cap and forming a seal therewith, said tubular portion being cylindrical.
23. A filter assembly comprising:
- a filter media element comprising a first end and a second end, the element being shaped to form a hollow interior extending from the first end to the second end, wherein the hollow interior defines an inner boundary of the element and the outer surface of the element defines an outer boundary;
- a first end cap disposed at the first end;
- a second end cap disposed at the second end, the second end cap covering both the filter element and the hollow interior at the second end; and
- a step disposed on the first end cap for reception of a flow tube, the step being a right angle.
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Type: Grant
Filed: Jun 7, 2007
Date of Patent: Sep 21, 2010
Assignee: Cummins Filtration IP Inc. (Minneapolis, MN)
Inventors: Larry T. Gunderson (Madison, WI), Thomas A. Fosdal (Stoughton, WI), Gregory J. Schoenmann (Stoughton, WI), Kelly R. Schmitz (Brentwood, TN)
Primary Examiner: Robert A Hopkins
Attorney: Andrus, Sceales, Starke & Sawall, LLP
Application Number: 11/759,884
International Classification: B01D 35/30 (20060101);