EP-4736982-A2 - FILTER ASSEMBLIES UTILIZING FULL CROSS-SECTION

EP4736982A2EP 4736982 A2EP4736982 A2EP 4736982A2EP-4736982-A2

Abstract

A filter assembly comprises a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall. A filter element is disposed within the internal volume. The filter element comprises a filter media pack at least a portion of which has an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the filter housing. A support structure is coupled to at least one longitudinal end of the filter media pack.

Inventors

VERDEGAN, BARRY MARK
BATES, Billy M.
WIECZOREK, MARK T.
BURBRINK, CLIFFTON J.
SOUTH, KEVIN C.
BAGCI, ISMAIL C
HOVERSON, GREGORY W.
ABDALLA, WASSEM

Assignees

Atmus Filtration IP Inc.

Dates

Publication Date: 20260506
Application Date: 20190628

Claims (14)

A filter assembly, comprising: a filter housing defining an internal volume; and a filter element disposed within the internal volume, the filter element comprising an axial flow filter media pack configured to allow a fluid to flow therethrough along a longitudinal axis in a first direction between a first longitudinal end and a second longitudinal end of the axial flow filter media pack, the axial flow filter media pack including a backing sheet and a filter media layer that is rolled with the backing sheet to form a rolled filter media pack, the backing sheet having a plurality of grooves defined thereon, the backing sheet and the filter media layer together defining: a plurality of first flow channels open at the first longitudinal end and sealed at the second longitudinal end, and a plurality of second flow channels open at the second longitudinal end and sealed at the first longitudinal end, the filter media layer being disposed between the plurality of first flow channels and the plurality of second flow channels, such that fluid entering axially into the plurality of first flow channels is filtered through the filter media layer and exits from the plurality of second flow channels axially through the second longitudinal end, the filter element and the filter housing together defining a flow reversal chamber that is configured to change a flow direction of the fluid from the first direction towards a second direction opposite the first direction when the fluid is flowing through the filter assembly.
The filter assembly of claim 1, wherein the axial flow filter media pack defines a central channel that extends along the longitudinal axis of the filter element, and wherein the axial flow filter media pack is further configured to allow the fluid to flow through the central channel in the second direction.
The filter assembly of claim 2, wherein the filter element further comprises a center tube positioned within the central channel, the center tube coupled to (i) the flow reversal chamber and (ii) one of an inlet and an outlet of the filter assembly.
The filter assembly of any one of claims 1-3, wherein the rolled filter media pack comprises a cylindrical roll of the filter media layer and the backing sheet that are rolled together.
The filter assembly of claim 4, wherein the backing sheet is made from a stronger material than the filter media layer.
The filter assembly of any one of claims 1-3, wherein the filter housing comprises a base and a sidewall extending perpendicular to the base from an outer edge of the base, the filter assembly further comprising a cap coupled to an end of the filter housing distal from the base, the cap defining both an inlet and an outlet of the filter assembly.
The filter assembly of any one of claims 1-3, wherein the filter housing comprises a base and a sidewall extending perpendicular to the base from an outer edge of the base, wherein the flow reversal chamber is at least partially defined by the base.
The filter assembly of any one of claims 1-3, wherein the internal volume of the filter housing has an inner cross-section defining an inner cross-sectional distance, at least a portion of the axial flow filter media pack has an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance.
The filter assembly of any one of claims 1-3, further comprising a sealing member disposed between the axial flow filter media pack and a sidewall of the filter housing so as to prevent the fluid from flowing around an outer diameter of the axial flow filter media pack.
A filter element configured to be disposed within a filter housing, the filter element comprising an axial flow filter media pack configured to allow a fluid to flow therethrough along a longitudinal axis in a first direction between a first longitudinal end and a second longitudinal end of the axial flow filter media pack, the axial flow filter media pack including a backing sheet and a filter media layer that is rolled with the backing sheet to form a rolled filter media pack, the backing sheet having a plurality of grooves defined thereon, the backing sheet and the filter media layer together defining: a plurality of first flow channels open at the first longitudinal end and sealed at the second longitudinal end, and a plurality of second flow channels open at the second longitudinal end and sealed at the first longitudinal end, the filter media layer being disposed between the plurality of first flow channels and the plurality of second flow channels, such that fluid entering axially into the plurality of first flow channels is filtered through the filter media layer and exits from the plurality of second flow channels axially through the second longitudinal end, the axial flow filter media pack configured to be arranged within the filter housing so that, when in operation, the fluid flows in the first direction around the axial flow filter media pack and in a second direction opposite the first direction through the axial flow filter media pack, the axial flow filter media pack defining a central channel that extends along the longitudinal axis of the filter element.
The filter element of claim 10, wherein the filter media layer includes a fully synthetic nanofiber media that is paired with influent and effluent mesh layers.
The filter element of claim 10, wherein the filter element further comprises a center tube positioned within the central channel.
The filter element of any one of claims 10-12, wherein the rolled filter media pack comprises a cylindrical roll of the filter media layer and the backing sheet that are rolled together.
The filter element of any one of claims 10-12, further comprising a support structure coupled to a longitudinal end of the axial flow filter media pack, the support structure configured to form a fluid tight seal against a housing.

Description

Technical Field The present disclosure relates generally to filters for use with internal combustion engine systems. Background Internal combustion engines generally use various fluids during operation. For example, fuel (e.g., diesel, gasoline, natural gas, etc.) is used to run the engine. Air may be mixed with the fuel to produce an air-fuel mixture, which is then used by the engine to run under stoichiometric or lean conditions. Furthermore, one or more lubricants may be provided to the engine to lubricate various parts of the engine (e.g., piston cylinder, crank shaft, bearings, gears, valves, cams, etc.). These fluids may become contaminated with particulate matter (e.g., carbon, dust, metal particles, etc.) which may damage the various parts of the engine if not removed from the fluid. To remove such particulate matter or other contaminants, the fluid is generally passed through a filter assembly (e.g., a fuel filter, a lubricant filter, an air filter, a water filter assembly, etc.) structured to remove the particulate matter from the fluid prior to delivering the fluid. Loss of pressure or leakage in a filter assembly can reduce the filtering efficiency of the filter assembly. Summary Embodiments described herein relate generally to filter assemblies including a filter media pack that is snugly fit within a filter housing of the filter assembly, so as to provide at least partial sealing with a sidewall of the filter housing. Embodiments described herein also relate generally to forward and reverse flow filter assemblies, axial flow filter elements, axial to radial flow filter elements, variable cross-section filter elements and coalescer filter assemblies including axial flow filter media. In a first set of embodiments, a filter assembly comprises a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall. A filter element is disposed within the internal volume. The filter element comprises a filter media pack, at least a portion of the first filter media pack having an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the housing. A support structure is coupled to at least one longitudinal end of the filter media pack. In another set of embodiments, a filter assembly comprises a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall. A filter element is disposed within the internal volume. The filter element comprises an axial flow filter media pack. A channel is defined through the filter media pack along a longitudinal axis of the filter assembly. The filter media pack is configured to allow a fluid to flow therethrough along the longitudinal axis in a first direction and be filtered, the filtered fluid flowing through the channel in a second direction opposite the first direction towards the outlet. At least a portion of the filter media pack has an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the housing. A support structure is coupled to at least one end of the filter media pack. In still another set of embodiments, a filter element is provided that is configured to be disposed within a filter housing having an inner cross-section defining a maximum inner cross-sectional distance. A filter media pack at least a portion of which has an outer cross-section defining a maximum outer cross-sectional distance that is substantially equal to the maximum inner cross-sectional distance of the internal volume of the filter housing. A support structure is coupled to at least one longitudinal end of the filter media pack. In yet another set of embodiments, a filter element is provided that is configured to be disposed within a filter housing having an inner cross-section defining an inner cross-sectional distance. An axial flow filter media pack is provided. A channel is defined through the axial flow filter media pack along a longitudinal axis of the filter element. The axial flow filter media pack is configured to allow a fluid to flow therethrough along the longitudinal axis in a first direction and be filtered, the filtered fluid flowing through the channel in a second direction opposite the first direction towards the outlet. The axial flow filter media pack has an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the housing. A support structure is coupled to at least one end of the axial flow filter media pack. It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not m