U.S. patent application number 15/175240 was filed with the patent office on 2016-10-06 for fuel filter.
The applicant listed for this patent is Central Illinois Manufacturing Company. Invention is credited to Jeffrey Alan Ayers, Vickie Lynn Conlin, Matthew David Valentine.
Application Number | 20160288029 15/175240 |
Document ID | / |
Family ID | 55911458 |
Filed Date | 2016-10-06 |
United States Patent
Application |
20160288029 |
Kind Code |
A1 |
Ayers; Jeffrey Alan ; et
al. |
October 6, 2016 |
Fuel Filter
Abstract
A fuel filter comprises a filter housing having a fuel inlet and
a fuel outlet, and a laminate positioned within said filter
housing, the laminate comprising a first layer and a second layer
having methyl hydroxyethyl cellulose between said first layer and
said second layer, wherein the fuel filter is configured to direct
fuel received at the fuel inlet to the fuel outlet through the
laminate.
Inventors: |
Ayers; Jeffrey Alan;
(Decatur, IL) ; Valentine; Matthew David; (Bement,
IL) ; Conlin; Vickie Lynn; (Arthur, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Central Illinois Manufacturing Company |
Bement |
IL |
US |
|
|
Family ID: |
55911458 |
Appl. No.: |
15/175240 |
Filed: |
June 7, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14931514 |
Nov 3, 2015 |
9381453 |
|
|
15175240 |
|
|
|
|
62076004 |
Nov 6, 2014 |
|
|
|
62190104 |
Jul 8, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 39/2024 20130101;
B01D 29/58 20130101; B01D 2201/12 20130101; F02M 37/34 20190101;
B01D 29/60 20130101; B01D 36/003 20130101; B67D 7/766 20130101;
B01D 29/216 20130101; B01D 35/005 20130101; B01D 2239/0654
20130101; B01D 39/04 20130101; B01D 27/148 20130101; B01D 35/143
20130101; B01D 39/18 20130101; B01D 29/21 20130101; B01D 2239/065
20130101; B01D 27/06 20130101 |
International
Class: |
B01D 35/00 20060101
B01D035/00; B01D 29/21 20060101 B01D029/21; F02M 37/22 20060101
F02M037/22; B01D 39/18 20060101 B01D039/18; B01D 39/20 20060101
B01D039/20; B01D 29/60 20060101 B01D029/60; B01D 39/04 20060101
B01D039/04 |
Claims
1. A fuel filter comprising: a filter housing having a fuel inlet
and a fuel outlet, wherein the fuel outlet is a threaded hole and
the fuel inlet is defined by a plurality of holes arranged around
said threaded hole; a particulate filter; and a water sensing
laminate having a first layer and a second layer, the water sensing
laminate having methyl hydroxyethyl cellulose dispersed between
said first layer and said second layer at a ratio of about 40 to 70
grams per square foot of laminate, wherein the fuel filter is
configured to direct fuel received at the fuel inlet to the fuel
outlet through the particulate filter and the laminate.
2. The fuel filter of claim 1, wherein the first layer is a
fiberglass material and the second layer is a cellulose backing
layer.
3. The fuel filter of claim 1, wherein each of the first layer and
the second layer is a fiberglass material.
4. The fuel filter of claim 1, further comprising a center tube and
a screen, wherein the water sensing laminate wraps around at least
a portion of the center tube and is secured in place by the
screen.
5. A fuel filter comprising: a particulate filter; and a fiberglass
laminate having a first fiberglass layer and a second fiberglass
layer, the fiberglass laminate having methyl hydroxyethyl cellulose
dispersed between said first fiberglass layer and said second
fiberglass layer.
6. The fuel filter of claim 5, wherein the particulate filter
includes a filtering material laminated to a cellulose backing
layer.
7. The fuel filter of claim 5, wherein the methyl hydroxyethyl
cellulose is dispersed between said first fiberglass layer and said
second fiberglass layer at a ratio of about 40 to 70 grams per
square foot of fiberglass laminate.
8. The fuel filter of claim 7, wherein the methyl hydroxyethyl
cellulose is dispersed between said first fiberglass layer and said
second fiberglass layer at a ratio of about 55 grams per square
foot of fiberglass laminate.
9. The fuel filter of claim 6, wherein the cellulose backing layer
is formed in a pleated configuration.
10. The fuel filter of claim 5, wherein the fiberglass laminate is
laminated to a cellulose backing layer.
11. The fuel filter of claim 5, wherein the particulate filter and
the fiberglass laminate are each cylindrical and concentric with
regard to one another.
12. The fuel filter of claim 5, further comprising a filter housing
having a fuel inlet and a fuel outlet, wherein the fuel outlet is a
threaded hole and the fuel inlet is defined by a plurality of holes
arranged around said threaded hole.
13. The fuel filter of claim 12, wherein the fuel filter is
configured to direct fuel received at the fuel inlet to the fuel
outlet through the particulate filter and the fiberglass
laminate.
14. A fuel filter comprising: a filter housing having a fuel inlet
and a fuel outlet; and a laminate positioned within said filter
housing, the laminate comprising a first layer and a second layer
having methyl hydroxyethyl cellulose between said first layer and
said second layer, wherein the fuel filter is configured to direct
fuel received at the fuel inlet to the fuel outlet through the
laminate.
15. The fuel filter of claim 14, further comprising a filter
housing having a fuel inlet and a fuel outlet, wherein the fuel
outlet is a threaded hole and the fuel inlet is defined by a
plurality of holes arranged around said threaded hole.
16. The fuel filter of claim 14, wherein the methyl hydroxyethyl
cellulose is dispersed at a ratio of about 40 to 70 grams per
square foot of laminate.
17. The fuel filter of claim 16, wherein the methyl hydroxyethyl
cellulose is dispersed at a ratio of about 55 grams per square foot
of laminate.
18. The fuel filter of claim 14, wherein the first layer is a
fiberglass material and the second layer is a cellulose backing
layer.
19. The fuel filter of claim 14, wherein each of the first layer
and the second layer is a fiberglass material.
20. The fuel filter of claim 19, wherein the laminate is laminated
to a cellulose backing layer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/931,514, filed on Nov. 3, 2015, which
claims priority to U.S. Provisional Patent Application No.
62/076,004, filed on Nov. 6, 2014, and U.S. Provisional Patent
Application No. 62/190,104, filed on Jul. 8, 2015, each of which is
hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to fuel filters and, more
particularly, to fuel filters for filtering particulate contaminant
from a fuel stream to be used in fuel dispensing applications. More
specifically, the present invention relates to fuel filters that
detect liquid contaminates by reacting with free or emulsified
water in fuel. For example, to identify alcohol blended fuel that
is subject to a phase separation condition.
BACKGROUND
[0003] It is often desirable to filter liquid to mechanically
separate impurities from the liquid prior to use, that is,
separating particulate material from the liquid. For example, in
the case of fuel, such material can plug carburetor jets (or
injection nozzles) and otherwise interfere with the operation of an
internal combustion engine. Thus, fuel is typically filtered at the
time it is dispensed at, for example, a service station, and is
filtered again just prior to its use by a fuel filter associated
with an internal combustion engine. While such filters adequately
rid the fuel of particulate contaminants by mechanical filtering,
such filters permit liquid contaminants to remain with the fuel.
Example fuel filters include those by Cim-Tek.RTM. Filtration,
which are available from Central Illinois Manufacturing Company of
Bement, Ill.
[0004] A particularly troubling fuel contaminant is water,
especially in alcohol-blended fuels. To provide background,
alcohols are often added to fuel to, inter alfa, boost octane,
oxygenate, extend fuel supply, replace ethers, and reduce the
impact of fossil fuels on the carbon cycle. Alcohol-blended fuels,
however, react differently in the presence of water than
alcohol-free fuels. That is, with alcohol-free fuels, water is
heavier than the fuel and simply drops to the bottom of the fuel
tank. Thus, as long as a proper maintenance protocol is followed,
the water level in the fuel tank should not reach the level of an
intake for a pump that draws the fuel from the fuel tank.
[0005] Unlike alcohol-free fuels, however, alcohol-blended fuels
separate into two or more layers when exposed to excess water. The
two or more layers typically include a denser, alcohol-water layer,
and a less dense, fuel layer that is depleted in octane rating and
alcohol soluble hydrocarbons. This separation is more commonly
known as phase separation, or a phase separation condition. For
example, ethanol-blended fuels (a common type of alcohol-blended
fuel) contain ethanol, which is hygroscopic, meaning that it seeks
out, and retains, water. At low water level concentrations, the
ethanol is able to retain the water it has dissolved and remain
associated with the fuel. That is, the fuel, water, and alcohol
mixture remains stable and usable as a motor fuel. Once the water
concentration exceeds a temperature-dependent threshold (e.g., the
saturation point) for a given alcohol concentration,
fuel-hydrocarbon content, and additives in the fuel (which
typically contain alcohol as a major component), the ethanol and
water phase separates from the fuel mixture. Under average
temperature conditions in the United States, for example, water
content of 0.3% to 0.5% by volume is typically a range within which
phase separation occurs. The alcohol-water layer does not support
combustion in a conventional gasoline engine, such as those in
vehicles and generators, and, if introduced to the engine, may
cause malfunction of internal combustion (e.g., engine stalling).
Water may also damage expensive engine components, particularly
fuel injectors.
[0006] To address phase separation concerns, developments have been
made to treat fuel that has succumbed to phase separation prior to
delivery from the storage tank to the engine. For example, commonly
owned U.S. Pat. No. 8,439,984 to Kevin Dewayne Hughes, which was
filed Apr. 14, 2009, discloses a method of treating a fuel to
reverse phase separation. The method involves adding a liquid to
the fuel to reverse the phase separation of the alcohol-water
layer. Similarly, commonly owned U.S. Pat. Nos. 4,604,205;
4,623,560; 4,832,844; 4,539,107; 4,618,388; and 5,298,160, each to
William R. Ayers et al., disclose filters, and filter media for use
in a filter, that separate water and/or particulate material from a
liquid to be purified, such as a hydrocarbon fuel.
[0007] Despite the forgoing techniques, a need remains for an
improved, more effective, apparatus, such as a filter, that can
detect excess water in fuel (indicating potential phase separation
in a fuel, such as alcohol-blended fuels) and, in certain aspects,
inhibiting delivery of such fuel to an engine, thereby mitigating
damage to the engine. In at least one aspect, such a filter would
be useful in fuel dispensers, such as those found at convenience
stores and fuel stations. The filter, however, may also be used in
applications other than fuel dispensers, such as being directly
coupled to an engine.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a filter configured to
detect water in fuel, detect phase separation in fuels (e.g.,
alcohol-blended fuels), and restrict the fuel flow through the
filter upon detection, thereby alerting the operator that there is
an issue with the fuel that needs to be addressed.
[0009] According to a first aspect, a fuel filter comprises: a
filter housing having a fuel inlet and a fuel outlet, wherein the
fuel outlet is a threaded hole and the fuel inlet is defined by a
plurality of holes arranged around said threaded hole; a
particulate filter; and a water sensing laminate having a first
layer and a second layer, the water sensing laminate having methyl
hydroxyethyl cellulose dispersed between said first layer and said
second layer at a ratio of about 40 to 70 grams per square foot of
laminate, wherein the fuel filter is configured to direct fuel
received at the fuel inlet to the fuel outlet through the
laminate.
[0010] According to a second aspect, a fuel filter comprises: a
particulate filter; and a fiberglass laminate having a first
fiberglass layer and a second fiberglass layer, the fiberglass
laminate having methyl hydroxyethyl cellulose dispersed between
said first fiberglass layer and said second fiberglass layer.
[0011] According to a third aspect, a fuel filter comprises: a
filter housing having a fuel inlet and a fuel outlet; and a
laminate positioned within said filter housing, the laminate
comprising a first layer and a second layer having methyl
hydroxyethyl cellulose between said first layer and said second
layer, wherein the fuel filter is configured to direct fuel
received at the fuel inlet to the fuel outlet through the
laminate.
[0012] In certain aspects, the particulate filter includes a
filtering material laminated to a cellulose backing layer.
[0013] In certain aspects, the methyl hydroxyethyl cellulose is
dispersed between said first fiberglass layer and said second
fiberglass layer at a ratio of about 40 to 70 grams per square foot
of fiberglass laminate.
[0014] In certain aspects, the methyl hydroxyethyl cellulose is
dispersed between said first fiberglass layer and said second
fiberglass layer at a ratio of about 55 grams per square foot of
fiberglass laminate.
[0015] In certain aspects, the cellulose backing layer is formed in
a pleated configuration.
[0016] In certain aspects, the fiberglass laminate is laminated to
a cellulose backing layer.
[0017] In certain aspects, the particulate filter and the
fiberglass laminate are each cylindrical and concentric with regard
to one another.
[0018] In certain aspects, the filter housing has a fuel inlet and
a fuel outlet, wherein the fuel outlet is a threaded hole and the
fuel inlet is defined by a plurality of holes arranged around said
threaded hole. For example, the fuel filter may be configured to
direct fuel received at the fuel inlet to the fuel outlet through
the particulate filter and the fiberglass laminate.
[0019] In certain aspects, the filter housing has a center tube and
a screen, wherein the water sensing laminate wraps around at least
a portion of the center tube and is secured in place by the
screen.
DESCRIPTION OF THE DRAWINGS
[0020] These and other advantages of the present invention will be
readily understood with the reference to the following
specifications and attached drawings, where like reference numbers
refer to like structures. The figures are not necessarily to scale,
emphasis is instead placed upon illustrating the principles of the
devices, systems, and methods described herein.
[0021] FIG. 1a illustrates a perspective view of an example filter
having portions thereof removed to expose filter components within
housing.
[0022] FIG. 1b illustrates an exploded perspective view of the
example filter of FIG. 1a.
[0023] FIG. 2a illustrates a side assembly view of the example
filter of FIG. 1a having portions thereof removed to expose filter
components within housing.
[0024] FIG. 2b illustrates a cross-sectional side assembly view of
the example filter of FIG. 1a.
[0025] FIG. 3a illustrates a side view of the example filter of
FIG. 1a having portions thereof removed to expose filter components
within housing.
[0026] FIG. 3b illustrates a cross-sectional side view of the
example filter of FIG. 1a illustrating fuel flow direction.
DETAILED DESCRIPTION
[0027] Preferred embodiments of the present invention will be
described herein with reference to the accompanying drawings. In
the following description, well-known functions or constructions
are not described in detail because they could obscure the
invention in unnecessary detail.
[0028] All documents mentioned herein are hereby incorporated by
reference in their entirety. References to items in the singular
should be understood to include items in the plural, and vice
versa, unless explicitly stated otherwise or clear from the text.
Grammatical conjunctions are intended to express any and all
disjunctive and conjunctive combinations of conjoined clauses,
sentences, words, and the like, unless otherwise stated or clear
from the context. Thus, the term "or" should generally be
understood to mean "and/or" and so forth.
[0029] Recitation of ranges of values herein are not intended to be
limiting, referring instead individually to any and all values
falling within the range, unless otherwise indicated herein, and
each separate value within such a range is incorporated into the
specification as if it were individually recited herein. The words
"about," "approximately," or the like, when accompanying a
numerical value, are to be construed as indicating a deviation as
would be appreciated by one of ordinary skill in the art to operate
satisfactorily for an intended purpose. Ranges of values and/or
numeric values are provided herein as examples only, and do not
constitute a limitation on the scope of the described embodiments.
The use of any and all examples, or exemplary language ("e.g.,"
"such as," or the like) provided herein is merely intended to
better illuminate the embodiments and does not pose a limitation on
the scope of the embodiments. No language in the specification
should be construed as indicating any unclaimed element as
essential to the practice of the embodiments.
[0030] In the following description, it is understood that terms
such as "first," "second," "top," "bottom," "side," "front,"
"back," and the like are words of convenience and are not to be
construed as limiting terms. Further, the word "exemplary" means
"serving as an example, instance, or illustration." The embodiments
described herein are not limiting, but rather are exemplary only.
It should be understood that the described embodiments are not
necessarily to be construed as preferred or advantageous over other
embodiments. Moreover, the terms "embodiments of the invention,"
"embodiments," or "invention" do not require that all embodiments
of the invention include the discussed feature, advantage, or mode
of operation.
[0031] As will be described below, a filter in accordance with an
aspect of the present invention detects the presence of water in a
fuel, which may be indicative of phase separation in, inter alia,
alcohol-blended fuels. Upon detection, the filter restricts the
flow of fuel through the filter. This function may be achieved
through the use of a water and/or phase separation sensing chemical
within the filter. Specifically, when a mixture of water and fuel
passes through the filter's water sensing layer, the water and
phase separation sensing chemical (e.g., a gelling and thickening
agent) reacts with the water to form an semi-impermeable or
impermeable barrier that restricts the flow of fuel to the fuel
delivery system, thereby alerting the operator that there is an
issue with the fuel and mitigating potential engine damage. In
addition to water and phase separation detection, the filter also
provides particulate filtration of the fuel via a filter media.
Exemplary applications for such a filter include engine fuel
delivery systems, such as those used in vehicles, and fuel
dispensers, such as those found at convenience stores, fuel
stations, and/or fuel storage containers.
[0032] Vehicles (or other engine-driven devices) and fuel
dispensers typically employ a fuel tank for holding fuel, while
fuel dispensers further comprise a fuel nozzle. A fuel dispenser
may comprise a head component containing a mechanical device or
embedded computer, which are configured to, inter alfa, control the
action of the pump, drive the pump's displays, and, in certain
aspects, communicate to an indoor sales system. The fuel dispenser
may further comprise a pumping component having, for example, an
electric motor, pumping unit, meters, pulsers and valves to
physically pump and control the fuel flow from a fuel tank to a
fuel nozzle. An example fuel dispenser is disclosed by U.S. Pat.
No. 7,948,376 to Jonathan E. DeLine, entitled "Fuel Dispenser." A
vehicle, on the other hand, employs a fuel pump that pumps fuel
from the fuel tank to the engine (e.g., carburetor or injection
nozzles). A filter in accordance with the present disclosure may be
positioned inline between the fuel tank and the fuel nozzle or the
engine. For example, the filter 100 may be position between the
pump and the nozzle of a fuel dispenser or between the pump and the
engine of a vehicle (or other engine-driven device).
[0033] With reference to the figures, an example filter 100 is
illustrated that is capable of detecting water in fuel, which is
indicative of fuel phase separation (e.g., in alcohol-blended
fuels), and restricting flow thereof. Depending on the design
needs, the filter 100 may be fabricated in various sizes. That is,
the diameter of the filter 100 may be adjusted to achieve a desired
target flow rate, while the length and/or diameter may be increased
to increase the surface area of the filter material, thereby
including dirt holding capacity and service life of the filter 100.
For example, the outer dimensions may be about 3 to 5 inches in
diameter and about 5 to 11 inches in length. Upon detection of
water, the filter 100's water sensing layer 122 (e.g., a wrap
formed via a first layer 122a and a second layer 122b) restricts
the fuel flow through the filter 100 so as to alert the operator
that a fuel issue exists and must be addressed. The filter 100
further provides particulate filtration of the fuel. As alluded to
above, particulate contamination of fuels and alcohol-blended fuel
can cause, among other things, dispenser meter wear, engine damage,
etc.
[0034] FIGS. 1a and 1b illustrate, respectively, a perspective view
of a filter 100 having portions thereof removed to expose the
filter components within housing 102, and an exploded perspective
view thereof. As illustrated, the filter 100 may comprise a housing
102 having an open end 104 and a closed end 128. The housing 102
may be configured to receive a filter assembly, the filter assembly
generally comprising a closed end cap 132, an open end cap 136, and
a filter element 116 positioned therebetween. While the filter
element 116, and component thereof, are illustrated as being
generally cylindrical, other shapes and designs are contemplated.
To secure the filter assembly within the housing 102, a threaded
end plate 110 may be coupled to the open end 104 of the housing
102. The threaded end plate 110 may be coupled to the housing 102
using one or more fixed securing techniques, including, for
example, crimping, adhesives, welding, rivets, etc., or removable
securing techniques (e.g., threadedly coupled).
[0035] The threaded end plate 110 may comprise a threaded hole 112
positioned at an approximate center of a circular plane defined by
the top surface of the threaded end plate 110. A plurality of holes
108 (e.g., about 2 to 10, more preferable about 2 to 8, most
preferable about 6) are further arranged around the threaded hole
112. In operation, the plurality of holes 108 serve as a fuel inlet
to the filter 100, while the threaded hole 112 in the end plate 110
serves as a fuel outlet. Preferably, the area of the threaded hole
112's opening is equal to, or greater than, the cumulative area of
the plurality of holes 108's openings so as to ensure that the
outlet can accommodate fuel flow from the inlet. The threaded hole
112 may be sized and configured to couple to a fuel delivery
system, whether a fuel dispenser or engine. An external seal 106 is
further provided along the top circumference of the open end 104,
which allows the housing 102 to form a fluid tight seal with a
corresponding mating component of the fuel delivery system. While
the plurality of holes 108 serve as the fuel inlet to the filter
100 in the illustrated example, one of skill in the art would
appreciate that other configurations are possible. For example, the
threaded hole 112 may function as the inlet, and the plurality of
holes 108 may function as the outlet. Thus, the subject teachings
need not be limited to a particular arrangement.
[0036] In certain aspects, the housing 102 may be fabricated from a
fuel resistant material (e.g., metal, thermoplastic, or other
resin), which may be further resistant to ultraviolet (UV) light.
For example, the housing 102 may be fabricated using cold rolled
carbon steel, which may be further painted or powder coated. In
certain aspects, however, the housing 102 may be fabricated from
one or more other non-corrosive metallic materials. When a metallic
material is not desirable, an example non-metallic fuel resistant
material includes, for example, BASF Ultramid 8233GHS BK 102.
[0037] FIGS. 2a and 2b illustrate, respectively, a side assembly
view of the filter 100 having portions thereof removed and a
cross-sectional side assembly view of the filter 100. As
illustrated, the filter element 116 may be positioned within the
housing 102 and held against the threaded end plate 110 by a force
(direction F), which may be imparted by a spring 124 positioned at
the closed end 128 of the housing 102 and configured to act upon
the closed end cap 132. At the open end of the filter element 116,
a seal 134 is provided and placed between the end plate 110 and the
open end cap 136. The seal 134 prevents unfiltered fuel from
passing between the open end cap 136 on the filter element 116 and
the end plate 110.
[0038] The spring 124 is sized and shaped to provide the pressure
needed to compress the seal 134 adequately so as to form a fluid
tight seal between the open end cap 136 and the end plate 110. The
spring 124 may be fabricated from a corrosion-resistant material,
such as 302 stainless steel. The external seal 106 and seal 134 may
be fabricated from a fuel resistant flexible material. Example fuel
resistant materials include, without limitation, fuel resistant
Nitrile rubber (also known as buna rubber), fluoroelastomer
materials (e.g., a viton compound), etc. The fuel resistant
flexible material's hardness may be, for example, about 50 to 100
durometer shore A, more preferably about 70 durometer shore A.
[0039] The closed end cap 132 and open end cap 136 may secure the
various components of the filter element 116 using, for example, a
potting compound 140 such as plastisol. Plastisol is a suspension
of polyvinyl chloride (PVC) particles in a liquid plasticizer.
Plastisol flows as a liquid and can be poured into a heated mold,
where the plastic and plasticizer mutually dissolve each other to
yield a flexible, permanently plasticized solid product upon
cooling.
[0040] The filter element 116 may comprise a particulate filter
component 118, and a water sensing component 138. The water sensing
component 138 may be generally cylindrical and may comprise a water
sensing layer 122 supported by a cylindrical center tube 114 (e.g.,
a louvered or perforated support tube or core). The water sensing
layer 122 may be used to detect and/or identify phase separation by
detecting water present in the fuel. The center tube 114 may be
fabricated from metal and configured to provide structural support
for both the particulate filter component 118 and water sensing
layer 122. In operation, fuel passing through the center tube 114
exits through the threaded hole 112 (which functions as a fuel
outlet) in the end plate 110 and continues through the fuel
delivery system.
[0041] The particulate filter component 118 may comprise, for
example, a fiberglass material 126 (or another filtering material)
laminated to a cellulose backing layer 130, which may be formed in
a pleated configuration to increase surface area. As illustrated,
the particulate filter component 118 may be generally cylindrical
and configured to receive the water sensing component 138. When
assembled, the various components for the filter 100, including the
particulate filter component 118 and water sensing component 138,
may be concentric.
[0042] The particulate filter component 118 provides particulate
filtration for the fuel as the fuel flows inwardly (i.e., towards
the center tube 114) through the particulate filter component 118.
While certain embodiments are shown and described, it is to be
understood that other configurations, such as a spirally wrapped
mat or batt configuration, may be employed. In an alternate design,
the fiberglass material and cellulose media may be substituted with
a different particulate filter media, such as cellulose only or
epoxy coated aluminum screen wire mesh supported fiberglass. This
layer may also be constructed of other materials that provide
suitable particulate only filtration. Examples include, for
example, melt blown and other non-woven glass media,
cellulose/glass combination (or hybrid) media, wet laid non-woven
media, felt, or other depth type filtration media.
[0043] The water sensing layer 122 may comprise, for example, two
or more layers 112a, 112b of fiberglass having a gelling and
thickening agent dispersed, or impregnated, therein or therebetween
(e.g., between first layer 112a and second layer 112b). A suitable
gelling and thickening agents include, without limitation, methyl
hydroxyethyl cellulose, which is a gelling and thickening agent
derived from cellulose. Methyl hydroxyethyl cellulose is sometimes
referred to as 2-hydroxyethyl methyl cellulose, 2-hydroxyethyl
methyl ether, or hydroxyethyl methyl cellulose. Suitable methyl
hydroxyethyl cellulose is includes Tylose.RTM. MHS 150003 P4,
available from ShinEtsu Tylose GmbH & Co.KG.
[0044] In certain aspects, the fiberglass wrap material may be
provided as a fiberglass-cellulose laminate. A fiberglass-cellulose
laminate can be advantageous over cellulose mechanical filtering
material because a fiberglass-cellulose laminate provides a higher
particulate retaining capacity, therefore resulting in a longer
lifespan when used with particulate-contaminated fuels. The
fiberglass-cellulose laminate may be fabricated from two or more
layers of fiberglass and cellulose. The two or more layers of
fiberglass and cellulose may be laminated together using a hot-melt
adhesive resin. The hot-melt adhesive resin may be a polyamide,
such as Arizona Chemical Uni-Rez.TM. 2626, or other suitable
hot-melt adhesive resin with resistance to fuels. The hot-melt
adhesive resin can be melted and sprayed, or otherwise applied,
between the two or more layers of fiberglass-cellulose. The
hot-melt adhesive resin can sprayed using a fiberized spray
applicator or similar device. A suitable fiberized spray applicator
includes Dynatec's UFD fiberized spray applicators, available from
Illinois Tool Works. Prior to the adhesive curing/solidifying, the
two or more layers of fiberglass and cellulose are pressed
together. Once the adhesive solidifies, the laminated material may
be processed as one laminated component material. Alternatively, in
lieu of a hot-melt adhesive resin, a liquid or other suitable
adhesive may be used.
[0045] As is appreciated, the methyl hydroxyethyl cellulose may be
provided between two layers of fiberglass (a fiberglass laminate or
fiberglass-fiberglass laminate) or, in another aspect, a layer of
fiberglass and a layer of cellulose (a fiberglass-cellulose
laminate). Thus, the first layer 112a and second layer 112b should
not be limited to fiberglass and may be formed from different
materials. The methyl hydroxyethyl cellulose, for example, may be
applied in a granular powder form, to form a thin layer to the top
of one side of a layer of fiberglass wrap material. A fine mist of
water, or other fluid, may be applied to the layer of methyl
hydroxyethyl cellulose powder prior adding a second layer of
fiberglass wrap material. The fine mist of water reacts with the
methyl hydroxyethyl cellulose and binds the two layers of
fiberglass wrap material together in a fashion suitable for further
processing into a finished filter 100. The fine mist of water
applied in this process naturally evaporates out of the methyl
hydroxyethyl cellulose under normal ambient conditions. Alternative
methods of applying methyl hydroxyethyl cellulose include, for
example, creating a slurry of water and methyl hydroxyethyl
cellulose that may be sprayed onto a substrate, such as a layer of
fiberglass wrap material, prior to combination with a second layer
of fiberglass wrap material. A disadvantage of this approach,
however, is that such a process could require energy (e.g., heat)
to dehydrate the methyl hydroxyethyl cellulose prior to further
processing. In certain aspects, the methyl hydroxyethyl cellulose
may be applied in other forms, rather than granular powder form.
For example, the methyl hydroxyethyl cellulose may be applied as a
fiber or film form between the two or more layers of fiberglass
wrap material.
[0046] The methyl hydroxyethyl cellulose, for example, may be
dispersed on the surface of a layer of fiberglass wrap material in
an amount of, for example, about 10 to 100 grams, more preferably
about 40 to 70 grams, and most preferably about 55 grams per square
foot of fiberglass wrap material surface area. To permit even
blockage, the methyl hydroxyethyl cellulose, or other gelling and
thickening agent, may be evenly dispersed (or distributed) over a
given layer of fiberglass wrap material's surface area. In certain
embodiments, the density of the methyl hydroxyethyl cellulose
granules may be greater near the outlet than near the inlet
because, as the granules swell, it is desirable that their density
be reduced near the inlet so as not to cause premature clogging of
the filter 100 due to the swelling of the granules. Higher amounts
of methyl hydroxyethyl cellulose than those prescribed above may
not necessarily add to the performance of the phase separation or
water detection capabilities of the filter 100, however, a reduced
amount of methyl hydroxyethyl cellulose will not sufficiently
restrict flow through the filter 100 to notify the operator of the
presence of excess water or phase separation. That is, testing has
shown that using more than the proscribed amount of methyl
hydroxyethyl cellulose only adds to the cost by adding unnecessary
methyl hydroxyethyl cellulose not necessarily required to restrict
fluid flow through the filter in the presence of water or phase
separation, but does not reduce the effectiveness of the filter's
ability to the presence of excess water or phase separation.
[0047] Compared to other gelling and thickening agents, methyl
hydroxyethyl cellulose has demonstrated unexpectedly beneficial
results when applied to filter 100, resulting in superior flow
restriction characteristics. Methyl hydroxyethyl cellulose has
shown to reduce flow from 10 gallons per minute (GPM) to less than
1 GPM in about 20 or fewer seconds, a 90% reduction in flow.
Starch-polyacrylonitrile graft copolymer, on the other hand, has
shown to only reduce flow from 12 GPM to 2 GPM in roughly the same
time period, an 83% reduction. Accordingly, a user would be more
quickly alerted as to a potential phase separation condition when
using methyl hydroxyethyl cellulose. Moreover, the physical
characteristics of methyl hydroxyethyl cellulose are more conducive
to flow restriction than known materials. For example, when a
starch-polyacrylonitrile graft copolymer (or other similar
material) encounters water, the material typically yields a less
viscous gel, while methyl hydroxyethyl cellulose coagulates to form
a singular more viscous gel material, namely a
cohesive-gelatinous-substance. Finally, using methyl hydroxyethyl
cellulose is more cost efficient as the cost of methyl hydroxyethyl
cellulose material is lower that other, often less effective,
materials, such as starch-polyacrylonitrile graft copolymer.
[0048] Other suitable gelling and thickening agents, which may be
applied in a substantially similar manner to that describe above,
may include, for example, methyl hydroxypropyl cellulose (which is
derived from cellulose), sodium polyacrylamide, sodium
polyacrylate, modified starches carrying copolymers such as
polyacrylamide, and/or other water-absorbing superabsorbent
polymers. Regardless of gelling and thickening agent, a filter 100
that has restricted the flow of fuel may be reused by dehydrating
the hydrated gelling and thickening agent by, for example, applying
heat to evaporate the water from the gelling and thickening agent.
The hydrating and dehydrating cycle, however, can affect the
absorption capacity of the gelling and thickening agent.
[0049] The term superabsorbent polymer refers to polymers that can
absorb and retain exceptionally large amounts of liquid relative to
its own mass. Water-absorbing polymers, which are classified as
hydrogels when cross-linked, absorb aqueous solutions through
hydrogen bonding with water molecules. A hydrogel refers to a
network of polymer chains that are hydrophilic, sometimes found as
a colloidal gel in which water is the dispersion medium. Hydrogels
and self-healing hydrogels are highly absorbent natural or
synthetic polymeric networks. A superabsorbent polymer's ability to
absorb water is a factor of the ionic concentration of the aqueous
solution. In deionized and distilled water, a superabsorbent
polymer may absorb 500 times its weight (from 30 to 60 times its
own volume) and can become up to 99.9% liquid. For example, sodium
polyacrylate absorbs from 500-800 times its weight in water.
[0050] The total absorbency and swelling capacity may be controlled
by the type and degree of cross-linkers used to make the gel.
Low-density cross-linked superabsorbent polymers generally have a
higher absorbent capacity and swell to a larger degree. These types
of SAPs also have a softer and stickier gel formation. High
cross-link density polymers exhibit lower absorbent capacity and
swell, but the gel strength is firmer and can maintain particle
shape even under modest pressure.
[0051] In the illustrated examples, the water sensing layer 122 is
wrapped around a center tube 114 and secured in place by a screen
120, which may be, for example, a vinyl coated fiberglass core yarn
mesh, such as a 16 mesh (0.009 in.) PVC screen. In certain aspects,
however, alternative materials may be used in place of the
fiberglass layers. Examples include, for example, melt blown and
other non-woven glass medias, cellulose/glass combination (or
hybrid) medias, wet laid non-woven medias, felt, or other depth
type filtration media. While the water sensing layer 122 is
illustrated and described as being wrapped around the center tube
114, the water sensing layer 122 may alternatively be positioned
elsewhere in the filter 100. For example, the water sensing layer
122 may be integrated with the particulate filter component 118,
positioned within the center tube 114, over the threaded hole 112,
etc. That is, a screening material that is impregnated with a
thickening agent (e.g., water sensing layer) may be positioned over
the inlet and/or outlet of the filter 100, in the illustrated
example, over the threaded hole 112 and/or the plurality of holes
108. As the surface area defined by the inlet and/or outlet is
generally less than the surface area of the center tube (or water
sensing layer 122), the filter 100 may respond more quickly to the
presence of water (i.e., more sensitive to blockage), thereby
indicating to the operator that a phase separation condition may
exist. In other aspects, the water sensing layer may be integrated,
wrapped, or otherwise used with particulate filter component 118,
water sensing layer 122, center tube 114, or portions/components
thereof
[0052] FIG. 3a illustrates a side view of an assembled filter 100
having portions thereof removed to expose filter components within
housing, while FIG. 3b illustrates a cross-sectional side view of
the example filter 100 illustrating fuel flow direction.
Specifically, as indicated by the arrows, the fuel enters the
filter 100 via the plurality of holes 108, which collectively
function as the fuel inlet. The fuel then travels between the outer
surface of the particulate filter component 118 and the inner
surface of the housing 102. The fuel is then passed through the
wall of the particulate filter component 118 (e.g., through
fiberglass material 126 and cellulose backing layer 130), which
filters out particulates. The fuel, having been filtered of
particulates, then travels through the water sensing component 138
(e.g., water sensing layer 122, center tube 114, and screen 120).
If present, water within the fuel (e.g., fuel subject to phase
separation) reacts with the gelling and thickening agent, which
will coagulate to ultimately create an impermeable barrier (or semi
impermeable barrier) between the inner region of the center tube
114 and a region defined between the particulate filter component
118 and the water sensing component 138. The impermeable barrier,
in turn, restricts or wholly prohibits the flow of fuel. Indeed,
the degree to which the gelling and thickening agent coagulates to
form an impermeable barrier (e.g., the degree in which flow of fuel
is blocked) generally correlates to the amount of water that passes
through the water sensing component 138. That is, the gelling and
thickening agent will more quickly form the impermeable barrier as
the amount of water increases. Accordingly, the filter may still
operate normally when nominal amounts of water are present, but the
flow of fuel will decrease as the amount of water increases,
thereby indicating a phase separation condition.
[0053] Any fuel that passes through the water sensing component 138
flows to the threaded hole 112, which functions as a fuel outlet
and may be coupled to a fuel delivery system. As illustrated, and
as described above, the spring 124 imparts a force upon the
underside of the closed end cap 132, which in turn urges the filter
element 116 against the seal 134, which creates a fluid tight seal
between the filter element 116's open end cap 136 and the threaded
end plate 110. When coupled to a fuel delivery system, the fuel
inlet and the fuel outlet are not in direct flow communication as
the fuel delivery system's coupling forms a barrier between the
fuel inlet and the fuel outlet.
[0054] The above-cited patents and patent publications are hereby
incorporated by reference in their entirety. Although various
embodiments have been described with reference to a particular
arrangement of parts, features, and the like, these are not
intended to exhaust all possible arrangements or features, and
indeed many other embodiments, modifications, and variations will
be ascertainable to those of skill in the art. Further, while the
forgoing has been described with regard to fuel delivery systems,
one of skill in the art would recognize that the techniques taught
herein may be employed with other applications where water
detection within a fluid is desired. Thus, it is to be understood
that the invention may therefore be practiced otherwise than as
specifically described above.
* * * * *