# US 10,765,975 B2 · Filter element and method of manufacturing a filter element > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,765,975 B2 - Document ID: US10765975B2 - Status: Granted - Kind: B2 - Application number: 15/201,299 - Filed: 2016-07-01 - Published: 2018-01-04 - Granted: 2020-09-08 - Earliest claimed: 2016-07-01 - Assignees: Caterpillar Inc. - Applicants: Caterpillar Inc. - Inventors: Thierry A. Marchione; Brent D. Widder; Rahul Gami - Web page: https://patentgrep.com/patent/US10765975B2 ## CPC - B22F 3/11: Making porous workpieces or articles - B01D 29/111: {Making filtering elements} - B01D 29/31: Self-supporting filtering elements - B01D 35/005: {Filters specially adapted for use in internal-combustion engine lubrication or fuel systems} - B01D 39/2034: {sintered or bonded by inorganic agents} - B01D 39/2037: {otherwise bonded} - B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B22F 10/36: of energy beam parameters - B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - B01D 2201/18: Filters characterised by the openings or pores - B01D 2239/1208: Porosity - B22F 10/68: Cleaning or washing - B23K 1/0008: {specially adapted for particular articles or work} - B23K 1/0056: {soldering by means of beams, e.g. lasers, electron beams [EB]} - Y02P 10/25: Process efficiency - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A filter element for the filtration of fluids can be manufactured from powdered metal using a laser manufacturing process. The powdered metal is deposited in a layer on fabrication platform and a laser beam is directed toward the layer of material so that the powdered metal granules fuse together to form a first component of the filter element. Successive layers of powdered metal can be deposited over the first component and also fused with the laser beam to form additional components. During the manufacturing process, the power or scan rate of the laser beam many be changed so that the formed layers of the filter element may have different porosity characteristics, for example, with certain portions being fluid permeable and other portions being fluid impermeable. ## Claims ### Claim 1 A filter element manufactured by a laser manufacturing process, the filter element comprising: a first component corresponding to a filtration media and having a first porosity that is permeable to fluid; and a second component integral to the first component and corresponding to a preexisting brazing barrier configured to block the flow of a brazing material in a liquid state into the first component, the brazing barrier comprising a solid component of the filter element having a second porosity less than the first porosity and that is impermeable to fluid; a solid housing component joined to the first component by brazing material; wherein the first component and the brazing barrier are manufactured from powdered metal that is different from the brazing material and are formed integrally adjacent to each other by a laser beam. ### Claim 2 (depends on 1) The filter element of claim 1, further comprising a third component having a third porosity different from the second porosity, the third porosity configured to receive flow of a brazing material. ### Claim 3 (depends on 2) The filter element of claim 2, wherein the filtration media has a cup-like shape with a closed top and an opened rim; the second component is formed as a first annular collar disposed adjacently around the opened rim; and the third component is formed as a second annular collar disposed adjacently around the second component. ### Claim 4 (depends on 3) The filter element of claim 3, wherein the second component include an overhanging leg extending radially over the third component and isolating the third component from the filtration media. ### Claim 5 (depends on 1) The filter element of claim 1, wherein the first porosity of the filtration media is provided by a plurality of interconnected voids. ### Claim 6 (depends on 5) The filter element of claim 5, wherein the first porosity has a range of about 5 microns to about 200 microns. ### Claim 7 (depends on 1) The filter element of claim 1, wherein the powdered metal material is selected from a group consisting of stainless steel, irons, copper, aluminum, titanium, cobalt, chromium, and alloys thereof. ### Claim 8 (depends on 1) The filter element of claim 1, wherein the brazing barrier is disposed at and extends around an annular open rim defining in part a hollow interior of the filtration media. ### Claim 9 (depends on 8) The filter element of claim 8, wherein the brazing barrier is interior of and adjacent to an exterior component disposed at the annular open rim, the exterior component having a porosity greater than the second porosity of the brazing barrier and is configured to receive liquid brazing material. ### Claim 10 (depends on 9) The filter element of claim 9, wherein the brazing barrier is adjacent to an interior component disposed at the annular open rim such that the brazing barrier is sandwiched between the exterior component and the interior component, the interior component having a porosity greater than the second porosity of the brazing barrier.