Modular base for a filter cartridge and method of manufacturing therefor

#This invention relates generally to fuel filter systems for internal combustion engines. More particularly, this invention relates to a modular base for retaining the filter cartridge and a method for manufacturing the modular base.

#In fuel filter systems to which the invention relates, such as those disclosed in U.S. Pat. Nos. 5,203,994, 5,302,284 and 5,766,463, a disposable filter cartridge is mounted to a base in such a way that it can be relatively easily removed at pre-established intervals for replacement purposes. The base typically has a pair of coaxial central conduits that provide the fuel inlet and outlet to the filter cartridge. The cartridge may contain a single or multiple stage filter configuration for filtering the fuel. In numerous embodiments the replaceable filter cartridge is suspended below the base, but other orientations are commonly employed. The base is mounted to the vehicle in any of a number of locations depending on the particular application and spatial constraints. The base typically also includes inlet and outlet connectors that may be in the form of posts or other structures which mount fittings to connect input and output lines to the base.

#The fuel filter is most commonly mounted in the engine compartment and may be subject to a number of dimensional and headroom constraints depending on the particular vehicle for which the filter assembly is employed. The placement and angular orientation of the inlet and outlet connectors or fittings are often critical for meeting the headroom and optimum system constraints of the application. A bracket typically projects from the base to provide a location for use of mounting hardware to fix the base to the vehicle. The base/vehicle attachment must be able to withstand the vibration and physical shock present in a vehicular environment.

#FIG. 1 is a sectional view through a modular base for a filter cartridge in accordance with the present invention;

#FIG. 2 is a top perspective view of the header portion of the modular base of FIG. 1;

#FIG. 3 is a side plan view of the header portion of FIG. 2;

#With reference to the drawings wherein like numerals represent like parts throughout the figures, a modular filter base in accordance with the present invention is generally designated by the numeral 10. The base 10 is preferably employed to provide a mounting location for a filter cartridge. Together, the base 10 and cartridge form a filter assembly for the removal of particulates and/or water from the fuel supply of an internal combustion engine. The illustrated preferred embodiments of a filter base employ components molded from 33% glass filled nylon. The phrase “integral” as used in this application will be understood by those of skill in the art to mean that the structures referred to as “integral” are produced from a single mold and connected to form a unitary major component. The material used to produce the base components is not critical to the invention. Other fabrication techniques and/or materials may be employed without departing from the spirit and scope of the present invention.

#FIGS. 1-8 illustrate a first preferred embodiment of a base 10 in accordance with the present invention. With reference to FIG. 1, the base 10 is constructed from two primary molded components; a header portion 20 and a communication module 40. The header portion 20 and communication module 40 are each molded components having integrally molded structures that serve various functions.

#FIGS. 1-6 illustrate the configuration of a first preferred embodiment of a header portion 20. The header portion 20 defines a receiving cavity and includes a retainer 22 for retention of a cartridge to the base. The retainer 22 defines a series of angularly spaced retaining channels 27 that receive and retain tabs projecting from a filter cartridge (best seen in FIGS. 5 and 6). The header portion 20 further includes a pair of mounting brackets 26 that define generally tubular passages 23 for reception of hollow steel reinforcements that will be further discussed below. Each mounting bracket includes a slot 30, best illustrated in FIGS. 2 and 4. Angularly spaced ribs 25 extend along the passages. An outlet conduit 24 extends into the receiving cavity to direct the flow of outgoing fluid and interact with sealing structures in a received filter cartridge (not shown). A lip 28 extends axially away from the outlet conduit 24 to provide surfaces for aligning and sealing the header portion 20 with the communication module 40. Together, the outlet conduit 24 and lip 28 define an axial opening 31 through which fluid will enter and exit the base 10.