Liquid filter construction and methods

Abstract

Liquid filter constructions include a baffle plate secured to a can, by way of laser welding. A filter element is operably oriented within the interior of the can. The filter element includes a first end cap and a media pack secured to the first end cap. In some embodiments, the first end cap radially abuts an outer, annular surface of a tubular member of the baffle plate to form a radially directed seal between the first end cap and the tubular member. Liquid filter constructions of this type have a burst strength between 500-800 psi (about 3.4-5.5 MPa), along a longitudinal section of the can wall. Constructions of this type eliminate a roll or lock seam, an inner gasket, an inner compressive spring, and a gasket retainer. Systems for using liquid filters are described herein. Methods of constructing and using these types of filter arrangements are also described.

We claim:  
     
         1 . A liquid filter construction comprising: 
 (a) a metal baffle plate having an inlet arrangement and an outlet arrangement; 
 (i) said metal baffle plate having an average cross-sectional thickness of at least 0.080 inch;  
   (b) a metal can having an interior and an average cross-sectional wall thickness different than that of said metal baffle plate thickness; said metal can average cross-sectional wall thickness being at least 0.008 inch; 
 (i) said metal can being secured to said steel baffle plate along a laser welded seam; and  
   (c) a filter element operably oriented within said interior of said metal can.    
     
     
         2 . A liquid filter construction according to  claim 1  wherein: 
 (a) one of said inlet arrangement and said outlet arrangement defines a tubular member having an outer, annular surface; and  
 (b) said filter element includes at least a first end cap and a media pack secured to said first end cap.  
 
     
     
         3 . A liquid filter construction according to  claim 2  further comprising: 
 (a) a radially directed seal between said first end cap and said outer, annular surface of said tubular member.  
 
     
     
         4 . A liquid filter construction according to  claim 3  wherein: 
 (a) said baffle plate includes an inner surface oriented within said can interior, and an opposite outer surface remote from said can interior; 
 (i) said baffle plate including a channel in said outer surface constructed and arranged to hold a seal member.  
 
 
     
     
         5 . A liquid filter construction according to  claim 4  wherein: 
 (a) said first end cap includes a plurality of axially extending protrusions engaging said inner surface of said baffle plate; and  
 (b) said first end cap radially abuts said outer, annular surface of said tubular member to form said radially directed seal.  
 
     
     
         6 . A liquid filter construction according to  claim 5  wherein: 
 (a) said filter element further includes a second end cap and an inner liner; 
 (i) said media pack extending between said first end cap and said second end cap  
 (ii) said media pack circumscribing said inner liner.  
 
 
     
     
         7 . A liquid filter construction according to  claim 6  further including: 
 (a) a rigid structural member oriented in said can interior; 
 (i) said rigid structural member abutting an end of said can remote from said baffle plate and supporting said filter element.  
 
 
     
     
         8 . A liquid filter construction according to  claim 7  wherein: 
 (a) said rigid structural member is secured to said second end cap.  
 
     
     
         9 . A liquid filter construction according to  claim 7  wherein: 
 (a) said rigid structural member is an integral part of said inner liner.  
 
     
     
         10 . A liquid filter construction according to  claim 7  wherein: 
 (a) said rigid structural member comprises a bypass valve assembly.  
 
     
     
         11 . A liquid filter construction according to  claim 6  wherein: 
 (a) said second end cap includes a plurality of radially directed protrusions engaging an inner portion of said can.  
 
     
     
         12 . A liquid filter construction according to  claim 6  wherein: 
 (a) said media pack comprises pleated paper potted within said first and second end caps;  
 (b) said first and second end caps comprise urethane or acrylic; and  
 (c) said inner liner comprises a rigid, plastic material.  
 
     
     
         13 . A liquid filter construction according to  claim 1  wherein: 
 (a) said baffle plate is steel and has an average cross-sectional thickness of no greater than 3.0 in.;  
 (b) said can is steel and has an average cross-sectional wall thickness of no greater than 0.048 in.  
 
     
     
         14 . A liquid filter construction according to  claim 13  wherein: 
 (a) said baffle plate has an outer annular surface; 
 (i) said laser welded seam being between said can and said outer annular surface of said baffle plate.  
 
 
     
     
         15 . A liquid filter construction according to  claim 1  wherein: 
 (a) said filter element is sealed against said baffle plate by an axially directed seal.  
 
     
     
         16 . A filtration system comprising: 
 (a) an engine having a size of at least 10 hp and a lubrication system; and    (b) a filter construction operably mounted to clean liquid flowing in said lubrication system; said filter construction including: 
 (i) a metal can having an interior and a first average cross-sectional wall thickness;  
 (ii) a metal baffle plate having an inlet oriented to take in liquid to be cleaned for said lubrication system and an outlet oriented to exhaust cleaned liquid; 
 (A) said metal baffle plate having a second average cross-sectional thickness; the second average cross-sectional wall thickness being at least 200% of the first average cross-sectional wall thickness;  
 (B) said metal can being secured to said metal baffle plate along a laser welded seam; and  
 
 (iii) a filter element operably oriented within said interior of said metal can.  
   
     
     
         17 . A filtration system according to  claim 16  wherein: 
 (a) said lubrication system is constructed and arranged to operate at pressures no greater than about 200 psi.  
 
     
     
         18 . A filtration system according to  claim 16  wherein: 
 (a) said filter element having at least a first end cap and a media pack secured to said first end cap; 
 (i) said first end cap radially abutting said outer, annular surface of said tubular member to form a radially directed seal between said first end cap and said tubular member.  
 
 
     
     
         19 . A method of constructing a filter; the method comprising: 
 (a) inserting a filter element into a metal can; the metal can having at least one open end and a first average cross-sectional wall thickness;    (b) covering the one open end with a metal baffle plate; the baffle plate having a second average cross-sectional thickness; 
 (i) the second average cross-sectional thickness being at least 200% of the first average cross-sectional wall thickness; and  
   (c) securing the baffle plate to the can by laser welding.    
     
     
         20 . A method according to  claim 19  wherein: 
 (a) said step of securing includes laser welding at least first and second, spaced tacks between the baffle plate and the can and then laser welding at least a 360° seam between the baffle plate and the can; 
 (i) the first average cross-sectional wall thickness of the can being at least 0.008 inch; and  
 (ii) the second average cross-sectional wall thickness of the baffle plate being at least about 0.08 inch.  
 
 
     
     
         21 . A method according to  claim 19  wherein: 
 (a) said step of securing includes laser welding at least first and second, spaced tacks between the baffle plate and the can; the first and second tacks being spaced about 160°-200° apart.  
 
     
     
         22 . A method according to  claim 19  further including: 
 (a) assembling the filter element by: 
 (i) securing a tubular construction of filtering media between first and second opposite end caps; the first end cap having an inner, annular surface defining a first opening; and  
 (ii) pressing a rigid structural member into the second end cap;  
 
 (b) inserting a neck of the baffle plate into the first opening and forming a radially directed seal between the neck and the first end cap;  
 (c) wherein said step of inserting includes placing the filter element in the can, until the rigid structural member abuts an end of the can; and  
 (d) wherein said step of covering includes engaging the baffle plate against the first end cap.  
 
     
     
         23 . A method according to  claim 19  wherein: 
 (a) said step of securing includes laser welding at a speed of at least 400 inches/minute.