FILTER INTERCONNECT USING A CORRELATED MAGNET TORQUE DESIGN

Abstract

A filtration system and method of using the same. The method comprises the steps of guiding, by alignment rail and mating boss, a filter cartridge into a manifold housing; aligning a filter magnet with a corresponding manifold magnet; rotating, by attractive magnetic forces, the manifold magnet upon rotation of the filter cartridge into an installed position; and actuating, by attractive magnetic forces, a manifold valve.

Claims

1. A method of using a filtration system comprising: guiding, by alignment rail and mating boss, a filter cartridge into a manifold housing; aligning a filter magnet with a corresponding manifold magnet; rotating, by attractive magnetic forces, the manifold magnet upon rotation of the filter cartridge into an installed position to generate a torque force on the manifold magnet; and actuating, by the torque force, a manifold valve.

2. The method of claim 1, wherein upon alignment of the filter magnet with the corresponding manifold magnet, the manifold magnet activates a switch.

3. The method of claim 1, wherein the manifold includes a threaded groove.

4. The method of claim 1, wherein the manifold comprises alignment tracks configured in a Z-shaped pattern.

5. The method of claim 1, the method further comprising: prohibiting, by mechanical stop of the manifold, the rotation of the manifold magnet in a first direction beyond a predetermined position upon rotation of the filter magnet.

6. The method of claim 5 wherein a sheath covers a surface of the manifold magnet, such that actuation of the manifold valve occurs without physical contact of the filter magnet and the manifold magnet.

7. The method of claim 5, wherein the manifold magnet rotates approximately 90 in the first direction from an initial insertion position within the manifold.

8. The method of claim 1, wherein the manifold magnet is fixably attached to a rotatable structure having a protrusion, and wherein the tab abuts a mechanical stop of the manifold upon alignment of the filter magnet with the corresponding manifold magnet.

9. The method of claim 1, further comprising: misaligning the filter magnet with the corresponding manifold magnet; and ejecting the filter cartridge from the manifold.

10. The method of claim 9, wherein magnetic repulsion assists the ejection of the filter cartridge.

11. The method of claim 9, wherein prior to misaligning the filter magnet, the method comprises: rotating the filter cartridge away from the installed position while maintaining the manifold magnet in the installed position.

12. The method of claim 1, wherein the filter cartridge includes a stem portion, the stem portion including a spool valve with water ingress and egress channels.

13. The method of claim 12, wherein after actuating the manifold valve, the method comprises: permitting, the ingress of water from the manifold to the filter cartridge in a radial direction and the egress of water from the filter cartridge to the manifold in the radial direction.

14. A manifold for a filtration system comprising: a manifold magnet comprising an array of correlated magnets; a valve for turning fluid ingress to said manifold ON or OFF; and a shroud having a plurality of predetermined alignment tracks on an inside surface for receiving a filter boss extending from a filter cartridge, such that said filter cartridge is guided upon insertion and extraction from said shroud by said alignment tracks.

15. The manifold of claim 14 wherein said manifold magnet is supported on a rotatable structure, rotatable relative to said manifold.

16. The manifold of claim 14 wherein a sheath covers a surface of said manifold magnet, such that said manifold magnet is separated from said filter magnet by a physical barrier, said sheath in proximity to said filter magnet when said filter magnet is inserted within said shroud.

17. A filtration system comprising: a filter manifold having a manifold magnet, a switch valve, and a shroud, wherein said shroud includes a manifold capture structure having a threaded portion for receiving a lid; and a filter cartridge having housing body, a stem extending from a top portion of said housing body, and a filter magnet located on or within said stem; wherein said manifold magnet and said filter magnet are interconnected via magnetic communication with one another upon rotation of said lid such that said filter cartridge is inserted within said shroud, and upon further rotation of said lid, said manifold magnet either rotates or is repelled, and is capable of actuating said switch valve to perform a primary function, such as turning ON or OFF fluid to said filter cartridge.

18. The filtration system of claim 17 wherein said lid is aligned within alignment tracks exposed on the inside of said manifold capture structure.

19. The filtration system of claim 18 wherein said alignment tracks are configured in a Z-shaped pattern such that said filter cartridge upon lid rotation is moved for a first portion of an arc-turn of said lid with little or no movement in an insertion direction, moves in said insertion direction within said shroud for a second portion of an arc-turn of said lid, then rotates for a third portion of an arc-turn of said lid with little or no movement in said insertion direction.

20. The filtration system of claim 17 wherein upon final insertion rotation of said filter cartridge, said filter magnet and said manifold magnet are magnetically aligned for attraction or repulsion, such that said manifold magnet activates said switch.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:

[0042] FIG. 1 depicts an apparatus of the prior art having two components magnetically attached to one another;

[0043] FIG. 2 depicts a quick connect air hose coupling of the prior art showing placement of correlated magnets for attachment;

[0044] FIG. 3A depicts a cross-section of a portion of a manifold and a shroud or housing;

[0045] FIG. 3B depicts a shroud having alignment railings to steer a filter boss on the filter cartridge;

[0046] FIG. 4A depicts a cross-sectional view of a portion of the manifold of the present invention and the filter cartridge within the shroud, in a connected or INSTALLED position or state;

[0047] FIG. 4B depicts the INSTALLATION position of filter cartridge, when the filter cartridge is inserted within the shroud with the filter boss being aligned in a portion of the shroud's alignment rail;

[0048] FIG. 4C depicts the polarity positions for the manifold magnet and filter magnet in the attracted or attached position;

[0049] FIG. 5A depicts a new alignment position of the rotated filter cartridge using a position indicator .Math. on each magnet;

[0050] FIG. 5B depicts the position of the filter boss when the filter cartridge and manifold place the system in the ON state;

[0051] FIG. 5C depicts the attraction polarities of each magnet when the filter boss is at the end position of the alignment rail;

[0052] FIG. 6A depicts position indicators .Math. out of phase with one another caused by the rotation of filter cartridge when filter boss is at an end point of the alignment rail for cartridge removal;

[0053] FIG. 6B depicts the filter boss at the end point of the alignment rail for EJECTION of the filter cartridge;

[0054] FIG. 6C depicts the magnet orientation at the EJECTION position;

[0055] FIG. 7 depicts a top portion of filter cartridge showing a spool valve 4 within the stem portion of the cartridge;

[0056] FIG. 8 depicts a second embodiment of a filtration system utilizing correlated magnets on a filter cartridge stem and on a manifold, with a filter boss following a predetermined alignment path on the manifold shroud during insertion and extraction;

[0057] FIG. 9 depicts an alignment path thread of the manifold shroud with a filter boss located at an upper leg portion of the thread;

[0058] FIG. 10 depicts an alignment path thread of the manifold shroud with a filter boss located at a lower leg portion of the thread; and

[0059] FIG. 11 depicts a third embodiment of a filtration system utilizing correlated magnets on a filter cartridge stem and on a manifold, with a lid rotatably connected to the manifold, the lid having extended lugs for following a threaded path on a manifold capture structure, where the threaded path represents a predetermined alignment path on the manifold capture structure insertion and extraction.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0060] In describing the preferred embodiment of the present invention, reference will be made herein to FIGS. 1-11 of the drawings in which like numerals refer to like features of the invention.

[0061] Correlated magnets contain areas of alternating poles. These codes of alternating poles can concentrate and/or shape magnetic fields to give matching pairs of magnets unique properties. The proposed design specifically uses a torque/align model, which allows for one magnet to apply a torque to a non-contacting corresponding magnet when they are in phase.

[0062] When the torque exceeds a maximum value either by application of excessive force or obstruction of the rotation of the connecting pair, the connecting pair components (each having a respective magnet) will have their magnets out of phase, and thus initiate a repulsion force against one another. The proposed design utilizes this property to attach a filter to a manifold, open and close a non-contacting valve (e.g., spool valve or other valve design) through rotation, and aid in filter removal by assisting in the ejection of the filter.

[0063] These features are accomplished by having at least a pair of magnets, preferably correlated magnets, oriented parallel to one another on each component of the connecting pair, wherein a first magnet is located on the top of a filter and a complementary magnet is located on the manifold designed to secure the filter into position. In at least one embodiment, a thin layer of material is introduced, physically separating the two magnets so they cannot have physical contacting surfaces, but they can still magnetically attract or repulse one another.

[0064] The function of the magnet located on the manifold is to assist in actuating a valve preferably through rotation (e.g., spool valve, cam and poppet valve, and other valve types). The manifold magnet is free to rotate, but restricted in rotational range. Preferably a ninety degree (90) rotation is used to correspond to the open and closed positions of the valve; however, other ranges of rotation are possible and not prohibited. The filter cartridge magnet is also free to rotate with the rotating filter cartridge, and designed in an embodiment that ensures the filter cartridge will rotate further than the manifold magnet.

[0065] By way of example, when the manifold magnet is rotatable up to 90, the filter cartridge magnet is designed to freely rotate to one hundred eighty degrees (180). The filter cartridge magnet is designed to perform two functions. The first function is to apply torque to the manifold magnet (that is, bring the manifold magnet along in rotation) in order to actuate a valve. The second function is to work in conjunction with a mechanical stop to force the magnet pair out of phase to aid in filter removal.

[0066] During initial installation, the filter is guided by an alignment rail and boss system so that the correlated magnet on the filter top surface (filter magnet) and the corresponding correlated magnet on the manifold (manifold magnet) are aligned (in-phase forming an attraction force) but not in contact. The correlated magnet in the manifold actuates a valve when rotated 90, said activation may be physically, electrically, or mechanically initiated.

[0067] When the filter is rotated the manifold magnet rotates along with it through attraction forces, and actuates the valve. Both the filter and manifold magnets are prevented from rotating past the point at which the valve is opened. To remove the filter, the filter is rotated in the counter-direction, bringing the manifold magnet along with it, at least partially along the rotational path, which causes the valve in the manifold to close. The magnet in the manifold is prevented from rotating past the closed position but the filter is free to over-rotate, or in the exemplary embodiment, rotate an additional 90. The over-rotation of the filter forces the magnets out of phase and produces a net repulsive force between the filter and the manifold which then aids in filter removal.

[0068] FIG. 3A depicts a cross-section of a portion of a manifold 12 with a shroud or housing 14. Manifold magnet 16 is situated at the top end of shroud 14. A separator 18, such as a plastic sheath, is attached below manifold magnet 16, which serves to form a gap between manifold magnet 16 and filter magnet 34 (not shown) when the filter cartridge 30 is inserted within shroud 14 and connected to manifold 12. This provides the physical separation between the manifold magnetic interconnection with the filter cartridge.

[0069] Manifold magnet 16 is rotatable about the center axis 22; however, for reasons discussed below, the rotation is purposely limited to be different than, and preferably less than, the rotational range of the rotatable filter magnet 34. A mechanical stop 24 on the manifold housing limits the rotation of the rotatable manifold magnet 16. In one embodiment, mechanical stop 24 limits and restricts the rotation of manifold magnet 16 to ninety degrees (90). Other rotational restrictions are possible based on the placement of the mechanical stop, and the present invention is not limited to a ninety degree restriction.

[0070] Shroud 14 includes alignment railings 20a-20d to steer a filter boss 32 which is shown on filter cartridge 30 of FIG. 3B. Alignment railings are preferably grooves embedded within shroud 14; however, other forms of alignment are possible and not precluded from the present design. For example, the alignment rails may form slots for a tongue-and-groove attachment to the filter cartridge boss, or form extended linear segments to receive a filter cartridge boss having a receiving slot.

[0071] Referring to FIG. 3B, which is a partial cross-sectional view of the filter cartridge 30, filter cartridge 30 includes a filter magnet 34 at the cartridge top end that is capable of rotation with respect to the axis of the filter cartridge. In this manner, the magnet may rotate concurrently with the cartridge rotation relative to the filter cartridge axis.

[0072] Alignment rail 20c on the manifold shroud 14 represents the entry track for filter cartridge 30 by receiving filter boss 32 when filter cartridge 30 is inserted within shroud 14. In this illustrative embodiment, filter boss 32 is an extended protrusion that extends in the radial direction outwards from the filter cartridge axial center.

[0073] Alignment rail 20d guides the filter boss 32 through rotation about the axial center of the filter cartridge 30. Alignment rail 20d directs the rotating position for filter boss 32 when filter cartridge 30 as the cartridge is fully inserted within shroud 14 and rotated such that filter boss 32 travels in alignment rail 20d to its end as its path partially circumvents the shroud's inner cavity. As will be shown in further detail below, this end rotational position of filter boss 32 within alignment rail 20d places the filter cartridge 30 in position for filtering operation.

[0074] FIG. 4A depicts a cross-sectional view of a portion of a manifold 12 and filter cartridge 30 (within shroud 14) in a connected or INSTALLED position or state, where the manifold 12, specifically, manifold magnet 16, is magnetically attached and attracted to filter magnet 34. Manifold magnet 16 is shown above and in alignment with filter magnet 16. For exemplary purposes, the alignment is depicted by the position indicator .Math. on each magnet. The magnets are physically separated by a sheath or layer of material 18, such as a plastic sheet, although other material types are certainly possible and not prohibited by the current design. The material of sheath 18 must be capable of allowing for magnetic attraction and repulsion forces to be transmitted therethrough, but allow for sliding rotation of the magnet surfaces.

[0075] Each magnet is a correlated magnet having a field emission structure. The manifold magnet field emission structure is configured to interact with the filter magnet field emission structure such that the magnets can be aligned to become attached (attracted) to one another or misaligned to become removed (repulsed) from one another. The manifold magnet can be released from the filter magnet when their respective field emission structures are moved relative to one another to become misaligned.

[0076] This INSTALLATION position of filter cartridge 30 is achieved by inserting filter cartridge 30 within shroud 14 with filter boss 32 aligned in alignment rail 20c, as shown in FIG. 4B traversing to the topmost position in alignment rail 20c, and stopping at the top edge of alignment rail 20d. When in this position, filter cartridge magnet 34 and manifold magnet 16 share an attraction force F (depicted in FIG. 4A), which attaches the filter cartridge to the manifold.

[0077] FIG. 4B depicts a perspective view of the position of filter boss 32 within the alignment rail 20 on shroud 14 when filter cartridge 30 is in the process of being placed in the INSTALLED position.

[0078] Filter cartridge 30 is first inserted within the entry rail 20c of shroud 14 until it reaches the top most portion of the alignment rail. At this point the manifold magnet 16 and filter magnet 34 are oriented for full attraction. That is, the correlated magnets that form the manifold and filter magnets are in their respective, opposite polarities for maximum attraction force. FIG. 4C depicts the polarity positions for the manifold magnet 16 and filter magnet 34 in the attracted or attached position. The positive polarities of the manifold magnet, as shown in a bottom side view, are aligned with the negative polarities of the filter magnet, as shown in a top side view, putting the magnets in-phase. In this position, manifold magnet 16, although now in attraction force with the filter cartridge magnet 34, has not yet been rotated, and as such, a valve (not shown) that would otherwise be actuated upon the manifold magnet's rotation remains in its OFF state.

[0079] As depicted in FIG. 4C, manifold magnet 16 is fixably attached to a rotatable structure, such as a disc 26, having a protrusion or tab 28 that moves with the rotation of the magnet. Tab 28 is designed to abut mechanical stop 24 in order to limit the range of rotation of manifold magnet 16. As shown in FIGS. 4B & 4C, when the filter cartridge 30 and filter boss 32 are inserted within alignment rail 20c, the magnets are in-phase, and mechanical stop 24 abuts, and is in contact with, tab 28.

[0080] Once filter cartridge 30 is installed within shroud 14, and filter boss 32 is located at the topmost portion of alignment rail 20d, the cartridge is then rotated such that filter boss 32 slidably extends to one end of alignment rail 20d. Since manifold magnet 16 and filter magnet 34 are magnetically aligned in their attracted state, when filter cartridge 30 (and thus, filter magnet 34) is rotated, manifold magnet 16 on disc 26 is correspondingly rotated. This new alignment position is depicted by the position indicator .Math. on each magnet (FIG. 5A), showing attraction alignment when filter boss 32 as at the end of alignment rail 20d. FIG. 5B depicts the location of the filter boss 32 within alignment rail 20d at this point of rotation.

[0081] At this position point of the filter cartridge and filter manifold, respectively, resulting from the rotation of manifold magnet 16 concurrent with the rotation of the filter cartridge magnet 34, a valve is actuated and the system is placed in an ON state, where typically water is allowed to flow into the filter cartridge. FIG. 5C depicts the attraction polarities of each magnet when the filter boss 32 is at the end position of alignment rail 20d. The magnets remain in complete attraction mode as they are rotated concurrently and in unison. Tab 28 of manifold disc 26 is rotated away from mechanical stop 24. In this exemplary embodiment, tab 28 is ninety degrees (90) away from mechanical stop 24. In other embodiments it is possible for the separation between tab 28 and mechanical stop 24 to be at a greater (or lesser) rotational distance.

[0082] FIG. 6 depicts the interim status of the system when, from the ON state, it becomes necessary to replace and therefore eject filter cartridge 30. Filter cartridge 30 is rotated from an endmost point of alignment rail 20d (FIG. 5B) back through the INSTALLED position (FIG. 4B) where filter boss 32 is in line with alignment rail 20c. At this point, as depicted in FIG. 6C, tab 28 abuts mechanical stop 24, which abutment physically prohibits any further rotation of manifold magnet 16 in the direction of arrows 23. At this juncture of the filter cartridge rotation, manifold magnet 16 stays in the INSTALLED position, and can rotate no further (in the direction of arrows 23).

[0083] To eject filter cartridge 30, rotation is continued, moving filter boss 32 slidably across shroud 14 to an opposite end point of alignment rail 20b. FIG. 6A depicts position indicators .Math. out of phase with one another caused by the rotation of filter cartridge 30 when filter boss 32 is at the end point of alignment rail 20b.

[0084] FIG. 6B depicts filter boss 32 at the end point of alignment rail 20b.

[0085] As depicted in FIGS. 6B & 6C, when the filter boss 32 is located at the end point of alignment rail 20b, manifold magnet 16 remains in its INSTALLED position, while filter magnet 34 continues to rotate ninety degrees (90) further from its INSTALLED position. This is caused by tab 28 abutting mechanical stop 24 when the filter boss 32 rotates through the INSTALLED position on its way to the EJECTION position.

[0086] FIG. 6C depicts the magnet orientation at this EJECTION position. The magnets are now out-of-phase with one another, and a resulting repulsion force assists in removing filter cartridge 30 from shroud 14.

[0087] FIG. 7 depicts a top portion perspective view of filter cartridge 30. Filter magnet 34 is shown on the top surface. Filter magnet 34 may be embedded within the stem portion 36 of the cartridge or exposed on the stem surface. A spool valve 40 is depicted within the stem portion 36 of the cartridge. Spool valve 40 includes two independent, separately located channels 40a,b for water ingress and egress. Upon rotation of filter cartridge 30, the inlet/outlet ports 42a,b of channels 40a,b, respectively, direct water flow. When the system is in the ON state, water is directed to the filter cartridge from the manifold to a first channel (which for exemplary purposes will be referred to as channel 40a), then through filter media within the filter cartridge, and ultimately exits through the second channel (e.g., 40b). This embodiment is considered a single-stem side-loaded filter design since both ingress and egress access ports are on a single filter cartridge stem and water enters and exits the stem radially inwards and outwards. Other valve configurations are possible, such as cam and poppet valves, and such valve configurations are not precluded from this design. Upon rotation in an opposite direction, the system is placed in an OFF state where channels 40a,b, and their respective inlet/outlet ports 42a,b, are not aligned with water ingress and/or egress ports on the manifold. As noted in FIG. 7, O-rings 44 may be used to keep the channel ports 42a,b separate, and out of fluid communication with one another.

[0088] FIG. 8 depicts another embodiment of the present invention having respective correlated magnets at the stem of the filter cartridge and at the base of the manifold 52, where the filter cartridge includes a boss 66 for following a path in the manifold to facilitate insertion. In this embodiment, cartridge 50 is rotatably inserted within manifold 52. A rotational direction is depicted by arrow A. Filter cartridge 50 includes a correlated magnet 54 at the end of its stem 68, which is designed to be in magnetic communication with correlated magnet 56 of manifold 52. Ingress water flows in the direction of arrow 64 into ingress channel 58, such that when filter cartridge 50 is completely inserted within the stem receiving portion 52b of manifold 52, water will flow through channel 58 into filter cartridge After filtration, water will then exit filter cartridge 50 into egress channel 60 in the direction of arrow 62.

[0089] As depicted in FIG. 9, boss 66 is designed to follow a thread or groove 70 formed in manifold 52. Thread or groove 70 may be a spiral thread path, or as depicted a Z-thread path for boss 66 to traverse. As shown in FIG. 9, boss 66 is in the top portion of thread 70 and in this configuration the filter cartridge stem 68 is not fully inserted within stem receiving portion 52b of manifold 52. Correlated magnets 54, 56 are not aligned for either maximum attraction or maximum repulsion.

[0090] The alignment tracks are configured in a Z-shaped pattern such that the filter cartridge upon insertable rotation rotates for a first portion of an arc-turn with little or no movement in an insertion direction, then moves in the insertion direction within the shroud for a second portion of an arc-turn, and finally rotates for a third portion of an arc-turn with little or no movement in the insertion direction.

[0091] As the filter cartridge 50 is rotated in the direction of arrow A, boss 66 traverses down the threaded path 70 to the bottom of the path, as shown in FIG. 10, and filter cartridge stem 68 is seated within stem receiving portion 52b of manifold 52. In this position, correlated magnets 54, 56 are ultimately aligned for either maximum attraction or maximum repulsion, and magnet 56 is positioned to activate a switch 81 either mechanically or magnetically. Such a switch is capable of providing a primary function to the filter system, such as turning on the ingress water, activating an electronic circuit for parametric measurements, and/or providing a status indicator to the user, to name a few.

[0092] When magnets 54 and 56 are aligned, if they are situated for an attraction upon alignment, they will rotate together as boss 66 traverses further down threaded path 70, or as shown, along the bottom straight portion of thread 70. The subsequent rotation of the aligned magnets together will place the manifold magnet 56 in communication with switch 81 for switch activation.

[0093] In an alternative embodiment, as depicted in FIG. 11, a filter cap 75 having lugs 77 is shown rotatable inserted within a manifold capture 79. Manifold capture 79 may include a threaded groove, in a similar fashion as threaded path 70. Upon rotation of filter cap 75, filter cartridge 50 and filter cartridge stem 68 are inserted within manifold cavity 52a until magnets 54 and 56 are aligned, in which case they may be capable of rotating together as the filter cartridge boss 66 further traverses down threaded path 70.

[0094] While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.