MX2008008904A - Needle-punched non-woven filtration media and in-tank fuel filters suitable for filtering alternative fuels - Google Patents

Abstract

Aspects of the present disclosure provide various embodiments of filtration media and in-tank fuel filters suitable for filtration of alternative fuels. In one exemplary embodiment, an in-tank fuel filter generally includes a filter body. The filter body includes an interior and first and second panels of filtration media. The first and second panels of filtration media include needle- punched non-woven filtration media. There is an opening in the filter body for providing fluid communication with the interior of the filter body.

Description

NON-WOVEN FILTRATION MEANS PERFORATED BY NEEDLE AND FILTERS OF FUEL WITHIN THE TANK ADEQUATE TO FILTER ALTERNATIVE FUELS FIELD OF THE INVENTION The present disclosure relates in general to needle-pierced nonwoven filtration media and fuel filters within the tank suitable for filtering alternative fuels, such as flexible fuels, methanol, ethanol, alcohol, etc.

BACKGROUND OF THE INVENTION The statements in this background section simply provide information related to the present disclosure and can not form the prior art. Fuel filters are used in vehicle fuel systems to filter undesirable contaminants from the fuel required for the operation of the vehicle's engine. In many fuel filters, a cloth was used to prevent the flow of unfiltered fuel into the engine, thereby helping to avoid unwanted particles (and possibly harmful particles) flowing into the engine. These fuel filters with cloth, in general have good performance with conventional gasoline engines. However, more recently, automobiles are being developed for operation with alternative fuels, such as methanol, ethanol, alcohol, flexible fuels, among other possible alternative fuels derived from sources other than oil, etc. Alternative fuels are often not compatible with cloth materials used in conventional fuel filters. For example, alternative fuels can be considerably dirty with numerous particles and / or rather large particles compared to gasoline.

Such dirty alternative fuels, therefore, require significant filtering, which can cause filtration fabrics to dilate and deprive the fuel engine if the filters are not replaced frequently. But frequent replacement of fuel filters can be cumbersome and lead to an increase in costs associated with cars that operate on alternative fuels.

BRIEF DESCRIPTION OF THE INVENTION In accordance with various aspects of the present disclosure, several exemplary embodiments of the filtration and fuel means are provided within the tank including the needle-punched nonwoven materials. In a particular exemplary embodiment, a fuel filter within the tank usually includes a filtering body. The filtration body includes an interior and first and second panels of the filtration means. The first and second panels of the filtration means include non-woven filtering media perforated by a needle. There is an opening in the filtration body to provide fluid communication with the interior of the filtration body. In another exemplary embodiment, filtration means are provided therein for fuel filter assemblies within the tank for the filtration of alternative fuels. The filtration means generally include at least one non-woven material perforated by a needle. Other aspects of the present disclosure relate to methods for filtering fluids. In a particular exemplary embodiment, a method generally includes placing a filter in relation to a fluid flow such that the non-woven filter media punctured by the needle is in fluid communication with the fluid flow to receive the fluid and then filter the particles of the fluid. Other aspects and features of the present disclosure will be apparent from the detailed description hereinafter. In addition, one or more aspects of the present disclosure may be applied individually or in any combination with one or more of the other aspects of the present disclosure. It should be understood that the detailed description and specific examples, while indicating the exemplary embodiments of the present disclosure, are intended for illustrative purposes only and are not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. Figure 1 is a schematic elevation view (with portions cut away for clarity) of a fuel tank including a fuel filter within the tank according to the exemplary embodiments of the present disclosure; Figure 2 is a perspective view of the fuel filter within the exemplary tank shown in Figure 1 with a portion cut away for clarity; Figure 3 is a partial cross-sectional view of the upper and lower fuel filter panels within the tank as shown in Figure 2 taken along line 3-3 in Figure 2 each panel having a protective layer outer, an inner layer of thermally bonded material, and a needle-punctured nonwoven filtration media between the outer protective layer and the thermally bonded layer in accordance with an exemplary embodiment of the present disclosure; Figure 4 is a partial cross-sectional view of a fuel filter inside the tank having an outer protective layer, a pair of layers of thermally bonded material, and a needle-punched nonwoven filtration media disposed between the thermally bonded layers according to the additional embodiments of copies of the present disclosure; Fig. 5 is a partial cross-sectional view of a fuel filter panel within the exemplary tank having needle-pierced nonwoven filtering means and an outer protective layer in accordance with the new exemplary embodiments of the present disclosure, and Fig. 6 is a partial cross-sectional view of a fuel filter panel within the exemplary tank having an outer protective layer, a non-woven filter media punctured by a needle, and a layer of thermally bonded material disposed between the protective layer outer and non-woven filtration media layer pierced by needle in accordance with the subsequent exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION The following description is merely exemplary in nature and has no intention of limiting the current disclosure, application, or uses. It is necessary to take into account that throughout the drawings, the corresponding reference numbers indicate corresponding or similar parts and characteristics. In accordance with different aspects of the present disclosure, various exemplary embodiments of the fuel tank and media including needle-punched non-woven materials are provided. In an exemplary embodiment, a fuel filter within the tank in general includes a filtration body. The filtration body includes interior filtration panels as well as a first and second one. The filtration body includes an interior and first and second panels of the filtration medium. The first and second panels of the filtration medium include needle-punctured nonwoven filtration media. There is an opening in the filtration body to provide a fluid communication with the interior of the filtration body. In another exemplary embodiment, there are provided filtration means for fuel filter assemblies within the tank suitable for use (eg, chemically compatible, etc.) in the filtration of alternative fuels, such as methanol, ethanol, alcohol, fuels. flexible, among other possible alternative fuels derived from sources other than oil, etc. Filtration media in general, include at least one non-woven material pierced by needle. Other aspects of the present disclosure relate to methods for filtering fluids. In an exemplary embodiment, a method generally includes placing a filter in relation to a fluid flow such that the needle-punctured non-woven filtration media is in fluid communication with the fluid flow to receive the fluid and, then filter the fluid particles. Additional aspects of the present disclosure relate to methods for manufacturing the needle-punched nonwoven filtration media and filters including the same. One or more aspects of the present disclosure may be implemented individually or in any combination with one or more of the other aspects of the present disclosure. Referring now to the figure, an exemplary vehicle 100 fuel tank is shown. Also shown in the figure is a fuel filter within the exemplary tank 150 placed within the fuel tank 100 to filter fuel with the vehicle fuel tank 100. Although aspects of the present disclosure are not limited to use with fuel tanks of any type or particular kind, a brief description will nevertheless be provided of the exemplary fuel tank of the vehicles 100. The fuel tank 100 can be manufactured from a wide variety of materials, such as metal, plastic, other suitable materials resistant to fuel, etc. The vehicle fuel tank 100 includes an inlet or fill tube 104 for receiving fuel in the fuel tank from a source external to the vehicle (e.g., a pump from a gas station on a highway, etc.) With continuous reference to Figure 1 a module of an electric fuel pump 108 is mounted within an opening 112 of the fuel tank 100. The electric fuel pump 108, may, for example, be secured to the fuel tank 100 through threaded bolts 1 16 and / or by means of other suitable fixing means. As can be seen, the electric fuel pump module 108 includes an electric pump 120 for pumping fuel under pressure to a fuel intake or supply line 124, which, in turn, is in fluid communication with the engine of the fuel pump. vehicle (not shown). The fuel pump 120 can receive electric power from an electric cable 128 (or through other suitable means, etc.). The electrical fuel pump module 108 also includes an input connector 132. The input connector 132 defines an opening of input in fluid communication with the suction side of the fuel pump 120. The input connector 132 receives and retains a fuel filter inside the tank 150 (also shown in Figure 2) that incorporates one or more aspects of the present disclosure. Before continuing with the description of the fuel filter inside the tank 150, it should be noted that the fuel tank 100 shown in Figure 1 is only an example of a fuel tank with which one or more filtration means can be used and / or fuel filters within the tank of the present disclosure. In further embodiments, the filtration means and / or the fuel filters within the tank of the present disclosure can be used with other configurations of fuel tanks, in addition to the fuel tank of the vehicle shown in Figure 1 including other tank configurations of vehicle fuel and / or stationary or non-automotive fuel tanks. In addition, aspects of the current disclosure should not be limited to fuel filtering applications only in that aspects of the current disclosure can also be used with a wide range of other applications for the filtering of other fluids, in addition to fuel. With reference to Figure 2, the fuel filter within the exemplary tank 150 includes the filtering body 154. The filtering body 154 includes a seam or seal 158 such that the filtering body 154 forms an interior space 162 that is closed (except for an output connector 166). The interior space 162 is generally defined between a first or upper panel 170A and a second or lower panel 170E3 (panels 170A and 170B are also shown in Figure 3). In this particular modality, the seam or seal 158 thus seals the pair of panels 170A and 170B (which are shown to be of equal size and corresponding to an irregular shape) together around their aligned, adjacent peripheries. Alternative embodiments of a fuel filter within the tank may include a filtration body that includes two or more regularly formed panels (eg, round, rectangular, oval, triangular, polygonal, hexagonal, pentagonal, etc.) sealed together throughout of its adjacent, aligned peripheries, aspects of the current disclosure are not limited to any particular configuration (eg, shape, size, etc.) of the filtering body. In additional embodiments, a fuel filter within the tank may include a filtration body formed from a single sample of the composite filtration media that replicates along at least one edge, and then closed by one or more seals along the remaining or non-folded edges. For example, a particular embodiment may include a single, generally rectangular sample of the filtering means folded along one of the four edges with the other three remaining or unfolded edges being closed by a seam or seal.

Accordingly, aspects of the present disclosure are not limited to filter bodies formed by any particular method or operation. With continuous reference to Figure 2 the fuel filter within the tank 150 includes an outlet connector 166. The outlet connector 166 is shown disposed along the top panel 170A and is generally circular. Alternative configurations (eg shapes, sizes, sites, etc.) are also possible for external connector 166, depending, for example, on the particular fuel tank in which the fuel filter will be used. The output connector 166 can be removably, permanently, or semi-permanently secured to the upper panel 170A using a wide range of fixing means (eg, metal mounting springs and retaining washers, adhesives, mechanical fasteners, combinations of them, etc). In addition, the output connector 166 may also include a wide range of means for removably, permanently, or semi-permanently securing the output connector 166 to the input connector 132 of the fuel pump 120 (Figure 1). For example, in those exemplary embodiments wherein the output connector 166 is attached to the upper panel 170A using a spring metal assembly and a retaining washer, the washer can include a plurality of radially extending inwardly extending tabs of the spring. arranged circularly. In the alternative embodiments, a wide variety of other suitable devices and means may be employed to couple the output connector 166 to the input connector of the fuel pump 132, such as the linking members, the spring clips, the mounting pins , locks, retention tabs, combinations thereof, etc. in the output connector 166 that cooperates with the characteristics configured in addition to the input connector of the fuel pump 132 to thereby join the fuel filter 150 to this. A wide range of materials can be used for the output connector 166, including fuel tolerant materials such as nylon, polyester, acetal, etc. In some embodiments, the output connector 166 may be molded in-situ at the top or bottom of the panel 170A or 170B of the fuel filter 150. In still other embodiments, the output connector 166 may be assembled from two or more parts of components. With continuous reference to Figure 2, the fuel filter 150 may also include one or more ribs, guides, or spacers 174. In various embodiments, these spacers 174 may be molded in-situ to either of the upper and lower 170A panels. and 170B. These separators 174 can be sized with sufficient height above the surface of the interior of the panel on which they are formed to help maintain the separation of the interior surfaces of the panels, apart from one another. This helps to maintain the interior space 162 in the filtration body 154, which, in turn, facilitates the flow of fuel into the interior space 162 towards the outlet connector 166. On the other hand, the spacers of 174 can be formed by other means in addition to in-situ molding, and / or 174 spacers may be formed, either with or independently of the outlet connector 166. Referring now to Figure 3, a partial cross-sectional view of the upper panels is shown and lower 170A and 170B of the fuel filter within the tank 150. As shown in Figure 3 each panel 170A and 170B includes three layers 178, 182 and 186. In addition, each panel 170A, 170B is joined (to the compressed regions 180). ) such that each group 170A, 170B has spaced regions of the laminated or coupled layers 178, 182 and 186. A wide range of methods can be used to establish the linkage to the panels 170A and 170B and form the spatial regions. of the laminated or coupled layers 178, 182, and 186. By way of example only, various embodiments include the panels 170A, 170B being ultrasonically welded or sonically fixed at their ends as evidence through the compressed regions. In said embodiments, portions of layers 178, 182, 186 disposed between two of those compressed regions 180 do not need to be directly and mechanically fixed to each other, for example, with adhesives, ultrasonically welded, etc. In still further embodiments, however, subsequent links may be employed between two or more layers 178, 182, 186, in addition to the junction to the compressed regions 180. In the illustrated embodiment of Figure 3 each panel 170A and 170B includes at least an outer protective layer 178, at least one inner layer of thermally bonded material 186, and at least one layer of non-woven filtration media perforated by needle 182 disposed generally between outer and inner layers 178 and 186. Alternatively each panel 170A and 170B may more or less include these three layers 178, 182, 186, and each panel 170A and 170B need not include the same type and number of layers as the other panel. On the other hand, one or more of these layers 178, 182, and 186 may be formed by more than a single layer of material. For example, any of the layers 178, 182, 186 may comprise two or more layers of laminate or otherwise be fixed with others. The outer layer 178 may be formed of a relatively thick part and a fuel tolerant material, such as nylon, polyester, acetal, teflon, or combinations thereof, etc. As an example only, several embodiments include an outer protective layer 178 which is a screen made of polyester or acetal fabric. In additional embodiments, the outer protective layer 178 may comprise a relatively thick extruded mesh formed from any wide range of suitable fuel tolerant materials, such as acetal, polyester, nylon, teflon or combinations thereof. In general, the relative roughness or comparison between the pore sizes of the outer layer 178 and the other layers 182, 186 means that the outer layer contributes relatively little from the filtration point of view (except perhaps for filtering large particles). . In contrast, various embodiments include one or more outer protection layers 178 to provide a suitably durable protective coating for the more fragile and less durable inner layers 182, 186 (which in this particular embodiment comprise spunbonded and perforated nonwoven materials). with needle).

The protection afforded by the outer layers 178 can also help to protect the inner layers 182, 186 against abrasion. Abrasion is a common circumstance for applications to the fuel filter inside the tank. This is because the fuel filters inside the tank will be removed at one end of a suction pipe or directly at the inlet of a fuel tank pump. To achieve sufficient fuel suction from the tank, the filter can be placed against the bottom surface of the fuel tank in such a way that it goes down to the surface of the fuel filter and can often be subjected to abrasive action due to movement relative and the contact between the lower surface of the filter and the lower surface of the fuel tank. The outer layers 178 are also configured to provide support and reinforcement to the inner layers 182, 186 during filtration. In addition to the outer protective layers 178 that we have just described, each of the groups 170A and 170B further includes at least one layer 182 of nonwoven filter media perforated by needles. In this particular embodiment of Figure 3, this perforated needle layer 182 provides primary or main filtration for the filter. The needle-pierced layer 182 can be relatively thin and adapt or be configured for filtration by focusing on the micron ranges of between seventy and one hundred microns (or approximately). However, alternative embodiments may include non-woven materials punctured by finer and / or rougher needle to filter larger or smaller particles. A wide range of materials can be used for non-woven filtering media means perforated by needle 182. Exemplary materials include felt materials, of needle-punched non-woven polyester and / or acetal formed from one or more polyester fibers, basic polyester fibers, acetal fibers, basic acetal fibers, poly-acetal fibers, basic poly fibers -acetal, acetal copolymer fibers, acetal copolymer base fibers, poly-acetal polymers, poly-acetal polymer fibers, poly-acetal polymer base fibers, Delrin® acetal acetal Celcon® combinations of same, among other suitable materials. By way of general background, Delrin® acetal (for example, a material made by DuPont® Corporation) generally refers to and includes the thermoplastic homopolymers made by the polymerization of formaldehyde. As a subsequent background, Celcon ® acetal (e.g., the one made by Celanese Corporation ®) generally refers to and includes thermoplastic copolymers made by the co-polymerization of trioxane (the cyclic trimer of formaldehyde), with a minor amount of comonomer. By way of example only, the perforated needle layer 182 may include a nonwoven needle punched felt having the following fiber and physical properties. In this particular example, the fibers used for the needle-punched nonwoven felt include 6-gram yarn polyester fibers that are approximately 24.8 microns in diameter. Continuing with this example, the needle-punched non-woven felt has a range of about 8.8 ounces per square yard and about 10.3 ounces per square yard, as measured by ASTM D-461-93 (Felt Test Methods, published in December 2000), and a thickness within the approximate range of .059 and approximately 0.83 inches. This needle-punched non-woven felt in this example was also burned on one of its sides through an open flame treatment to highlight the fibers of the surface. This particular needle-punched non-woven felt has an air permeability in the radius of about 130 cubic feet per square foot and about 210 cubic feet per square foot at a differential pressure of 0.50 inches of water (.50"H2O). differential pressure), as measured by ASTM D 737-96 (Standard test method for air permeability of tissues, approved February 10, 1996.) Through the ASTM D 737-96 standard, permeability air generally refers to the air flow rate that passes perpendicularly through a known area under a prescribed air pressure differential between the two surfaces of a material.The fibers and the physical properties of the nonwoven filter perforated by Needles set forth in the previous paragraph are immediately exemplary only, as additional filter modalities that may include other non-woven materials perforated by needle that have different fiber types, size s, configurations, air permeability, and / or other physical properties differ depending on, for example, the particular application (eg, fluid flow requirements, filtration requirements, desired life or longevity of the media filtration, etc.) ) where the non-woven filter media perforated by needle will be used. Any of the various embodiments of the present disclosure may include needle-punched nonwoven filtering media configured with a decrease in a declining filtration (increased upstream and downstream density opening) to achieve deep filtration. In such embodiments, the needle-punctured nonwoven filtering media may be provided with different regions or interstitial decrease layers or pore size and / or with a single region in which the interstitial or pore size decreases with depth. In such modalities, this planned filtration or depth can improve the retention capacity of the particles and guide to optimize or improve a lower flow restriction through this. Planned or bottom media can also improve filter life to the extent that each region or layer depth media or graduated filtration material is exposed to smaller particles. This occurs since each filtration region only traps the particles that have a size in relation to the filament and pore (interstitial) in size of those larger particles that should have been trapped by the larger anterior filaments and pore sizes (interstitial). ) and with the smaller particles traveling through these to be trapped by subsequent finer filaments and smaller pore sizes (interstitial). In the illustrated embodiment of figure 3 for example, the layer 182 of the needle-punched nonwoven filtration media can be provided with a decrease in the declining density by calendering a surface downstream of the layer 182 such that the downstream surface has a smaller interstitial or pore size than the ascending portion of layer 182. In additional embodiments including needle-punched nonwoven media with a decreasing density, layer 182 may include two or more needle-punched non-woven felts that are laminated together to form the layer 182. In these particular embodiments, each felt may have smaller interstitial or smaller pore size than the felt upstream thereof. In alternative additional embodiments, the needle-punched nonwoven filtration media may include both a calendered downstream surface and two or more felts laminated together. The graduated pore size provided by the route and / or laminate allows the non-woven filter media perforated by needle first to filter the larger particles, and then filter the smaller particles. Still further embodiments, however, may include needle-pierced nonwoven filtration media that is not configured to reach said filter bottom. With continuous reference to Figure 3, each panel 170A and 170B also includes the 186 layer. As shown in Figure 3, the layer 186 is disposed downstream of the levels 178 and 182. In various embodiments, the layer 186, configured to function as a migration barrier that inhibits the migration fiber of non-woven needle-punched filtration media. In this particular embodiment of Figure 3 layer 186 has a thermally bonded material, such as thermally bonded material polyester, acetal, Teflon, and combinations thereof, among other suitable fuel tolerant materials. In further embodiments, in addition to other spin-bonded materials, they can be used for the 186 layer. In additional embodiments, the layer 186 of thermally bonded material is removed as indicated in the exemplary embodiments of Figures 5 and 6. In several embodiments, embodiments, the layer 186 of thermally bonded material has comparative or rough pore relative size larger than the nonwoven filtration media punctured by needle 182. In which case, the layer 186 of the thermally bonded material may contribute relatively a little from Filtration point of view. In further embodiments, however, layer 186 may be configured to have interstitial or pore sizes smaller than layer 182 such that layers 182 and 186 cooperatively achieve deep filtration. Referring now to Figure 4, a partial cross-sectional view of an alternative embodiment of a top panel 270A of filtration means is shown. Top panel 270A (together with a bottom filtration panel of means similar to panel 270A) can be used in a filtration body for a fuel filter inside the tank. Alternatively, upper panel 270A can be used with a lower filtering panel having a different configuration than panel 270A. For example, upper panel 270A can be used with lower panel 170B (Figure 3), or can be used with a lower panel having a configuration similar to panel 370A (Figure 5) or 470A (Figure 6).

As shown in Figure 4, panel 270A includes a composite, interleaved or stack of layers 278, 282, 286 and 290. Panel 270A is joined (in compressed regions 280) such that panel 270A has spaced regions or coupled laminates 278, 282, 286 and 290. In various embodiments, the layers 278, 282 and 286 may be identical to the respective layers 178, 182, and 186 described below. In such embodiments then, the outer layer 278 may comprise an outer protective cover, the layer 282 may comprise needle-pierced nonwoven filtration means, and the layer 286 may comprise spin-bonded materials. In this particular embodiment, the panel 270A further includes the layer 290 disposed between the layers 278 and 282. The layer 290 can be configured to have greater interstitial or pore sizes than the non-woven layer pierced by needle 282 in such a way that layers 290 and 282 in cooperation reach a deep filtration. In addition, the layer 290 can be configured to have an interstitial or smaller pore size than the outer layer 278 such that the layers 278 and 290 also cooperatively, at least, reach a certain level of deep filtration. The layers 286 and 290 can be configured to function as migration barriers that inhibit the respective migration of fibers downstream and upstream from the needle-pierced nonwoven filtration media 282. In the embodiment illustrated in Figure 4, the needle-pierced nonwoven media 282 are encapsulated and contained within layers 286 and 290 of the thermally bonded material. Accordingly, the layers 286 and 280 can thus inhibit the migration of the needle-punched fibers into the fuel and fuel system of the vehicle. In various embodiments, layer 290 comprises a thermally bonded material, such as polyester of thermally bonded material, acetal, teflon, a combination thereof, among other suitable fuel tolerant materials. In additional embodiments, different materials, in addition to the yarn-bound materials may be used for the layer 290. In addition, the materials used for the layer 290 may be the same or different from the materials used for the layer 286. Figure 5 illustrates another embodiment of the upper panel 370A of a filtration medium. This upper panel 370A (together with a bottom panel of the filter media similar to the panel 370A) can be used in the filtration body a fuel tank. Alternatively, the upper panel 370A can be used with other filters and / or the upper panel 370A can be used with a lower filtration panel having a different configuration from that of the panel 370A. For example, the upper panel 370A can be used with the lower panel 170B (figure 3), or it can be used with a lower panel having a configuration similar to that of the panel 370A (figure 5) or 470A (figure 6). As shown in Figure 5, panel 370A includes a composite, interleaved or stack of layers 378 and 382. Panel 370A is joined (in compression regions 380) such that the panel has 370A have spaced regions of layers laminated or coupled 378 and 382. In various embodiments, the layers 378 and 382 may be identical to the respective layers 178, 278, 182 and 282 described above. In such embodiments then, the outer layer 378 may comprise an outer protective cover, and the layer 382 may comprise non-woven filtering media perforated by a needle. In this particular embodiment, however, panel 370A does not include an internal layer to inhibit the migration of needle-punched fibers. In some filtering applications, there may be little or no fiber migration so that a fiber migration barrier (eg, 186, 286, etc.) is not necessarily mandatory for panel 370A. For example, the panel 370A can be used to filter the flow of fluids that is sufficiently low such that the flow of fluids does not cause any significant or appreciable migration of the needle-punched fibers. Or, for example, the nonwoven filter media perforated by needle 362 can be configured in such a way that its fibers are sufficiently strong (eg, fixed to others, etc.) to support the flow of fluid without significant or appreciable migration. Figure 6 illustrates a new embodiment of a top panel 470A of filtration means. This upper 470A panel (along with a bottom panel of filtration media similar to panel 470A) can be used in the filtering body for a fuel filter inside the tank. Alternatively, the upper panel 470A can be used with other filters and / or the upper panel 470A can be used with a lower filtering panel having a different configuration to the panel 470A. For example, upper panel 470A can be used with lower panel 170B (figure 3), or it can be used with a lower panel having a similar configuration for panel 270A (figure 4) or 370A (figure 5). ). As shown in Figure 6, panel 470A includes a composite, interleaved or stacked layers 478, 482, and 490. Panel 470A is joined (in compressed regions 480) such that panel 470A has spaced regions of the laminated or coupled layers 478, 482, and 490. In various embodiments, the layers 478, 482, and 490 may be identical to the respective layers 178, 278, 378, 182, 282, 382, 290 described above. In such embodiments then, the outer layer 478 may encompass an outer protective cover, and the layer 482 may encompass the needle-punctured nonwoven filtration media. Continuing with this example, layer 490 may comprise a thermally bonded material (or other suitable material) configured to inhibit migration of perforated fibers by needles. In addition, or alternatively, the layer 490 can be configured to have larger pore sizes or interstitial than the non-woven layer pierced by needle 482 so that said layers 490 and 482 cooperatively achieve deep filtration. In addition, layer 490 can be configured to have smaller sizes of interstitial or pore than outer layer 478 so that layers 478 and 490 also cooperatively reach at least some level of depth filtration. In the particular embodiment shown in Figure 6, the panel 470A does not include again an internal layer to inhibit the migration of the perforated fibers by needles. In some filtration applications, there may be little or no migration of the fiber such that the migration barrier of the fiber (example 186, 286, etc.) is not necessarily mandatory for panel 470A. For example, the panel 470A can be used to filter a fluid flow that is sufficiently low so that the fluid flow does not cause any significant or appreciable migration of the needle-punched fibers. Or, for example, the nonwoven filter media perforated by needle 482 can be configured in such a way that its fibers are sufficiently strong (eg, fixed to others, etc.) to support a fluid flow without significant or appreciable migration . In various embodiments of the present disclosure, the filter can be adapted or configured for filtering the focused fuel in a range of seventy to one hundred microns (or approximately). For example, such filters can be adapted to efficiently filter particles that vary in size from about seventy microns to about one hundred microns. The inventors of this have recognized that the configuration of a filter (example., 150, etc.) for filtering the focused fuel within this range of seventy to one hundred microns (or approximately) allows said filters to have a relatively long service life. long when used with alternative fuels, such as flexible fuels, methanol, ethanol, alcohol, among other alternative fuels derived from resources other than oil, etc.

In comparison, existing filters that rely on blow-molded materials would likely leak out many particles of an alternative fuel (which are normally considered unclean) that their lifetimes would be relatively short and would require frequent replacement to avoid clogging and that little fluid pass through the filter. As previously recognized by the inventors of this, filters adapted or configured for fuel filtration focused in the range of seventy to one hundred microns (or approximately) are capable of separating potentially problematic large particles from an alternative fuel (example, very large particles that could spoil the engine if allowed to pass to the engine) while allowing smaller particles to pass through it. Accordingly, various embodiments of the present disclosure were specially configured and adapted for fuel filtration focused in a range of seventy to one hundred microns (or approximately), which, in turn, can provide filters with a better particle retention capacity. and useful life than what is available with some options of current filtering media. To demonstrate various aspects and characteristics of the embodiments of the present disclosure (example, flow resistance, filtration efficiency, particle retention, chemical compatibility with flexible fuels, etc.), test specimens and samples specimens created to perform the multipath and flow restriction test, the results are stipulated below only for illustration purposes. For this multi-step test and the fluid restriction test, specimens or test samples included needle-punched polyester material, the external or upstream polyester material, and the thermally bonded polyester material downstream. More particularly, the external polyester material of the test specimens included the following (or approximately) exemplary characteristics: pore size of 800 microns, percentage of open areas of 55%, fabric thickness of 520 microns, 4.87 ounces per square yard, 280 micron fiber diameter, flat wave type, and 22.9 mesh count. For the needle-punched polyester material of the test specimens, the 6-gram yarn polyester fibers were used at approximately 24.8 microns in diameter. Non-woven polyester perforated by needle had a weight within the range of about 8.8 ounces per square yard and about 10.3 ounces per square yard as measured by ASTM D-461-93 (test methods for felt, published on December 2000), and a thickness within a range of about .059 inches and about .083 inches. The needle-punched non-woven polyester for the test specimens was also burned on one side by the open flame treatment of protruding raised fibers, and had an air permeability within a range of about 130 cubic feet per minute per square foot and close to 210 cubic feet per minute per square foot, approximately a pressure differential of 0.50 inches of water (.50"differential pressure of H2O) as measured by ASTM D 737-96 (standard test method for air permeability of fabrics of textile material, approved on February 10, 1996.) Continuing with the description of the test specimens, the thermally bonded polyester material internally or downstream had a weight of about 34 grams per square meter (or near 1.0 oz per square yard) and a thickness of about 12 mils The thermally bonded polyester material for the test specimens also had a permeability of about 900 cubic feet per minute per square foot, a Mullen explosion of about 33 pounds per square inch, and a tension grip of about 18/12 machine direction / cross machine direction, pounds. In a particular series of tests, the operation of the filter was evaluated using the multi-step test by ISO 16889 ("the filtered hydraulic fluid energy - the multi-step method for evaluating the filtering performance of a filter element", adopted December 1999). A test bench (multiple steps TS010) and one housing (flat sheet, 156 millimeters (6.13 inches) of internal diameter of the disc) were used to carry out the test specimens during the multi-step test. The counterpart particle connectors for the test were 30, 40, 50, 60, 70, 80, 90, 100 microns. The test liquid used was Mobil Aero-HFA (MIL-H5606) at a flow of 4.0 gallons per minute (GPM), a temperature of 100 degrees Fahrenheit, an upstream concentration of 13.0 milligrams per liter (mg / L) , and a completion point of 10.0 pounds per differential of square inch (psid). The contaminant for the test was ISO Test Thick Powder. The results of the multiple step test are set forth in tables 1 and 2 below with illustrative purposes only.

Table 1 Average Multiple Trajectory Test Results Table 2 As can be seen in Table 2, the test specimens were very efficient (eg, approximately ninety percent efficiency, etc.) in the filtration particles that were larger than fifty microns. The inventors of this have recognized that filters configured or adapted with filtration focused on fuel filtration that consists of experimental data shown in table 2 must have relatively long lifetimes when used with alternative fuels allowing smaller particles Go through this, while also effectively filtering out the larger particles of alternative fuel. And, according to the indications in Table 1, the test specimens with their deep filtration also have a better particle retention capacity than the existing conventional filter screens having only a surface filtration. In another particular series of tests, the operation of the filter was evaluated using the flow restriction test by modified SAE J905 ("the fuel filter test methods", January 1999). A test bench (TS3 fuel flow) and a connector (47 mm ID bore with internal seals and perforated stainless steel media holders) were used to hold the test specimens during the flow restriction test . The calibrators used were the Mark III digital manometer of the Dwyer 476 series (S / N N00253). The test fluid used was mineral beverages at room temperature. The flow rates for the test were from 20 to 180 liters per hour (LPH) in increments of 10. The exemplary results of the flow restriction test are set forth later in Table 3 for illustration purposes only.

Table 3 In various embodiments of the present disclosure, the filtering means and / or the fuel filter within the tank may also include other non-woven materials (in addition to, or as an alternative to) that similar performance of the supply as do the materials needle-pierced nonwoven fabrics described above. A wide range of non-woven materials can be used instead of or together with (example adjacent and / or attached to this, etc.) non-woven materials perforated by needle. Examples of such nonwoven materials include thermally bonded nonwoven materials, spunbond nonwoven (hydroentangled) materials, stitched nonwoven materials, and combinations thereof, among other suitable nonwoven materials bonded with other media in addition to the needle piercing By means of only the second plane, an exemplary thermally bonded nonwoven method can include fiber melt surfaces between them by damping the surface of the fiber (eg, if melted at low temperatures, etc.) and / or by melting the additives. of fuses in the form of powders or fibers. An exemplary spinning process (also referred to as generally hydroentangled) can use high velocity water ejectors to impact the fibrous tissue and make the fibers bristle and tangle with each other. An exemplary sewing process can use a continuous filament to sew fabric from fibers not attached to a fabric with a stitch pattern. Certain terminology is used in the present for reference purposes only, and is not intended to limit. For example, terms such as "upper", "lower", "on", and "below" refer to directions in the drawings to which the reference is made. Terms such as "front", "back", "back", "bottom" and "side", describe the orientation of the portions of the component within a consistent but arbitrary reference frame that is clearly made by the reference to the text and associated drawings that describe the component under discussion.

Said terminology may include the words mentioned specifically above, the derivatives of this, and the words of similar import. Similarly, the terms "first," "seconds," and other numerical terms that refer to structures do not imply a sequence or order unless clearly indicated through the context. By introducing elements or features of the present disclosure and the exemplary modalities, the articles "a", "a", "the" and "said" are intended to have the meaning that there is one or more of said elements or characteristics. The terms "comprise", "include" and "having" are thought to be inclusive and mean that there may be additional elements or features other than those specifically noted. It should further be understood that the steps of the method, processes, and operations described herein are not to be construed as necessarily requiring performance as a particular order discussed or illustrated, unless specifically identified as an operating order. It should also be understood that additional or alternative steps can be employed.

The description of the disclosure is simply exemplary in nature and, thus, variations that do not deviate from the main aspect of the disclosure are intended to be within the scope of the disclosure. These variations should not be considered as deviations from the spirit and scope of the disclosure.

Claims (26)

1. CLAIMS 1. A fuel filter inside the tank suitable for filtering alternative fuels, characterized in the filter because it comprises a filtration body having interior and first and second filtration media panels, the first and second filtration media panels include filtering means nonwovens perforated by needles comprising at least one or more of polyester and acetal, and an opening in the filtration body to provide fluid communication with the interior of the filtration body.
2. 2. The filter according to claim 1, further characterized in that the non-woven filter media perforated by needle comprises acetal fibers.
3. 3. The filter according to claim 1, further characterized in that the non-woven filter media perforated by a needle comprises polyester fibers.
4. 4. The filter according to claim 1, further characterized in that the filter is designed to filter particles that are less than about fifty microns in size at an efficiency of about ninety percent or less and to filter particles having a larger size. to fifty microns with an efficiency of approximately ninety percent or greater.
5. 5. The filter according to claim 1, further characterized in that the filter is designed for fuel filtration focused within the range of about seventy microns to about one hundred microns.
6. 6. The filter according to claim 1, further characterized in that at least part of the first and second means of the filtration panels are configured with a decreasing declining density in the direction of fluid flow to achieve a graduated filtration as soon as possible. at depth The filter according to claim 1, further characterized in that the needle-punctured non-woven filtration means includes at least a portion of the calendered downstream surface to achieve a depth graduated filtration within the needle-punched nonwoven filtration medium. in the direction of fluid flow through the non-woven filter media punctured by needle. The filter according to claim 1, further characterized in that the non-woven filter media perforated by needle includes at least two non-woven material layers pierced by needle having different pore sizes, the layer has the smallest pore size arranged downstream of another layer to achieve a depth graduated filtration inside the needle-punched non-woven filtration media in the direction of fluid flow through the needle-punched nonwoven filtration media. The filter according to claim 1, further characterized in that the first and second panels of filtration means include at least one outer protective layer of the needle-punctured nonwoven filtering media. The filter according to claim 1, further characterized in that the first and second panels further include a thermally bonded material. The filter according to claim 10, further characterized in that at least a portion of the thermally bonded material is disposed upstream of the needle-punched nonwoven filtration media to provide a depth graduated filtration in the direction of fluid flow to through the first and second panels. The filter according to claim 10, further characterized in that at least a portion of the thermally bonded material is disposed downstream of the needle-punched nonwoven filtration media to inhibit fiber migration of the needle-punched filtration medium. The filter according to claim 10, further characterized in that the non-woven filtering media pierced by a needle is contained within the thermally bonded material. 14. Filtration media for the fuel filter assembly inside the tank suitable for the filtration of alternative fuels, the filtration means comprise at least one non-woven material perforated by a needle, the non-woven material perforated by a needle comprises at least one or more of polyester and acetal. The filtration means according to claim 14, further characterized in that the filtration means is designed to filter particles having a size of less than about fifty microns in an efficiency of about ninety percent or less, and to filter particles having larger than about fifty microns in an efficiency of approximately ninety percent or greater. 16. The filtration medium according to claim 14, further characterized in that the filtration medium is designed for a focused fuel filtration within the range of about seventy microns to one hundred microns. 17. The filtration medium according to claim 14, further characterized in that the non-woven material perforated by a needle comprises acetal fibers. 18. The filtration medium according to claim 14, further characterized in that the needle-punched nonwoven material comprises polyester fibers. The filtration medium according to claim 14, further characterized in that at least the portions of the needle-punched nonwoven material are configured with a decreasing declining density in the direction of the fluid flow to achieve a depth graduated filtration. . The filtration medium according to claim 14, further characterized in that the needle-punched nonwoven material includes at least a portion of the calendered downstream surface to achieve a depth graduated filtration within the non-woven material perforated by needle in the direction of fluid flow through the needle-punched non-woven material. The filtration medium according to claim 14, further characterized in that the needle-punched nonwoven material includes at least two layers of needle-punched nonwoven material having different pore sizes, the layer having the pore size. smaller which is disposed downstream of the other layer to achieve graduated depth filtration within the needle-punched nonwoven material in the direction of fluid flow through the needle-punched nonwoven material. 22. The filtration medium according to claim 14, further comprising at least one material upstream of and having a pore size longer than the non-woven material perforated by a needle to provide a graduated filtration of depth in the direction of the Fluid flow through the filtration medium. 23. The filtration medium according to claim 14, characterized in that it further comprises at least one material disposed generally downstream from the needle-punched nonwoven material to inhibit migration of fiber from the needle-punched nonwoven material. 24. The filtration medium according to claim 14, characterized in that it further comprises first and second layers of thermally bonded material, and wherein the non-woven material perforated by a needle is generally disposed between the first and second layers of thermally bonded material, wherein the needle-punched non-woven material cooperates with the first layer of thermally bonded material to achieve a depth graduated filtration, and wherein the second layer of thermally bonded material inhibits migration of the fiber from the needle-punched nonwoven material. 25. A method of filtering particles from an alternative fuel with a filter having a non-woven needle-punched filtration media that includes at least one or more polyester and acetal, and is designed for fuel filtration by focusing within from a range of seventy microns to one hundred microns, characterized in the method because it comprises placing the filter with respect to the alternative fuel flow so that the filter filters from the alternative fuel at least ninety percent or more of the particles that have a size greater than fifty microns, and filtering from the alternative fuel approximately ninety percent or less of the particles having a size of less than about fifty microns. 26. The method according to claim 25, further characterized in that the placement of the filter with respect to the flow of the alternative fuel includes placing the filter with respect to the flow of at least one or more methanol, ethanol, alcohol, flexible fuel or a combination of them.