Seal arrangement for filter element; filter element assembly; and, methods

Abstract

A filter element arrangement is provided which includes a media pack comprising Z-filter media, a preform and an overmold sealing a portion of the interface between the preform and the media pack, and also forming an air cleaner seal for the filter element. The overmold preferably comprises molded, foamed, polyurethane. A variety of media pack shapes can be used.

1 . A filter element comprising:
 a filter media pack, a molded seal component, and a preform part operatively connecting the molded seal component to the filter media pack, the molded seal component being formed separately from the preform part;   the filter media pack having first and second oppositely facing flow faces, and defining a longitudinal axis passing through the first and second flow faces; and   the preform part including a canted annular extending portion, for supporting the molded seal component, the canted annular extending portion projecting from one of the first and second flow faces of the filter media pack at an oblique angle to the longitudinal axis, and having a first and a distal end;   the preform part further including an inwardly canted skirt extending between the first end of the canted annular extending portion and the one of the first and second flow faces of the filter media pack, to thereby form a V-shaped, outwardly opening, annular groove at the juncture of the canted annular extending portion and the inwardly canted skirt.   
   
   
       2 . The filter element of  claim 1 , wherein the filter media pack includes a fluted filter media having a plurality of flutes of porous filter material. 
   
   
       3 . The filter element of  claim 1 , wherein the first end of the canted annular extending portion is disposed nearer than the distal end thereof to the longitudinal axis, such that the canted annular extension is canted outward from the longitudinal axis. 
   
   
       4 . The filter element of  claim 3 , wherein the molded seal component is molded onto the canted annular extending portion using a mold, and the canted annular extending portion defines an inner surface thereof having a projection extending therefrom for contacting and sealing against the mold, to thereby limit the extent of the molded seal component along the inner surface of the canted annular extending portion. 
   
   
       5 . The filter element of  claim 3 , wherein a portion of the molded seal component extends into the V-shaped annular groove. 
   
   
       6 . A filter element comprising:
 (a) a filter media pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces; the filter media pack having an outer side extending between the first and second flow faces;   (b) a seal support having an extension disposed at least partially over the second flow face; the extension having an interior surface, facing inwardly generally toward the axis, and an opposite surface;   (c) a seal component molded on, and around, the extension; and,   (d) a projection on the seal support disposed toward the central axis from the interior surface of the extension;
 (i) the projection being a portion of the seal support in contact with a mold when the seal component is molded; and, 
 (ii) the projection extending to a location radially inwardly of the seal component. 
   
   
   
       7 . The filter element of  claim 6  wherein:
 (a) the projection, on the seal support, disposed toward the central axis from the interior surface of the extension is an annular projection.   
   
   
       8 . The filter element of  claim 7 :
 (a) the projection on the seal support projects in a direction different from a direction of projection of the extension.   
   
   
       9 . The filter element of  claim 6  including:
 (a) an annular extension joined to the extension at a bend and extending between the extension and the second flow face; and   (b) the projection on the seal support, disposed toward the central axis from the interior surface of the extension, is configured and positioned to inhibit mold material from rising along a surface portion of the seal support, when the projection is in contact with a mold as the molded seal component is formed.   
   
   
       10 . The filter element of  claim 9  wherein:
 (a) the seal support comprises a portion of a preform having a portion extending around a side of the filter media pack.   
   
   
       11 . The filter element of  claim 9  wherein:
 (a) the annular extension, joined to the extension at a bend, includes a portion thereon extending around a side the filter media pack.   
   
   
       12 . The filter element of  claim 6  wherein:
 (a) the seal component includes a portion positioned on an outer surface of the extension and has a seal surface configured to form an outwardly directed radial seal with an air cleaner housing; and   (b) the seal component includes a portion extending over an end of the extension, and a portion of the seal component is positioned along the interior surface of the extension, wherein the portion of the seal component positioned along the interior surface of the extension is inhibited from having radially inner flash by the projection on the seal support, disposed toward the central axis from the interior surface of the extension, when the projection is in contact with a mold, and while the molded seal component is formed.   
   
   
       13 . The filter element of  claim 6  wherein:
 (a) the projection on the seal support disposed toward the central axis defines a smaller inner perimeter than an inner perimeter of the seal component.   
   
   
       14 . The filter element of  claim 6  wherein:
 (a) the filter media pack includes fluted media having:
 (i) a set of flutes closed proximate the second flow face; and, 
 (ii) a set of flutes closed proximate the first flow face; and, 
   (b) the media pack comprises a fluted sheet of media attached to a second sheet of media and wound about the axis.   
   
   
       15 . The filter element of  claim 14  wherein:
 (a) the seal support comprises a portion of a preform including a media face crosspiece arrangement extending over the second flow face.   
   
   
       16 . The filter element of  claim 6  wherein:
 (a) the filter media pack has a generally circular outer perimeter.   
   
   
       17 . The filter element of  claim 6  wherein:
 (a) filter media pack has an oval outside perimeter shape.   
   
   
       18 . The filter element of  claim 6  including:
 (a) an end piece at an opposite end of the media from the seal component;
 (i) the end piece including a portion surrounding the media pack. 
   
   
   
       19 . The filter element of  claim 18  wherein:
 (a) the end piece is separate from the seal component.   
   
   
       20 . A filter element comprising:
 (a) a filter media pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces; the filter media pack having an outer side extending between the first and second flow faces;   (b) a seal support having an extension disposed at least partially over the second end face; the extension having: an interior surface facing the axis; and, an opposite surface;   (c) a seal component molded on, and around, the extension;
 (i) the seal component including a portion positioned along the interior surface of the extension; 
   (d) the seal support including a projection disposed toward the axis from the interior surface of the extension;
 (i) the projection being a portion of the seal support in contact with a mold, when the seal component is molded; and 
 (ii) the projection, while in contact with the mold, being configured to inhibit flow of material forming the seal component, when the seal component is molded, so that the seal component extends a greater distance toward the first flow face over the opposite surface as compared to the inner surface. 
   
   
   
       21 . The filter element of  claim 20  wherein:
 (a) the seal support and the projection disposed toward the central axis from the interior surface are portions of a preform.   
   
   
       22 . The filter element of  claim 21  wherein:
 (a) the projection disposed toward the central axis from the interior surface projects in a direction different from a direction of projection of the extension of the seal support.   
   
   
       23 . The filter element of  claim 21  including:
 (a) an annular extension joined to the extension at a bend and extending between the extension and the second flow face;
 (i) the projection on the seal support, disposed toward the central axis from the interior surface of the extension, being positioned to inhibit mold material from rising along a surface of the annular extension when the projection is in contact with a mold as the molded seal component is formed. 
   
   
   
       24 . The filter element of  claim 20  wherein:
 (a) the seal support comprises a portion of a preform having a portion extending around a side of the filter media pack.   
   
   
       25 . The filter element of  claim 20  wherein:
 (a) the projection on the seal support disposed toward the central axis defines a smaller inner perimeter than an inner perimeter of the seal component.   
   
   
       26 . The filter element of  claim 20  wherein:
 (a) the filter media pack includes fluted media having:
 (i) a set of flutes closed proximate the second flow face; and, 
 (ii) a set of flutes closed proximate the first flow face; and, 
   (b) the media pack comprises a fluted sheet of media attached to a second sheet of media and wound about the axis.   
   
   
       27 . The filter element of  claim 26  wherein:
 (a) the seal support comprises a portion of a preform including a media face crosspiece arrangement extending over the second flow face.   
   
   
       28 . A filter element comprising:
 (a) a filter media pack having first and second flow faces and defining an axis extending through the first and second flow faces; the filter media pack having an outer side extending between the first and second flow faces;   (b) a seal support having an extension disposed at least partially over the second flow face; the extension having: an interior surface facing toward the axis, and, an opposite surface;   (c) a seal component molded on, and around, the extension;
 (i) the seal component including a portion positioned along the interior surface of the extension; and, 
   (d) the seal support including a projection disposed toward the central axis from the interior surface of the extension;
 (i) the projection disposed toward the central axis being between the portion of the seal component on the interior surface and the second flow face. 
   
   
   
       29 . The filter element of  claim 39  wherein:
 (a) the projection projects in a direction different than a direction of projection of the extension.   
   
   
       30 . The filter element of  claim 29  including:
 (a) an annular extension joined to the extension at a bend and extending between the extension and the second flow face;
 (i) the projection on the seal support, disposed toward the central axis from the interior surface of the extension, being positioned to inhibit mold material from rising along an interior surface of the annular extension when the projection is in contact with a mold, when the molded seal component is formed; the projection also separating material of the seal component, along the interior surface, from the annular extension. 
   
   
   
       31 . The filter element of  claim 44  wherein:
 (a) the seal support comprises a portion of a preform having a portion extending around a side of the filter media pack.   
   
   
       32 . The filter element of  claim 31  wherein:
 (a) the seal component is positioned on an outer surface of the extension and has a seal surface configured to form an outwardly directed radial seal with an air cleaner housing; and   (b) the seal component includes a portion extending over an end of the extension and a portion of the seal component is positioned along the interior surface of the extension, wherein the portion of the seal component positioned along the interior surface of the extension is inhibited from having radially inner flash by the projection on the seal support disposed toward the central axis from the interior surface of the extension, when the projection is in contact with a mold, as the molded seal component is formed.   
   
   
       33 . The filter element of  claim 32  wherein:
 (a) the filter media pack includes fluted media having:
 (i) a set of flutes closed proximate the second flow face; and, 
 (ii) a set of flutes closed proximate the first flow face; and, 
   (b) the media pack comprises a fluted sheet of media attached to a second sheet of media and wound about the axis.   
   
   
       34 . The filter element of  claim 33  wherein:
 (a) the seal support comprises a portion of a preform including a media face crosspiece arrangement extending over the second flow face.   
   
   
       35 . The filter element of  claim 28  wherein:
 (a) the projection on the seal support disposed toward the central axis defines a smaller inner perimeter than an inner perimeter of the seal component.   
   
   
       36 . The filter element of  claim 34  wherein:
 (a) the seal support includes a portion of an overmold sealing preform and the media pack.   
   
   
       37 . A filter element comprising:
 a filter pack, a seal member, and a seal support frame operatively connecting the seal member to the filter pack, the seal member being formed separately from the seal support frame;   the filter pack having first and second oppositely facing flow faces, and defining a longitudinal axis passing through the first and second flow faces; and   the seal support frame including a canted annular extension thereof, for supporting the seal member, the canted annular extension projecting from one of the first and second flow faces of the filter pack at an oblique angle to the longitudinal axis, and having a first end and a distal end thereof;   the seal support frame further including an inwardly canted intermediate annular segment extending between the first end of the canted annular extension and the one of the first and second flow faces of the filter pack, to thereby form a V-shaped, outwardly opening, annular groove at the juncture of the canted annular extension and the inwardly canted intermediate annular segment.   
   
   
       38 . The filter element of  claim 37 , wherein the filter pack includes a fluted filter media having a plurality of flutes of porous filter material. 
   
   
       39 . The filter element of  claim 37 , wherein the first end of the canted annular extension is disposed nearer than the distal end thereof to the longitudinal axis, such that the canted annular extension is canted outward from the longitudinal axis. 
   
   
       40 . The filter element of  claim 39 , wherein the seal member is molded onto the canted annular extension using a mold, and the canted annular extension defines an inner surface thereof having a raised annular rib extending therefrom for contacting and sealing against the mold, to thereby limit the extent of the seal member along the inner surface of the canted annular extension. 
   
   
       41 . The filter element of  claim 37 , wherein a portion of the seal member extends into the V-shaped annular groove. 
   
   
       42 . A filter element, comprising:
 a filter pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces, the filter pack having an outer filter pack surface extending transversely between the first and flow faces;   a seal support frame including an annular extension disposed at least partially over the second flow face, the seal support frame having an inner surface facing inwardly generally toward the axis and an outer surface facing generally outwardly away from the axis;   an annular seal member molded along the annular extension; and   an annular mold contact formed along the inner surface of the seal support frame, the annular mold contact disposed inwardly of the annular seal member along the inner surface relative to the axis.   
   
   
       43 . The filter element of  claim 42 , wherein the annular mold contact is provided by an annular rib projecting from the seal support frame. 
   
   
       44 . The filter element of  claim 43 , wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension. 
   
   
       45 . The filter element of  claim 42 , wherein the seal support further includes a canted annular segment joined to the annular extension at a bend, the canted annular segment extending generally between the annular extension and the second flow face, the annular mold contact preventing mold material from rising along the inner surface along the canted annular segment. 
   
   
       46 . The filter element of  claim 45 , further comprising an annular sidewall joined to the canted annular segment, the annular sidewall extending around the outer filter pack surface. 
   
   
       47 . The filter element of  claim 42 , wherein the seal member is molded over the outer surface of the seal support frame to provide an annular outer seal surface adapted for forming a radial seal, and wherein the seal member is also molded over an end of the annular extension and along the inner surface to provide an annular inner seal surface, the annular inner surface being disposed outwardly of the mold contact relative to the axis. 
   
   
       48 . The filter element of  claim 42 , wherein the annular mold contact defines a smaller inner perimeter than an inner perimeter of the annular seal member. 
   
   
       49 . The filter element of  claim 42 , wherein the filter pack is a fluted media having a plurality of flutes including a first set of flutes that are closed proximate to the first flow face and a second set of flutes that are closed proximate to the second flow face, the fluted media pack having a fluted sheet joined to a face sheet which are wound about the axis into an annular shape. 
   
   
       50 . The filter element of  claim 49 , wherein said seal support frame integrally includes a flow face screen extending over the second face. 
   
   
       51 . A filter element, comprising:
 a filter pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces, the filter pack having an outer filter pack surface extending transversely between the first and flow faces;   a seal support frame including an annular extension disposed at least partially over the second flow face, the seal support frame having an inner annular surface facing inwardly generally toward the axis and an outer annular surface facing generally outwardly away from the axis;   an annular seal member molded around the annular extension along the inner annular surface and the outer annular surface; and   an annular mold contact formed along the inner surface of the seal support frame, the annular mold contact preventing flow of mold material along the inner surface such that the annular seal member extends a greater distance toward the first flow face over the outer annular surface as compared to the inner annular surface.   
   
   
       52 . The filter element of  claim 51 , wherein the annular mold contact is provided by an annular rib projecting from the seal support frame. 
   
   
       53 . The filter element of  claim 52 , wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension. 
   
   
       54 . The filter element of  claim 53 , wherein the seal support further includes a canted annular segment joined to the annular extension at a bend, the canted annular segment extending generally between the annular extension and the second flow face, the annular mold contact preventing mold material from rising along the inner surface along the canted annular segment. 
   
   
       55 . The filter element of  claim 51 , further comprising an annular sidewall joined to the canted annular segment, the annular sidewall extending around the outer filter pack surface. 
   
   
       56 . The filter element of  claim 51 , wherein the annular mold contact defines a smaller inner perimeter than an inner perimeter of the annular seal member. 
   
   
       57 . The filter element of  claim 51 , wherein the filter pack is a fluted media having a plurality of flutes including a first set of flutes that are closed proximate the first flow face and a second set of flutes that are closed proximate the second flow face, the fluted media pack having a fluted sheet joined to a face sheet which are wound about the axis into an annular shape. 
   
   
       58 . The filter element of  claim 57 , wherein said seal support frame integrally includes a flow face screen extending over the second face. 
   
   
       59 . A filter element, comprising:
 a filter pack having oppositely facing first and second flow faces and defining an axis extending through the first and second flow faces, the filter pack having an outer filter pack surface extending transversely between the first and flow faces;   a seal support frame including an annular extension disposed at least partially over the second flow face, the seal support frame having an inner surface facing inwardly generally toward the axis and an outer surface facing generally outwardly away from the axis;   an annular seal member molded along the annular extension at least partially over the inner surface; and   annular rib projecting from the seal support frame along the inner surface, the annular rib being disposed between the seal material along the inner surface and the second flow face.   
   
   
       60 . The filter element of  claim 59 , wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension. 
   
   
       61 . The filter element of  claim 60 , wherein the seal support further includes a canted annular segment joined to the annular extension at a bend, the canted annular segment extending generally between the annular extension and the second flow face, the annular rib separating mold material along the inner surface from the canted annular segment. 
   
   
       62 . The filter element of  claim 61 , further comprising an annular sidewall joined to the canted annular segment, the annular sidewall extending around the outer filter pack surface. 
   
   
       63 . The filter element of  claim 61 , wherein the seal member is molded over the outer surface of the seal support frame to provide an annular outer seal surface adapted for forming a radial seal, and wherein the seal member is also molded over an end of the annular extension and along the inner surface to provide an annular inner seal surface, the annular inner surface being disposed outwardly of the annular rib relative to the axis. 
   
   
       64 . The filter element of  claim 63 , wherein the filter pack is a fluted media having a plurality of flutes including a first set of flutes that are closed proximate to the first flow face and a second set of flutes that are closed proximate to the second flow face, the fluted media pack having a fluted sheet joined to a face sheet which are wound about the axis into an annular shape. 
   
   
       65 . The filter element of  claim 64 , wherein said seal support frame integrally includes a flow face screen extending over the second face. 
   
   
       66 . The filter element of  claim 59 , wherein the annular rib defines a smaller inner perimeter than an inner perimeter of the annular seal member.