Cast formed filter and method of making the same

Abstract

A cast formed filter and a method for making the filter is provided. The method includes disposing a liquid filter media in a cavity of a molding tool, the molding tool having a plurality of features configured so that the filter media is formed about the plurality of features to form a plurality of inlet openings and a plurality of outlet openings in the filter media; applying at least one of pressure and heat to the filter media disposed in the molding tool to cure the liquid filter media and obtain a cast formed filter media defined by the cavity of the molding tool; and removing the cast formed filter media from the molding tool, wherein the cast formed filter media maintains a configuration having a three-dimensional periphery and the plurality of inlet openings extend from an inlet end of the cast filter media into the cast formed filter media so a first portion of the cast formed filter media is disposed between each of the plurality of inlet openings and an outlet end, and the plurality of outlet openings extend from the outlet end into the cast formed cast filter media so a second portion of the cast formed filter media is disposed between each of the plurality of outlet openings and the inlet end.

1 . A method of making a cast formed filter, comprising:
 disposing a liquid filter media in a cavity of a molding tool, the molding tool having a plurality of features configured so that the filter media is formed about the plurality of features to form a plurality of inlet openings and a plurality of outlet openings in the filter media;   applying at least one of pressure and heat to the filter media disposed in the molding tool to cure the liquid filter media and obtain a cast formed filter media defined by the cavity of the molding tool; and   removing the cast formed filter media from the molding tool, wherein the cast formed filter media maintains a configuration having a three-dimensional periphery and the plurality of inlet openings extend from an inlet end of the cast filter media into the cast formed filter media so a first portion of the cast formed filter media is disposed between each of the plurality of inlet openings and an outlet end, and the plurality of outlet openings extend from the outlet end into the cast formed cast filter media so a second portion of the cast formed filter media is disposed between each of the plurality of outlet openings and the inlet end.   
     
     
         2 . The method as in  claim 1 , further comprising curing the cast formed filter media disposed in the molding tool. 
     
     
         3 . The method as in  claim 2 , wherein the filter media is synthetic fiber. 
     
     
         4 . The method as in  claim 3 , wherein the synthetic fiber is polyester fiber. 
     
     
         5 . The method as in  claim 1 , wherein the filter media is synthetic fiber. 
     
     
         6 . The method as in  claim 5 , wherein the synthetic fiber is polyester fiber. 
     
     
         7 . The method as in  claim 1 , wherein the plurality of inlet openings are a plurality of rows of inlet openings. 
     
     
         8 . The method as in  claim 1 , wherein the plurality of inlet openings are a plurality of columns of inlet openings. 
     
     
         9 . The method as in  claim 1 , wherein the plurality of inlet openings are a plurality of rows of inlet openings and a plurality of columns of inlet openings. 
     
     
         10 . The method as in  claim 1 , wherein the plurality of outlet openings are a plurality of rows of outlet openings. 
     
     
         11 . The method as in  claim 1 , wherein the plurality of outlet openings are a plurality of columns of outlet openings. 
     
     
         12 . The method as in  claim 1 , wherein the plurality of outlet openings are a plurality of rows of outlet openings and a plurality of columns of outlet openings. 
     
     
         13 . The method as in  claim 1 , wherein at least one of the plurality of inlet openings has a hexagonal cross-sectional shape. 
     
     
         14 . The method as in  claim 1 , wherein at least one of the plurality of outlet openings has a circular cross-sectional shape. 
     
     
         15 . The method as in  claim 1 , wherein at least one of the plurality of inlet openings has a configuration that is not the same as a configuration of at least one of the plurality of outlet openings.