Method for Making Filter Element

Abstract

A filter includes a filter element formed of filter media, and a plastic framework molded and bonded to and structurally supporting the filter media. One embodiment desirably provides a two-component assembly consisting solely of two components, namely the filter media and the plastic framework molded thereon. In a further embodiment, the plastic framework includes a resilient seal integrally molded therewith and of the same plastic material thereof, eliminating a separate component for the seal. In a further embodiment, a filter combination includes a primary filter element and a secondary filter element. In a further embodiment, a resilient integrally molded seal is provided.

1 - 51 . (canceled) 
   
   
       52 . A method for making a filter element comprising providing filter media composed of fibers, overmolding a plastic framework to said filter media to structurally support said filter media, said framework comprising a rib network comprising a plurality of ribs, selecting the material of said framework from a family chemically compatible with the material of said fibers, chemically bonding said ribs of said framework to said filter media during said overmolding of said framework, entangling the plastic material of said ribs of said framework to some of said fibers of said filter media during said overmolding of said framework to additionally mechanically bond said ribs of said framework to said filter media, to both chemically and mechanically bond said ribs of said framework to said filter media. 
   
   
       53 . The method according to  claim 52  comprising providing said filter element as an annular filter element extending axially along an axis between distally opposite first and second axial ends, overmolding said framework to extend axially along said axis between distally opposite first and second axial ends at respective said first and second axial ends of said filter element. 
   
   
       54 . The method according to  claim 53  comprising overmolding said framework to have an outer peripheral surface at said first end of said framework having a resilient seal integrally overmolded therewith. 
   
   
       55 . The method according to  claim 54  comprising overmolding said seal and said ribs of the same plastic material as said framework. 
   
   
       56 . The method according to  claim 54  comprising overmolding said seal to form at least one flexible annular flange extending obliquely relative to said axis and radially deflectable relative to said axis. 
   
   
       57 . The method according to  claim 56  comprising overmolding said framework to have a plurality of axial ribs extending axially between said first and second axial ends of said framework, and to have a plurality of trusses at said first axial end of said framework extending radially between said axial ribs and said annular flange providing said seal. 
   
   
       58 . The method according to  claim 53  comprising overmolding said framework to have a plurality of arcuate ribs extending laterally relative to the axial extension of said framework. 
   
   
       59 . The method according to  claim 53  comprising overmolding said framework to have a plurality of axial ribs extending axially between first and second axial ends of said framework, and a plurality of arcuate ribs extending laterally between said axial ribs. 
   
   
       60 . The method according to  claim 52  comprising providing said filter element as an annular filter element extending axially along an axis between distally opposite first and second axial ends and having a hollow interior, providing said filter media with an interior facing said hollow interior, and an exterior facing away from said hollow interior, overmolding said framework to form a first plastic frame along said exterior of said filter media, and to form a second plastic frame along said interior of said filter media, overmolding said framework to form said first frame to provide a first rib network comprising a first set of a plurality of ribs extending along said exterior of said filter media and overmolded thereto, and overmolding said framework to form said second frame to provide a second rib network comprising a second set of a plurality of ribs extending along said interior of said filter media and overmolded thereto, to sandwich said filter media between said first and second sets of ribs on opposite exterior and interior sides of said filter media and overmolded bonded respectively thereto. 
   
   
       61 . The method according to  claim 60  comprising overmolding said framework to extend axially along said axis between distally opposite first and second axial ends at respective first and second axial ends of said filter element, and overmolding said framework to form an integral connection between said first and second frames at at least one of said first and second axial ends.