Filter element and method of manufacturing a filter element

Abstract

The disclosure relates to a filter element comprising a filter medium pack and a support device comprising at least a shell member, and wherein a portion of the shell member is heat welded to a circumferential face of the filter medium pack. The disclosure further relates to a method of manufacturing such a filter element, the method comprising: heating at least a portion of a shell member of a support device; positioning the shell member around a circumferential face of a filter medium pack; pushing the heated circumferential portion of the shell member against the circumferential face of the filter medium pack; and allowing the circumferential portion of the shell member to cool down.

Description

[0001] This application was filed as a PCT international application on 27 January 2022 and claims priority to European application serial number EP 21153828.5 filed on 27 January 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to a filter element and a method for manufacturing a filter element, and more specifically, to a filter element comprising a filter media package and a support device attached to the filter media package. The filter element includes a filter media package comprising a circumferential surface extending longitudinally from a fluid inlet flow surface to an opposing fluid outlet surface. Background Technology

[0003] Filter elements (also known as filter cartridges) used to filter fluids are used in a wide variety of filtration applications. The fluid can be a liquid or a gas (including, for example, air).

[0004] Filter elements are typically removed from and replaced from the housing of the filter system at regular time intervals or when the filtration performance drops below a critical threshold level.

[0005] A filter element includes a filter media package containing filter media material for removing contaminants as fluid flows through it. Commonly used and commercially available filter media are, for example, pleated or grooved media. Grooved media are also known as Z-shaped filter media.

[0006] Typically, for a so-called straight-through flow filter arrangement, the filter media package is defined by a circumferential surface extending in the longitudinal direction, a fluid inlet flow surface, and an opposing fluid outlet flow surface.

[0007] When the filter media pack is inserted into the housing of the filter system, additional elements, typically support devices, are attached to the filter media pack to form filter elements that can be inserted into the housing of the filter system.

[0008] The support device can be, for example, a sealing device that includes a sealing member for sealing to the housing of the filter system. In fact, for the filter element to operate properly, the filter media package must be properly sealed to the housing in which it is inserted.

[0009] Various manufacturing methods have been proposed to manufacture filter elements that include a filter media package and a support device (e.g., a sealing device) attached to the filter media package.

[0010] U.S. Patent No. 7,396,376 discloses a filter element comprising a grooved filter media pack and a polyurethane foam (PU) sealing device. During the manufacturing process, the filter media pack, along with a reinforcing frame element, is placed in a mold. The mold is then filled with PU, and after an ascent process, a so-called foam PU overmolded part is formed. The reinforcing frame element provides strength to the sealing member and also compensates for irregular shapes of the filter media pack.

[0011] U.S. Patent No. 7,674,308 discloses a filter element comprising grooved filter media, wherein the filter media package is enclosed by a plastic housing. In these filter element configurations, the filter media package is secured to the housing with an adhesive, and a PU sealing member is positioned to be completely external to the plastic housing.

[0012] However, a drawback of PU sealing devices is that they are not well-suited for environments where temperatures may rise (e.g., above approximately 80°C). Furthermore, due to the manufacturing process of foamed PU, filter elements do not always have an aesthetically pleasing appearance.

[0013] In addition, sealing devices in the form of end caps connected to the inlet or outlet of the filter media package can partially block fluid flow.

[0014] Therefore, there is room for improvement in the manufacturing process of filter elements to produce robust and cost-effective filter elements, especially for filter elements in which the filter media package includes opposing fluid inlet flow surfaces and fluid outlet flow surfaces. Summary of the Invention

[0015] The purpose of this disclosure is to provide a robust and cost-effective filter element for filtering fluids, and more specifically, a filter element wherein the filter media package includes opposing fluid inlet and outlet flow surfaces. Another purpose of this disclosure is to provide a method for manufacturing such a filter element in a cost-effective manner.

[0016] This disclosure is defined in the appended independent claims. Dependent claims define preferred embodiments.

[0017] According to a first aspect of this disclosure, a filter element is provided, comprising a filter media package and a support device. The filter media package includes a circumferential surface extending longitudinally from a fluid inlet flow surface to an opposing fluid outlet flow surface, and the support device includes a housing member extending longitudinally, wherein the housing member externally contacts at least a portion of the circumferential surface of the filter media package. The filter element according to this disclosure is characterized in that at least a portion of the housing member is thermally welded to the circumferential surface of the filter media package.

[0018] By using thermal welding, the housing components of the support device are directly attached to the circumferential side of the filter media pack, eliminating the need for glue or other adhesives and resulting in a robust filter element.

[0019] In one embodiment, the filter media package includes a wound layer of filter material.

[0020] In one embodiment, the filter media package includes a wound layer of filter material, wherein the circumferential surface of the filter media package is the outer surface of the outer layer of the wound layer of filter material. In other words, a portion of the housing component is directly thermally welded to the material of the filter media package. Typically, the filter material includes cellulose fibers, synthetic fibers, or a combination of both.

[0021] In one embodiment, the circumferential surface of the filter media pack is formed by a plastic wrapping surrounding the filter material of the filter media pack.

[0022] In one embodiment, the filter media package includes a wound layer of filter material, and the outer layer of the wound layer is covered by a plastic wrapping, wherein the outer surface of the plastic wrapping forms the circumferential surface of the filter media package.

[0023] In these embodiments, the filter media package includes a wound layer of filter material, and the outer layer of the wound layer is at least partially covered by a plastic wrapping. Therefore, in these embodiments, at least a portion of the circumferential surface of the filter media package includes the plastic wrapping. In these embodiments, a heat-welded portion of the housing member is heat-welded to the portion of the circumferential surface of the filter media package that includes the plastic wrapping.

[0024] In one embodiment, the circumferential surface of the filter media package is at least partially formed by a plastic wrapping, and the heat-welded portion of the housing component is heat-welded to the plastic wrapping.

[0025] In an embodiment, the thermally welded portion of the housing component is the circumferential portion that forms a circumferential leak-proof joint between the housing component and the circumferential surface of the filter media package.

[0026] In one embodiment, the leak-proof connector has a circular outline; in other embodiments, the leak-proof connector has a non-circular outline. In an embodiment, the leak-proof connector has a circular outline and is circumferentially spaced from both the fluid inlet flow surface and the fluid outlet flow surface, wherein S 入 >0.05x H and S 出 >0.05xH, preferably S 入 >0.10xH and S 出 >0.10x H, and where S 入 and S 出It is the separation distance measured along the longitudinal direction between the leak-proof joint and the inlet and outlet flow surfaces, respectively, where H is the height of the filter media pack measured along the longitudinal direction between the inlet flow surface and the outlet flow surface.

[0027] In an embodiment, the housing member, or at least the portion of the housing member that is thermally welded to the circumferential surface of the filter media package, is made of a thermoplastic material. Preferably, the thermoplastic material is any of the following materials or mixtures and combinations thereof: acrylonitrile butadiene styrene, polypropylene, polyamide, polyethylene terephthalate, polylactic acid, polyethylene, polycarbonate, polystyrene, or polyvinyl chloride.

[0028] In one embodiment, the housing member, or at least the portion of the housing member that is thermally welded to the circumferential surface of the filter media package, is made of a thermoplastic material, wherein a structurally stronger material, such as glass fiber, is added. This facilitates the thermal welding of the housing member to the filter media package.

[0029] In embodiments, the thermoplastic material of the housing component further comprises glass fiber or minerals or combinations thereof.

[0030] In some embodiments, the support device is, for example, a sealing device. In these embodiments, a housing member or at least a portion thereof forms a sealing element carrier for supporting the sealing member to seal the filter element to the housing of the filter system. The sealing element carrier is understood as a sealing frame for supporting the sealing member.

[0031] In embodiments where the support device is a sealing device, by providing a circumferential leak-proof joint between the housing member and the circumferential surface of the filter media package, no additional sealing member is required downstream of the leak-proof joint. Downstream here is defined relative to the flow direction from the fluid inlet flow surface to the fluid outlet flow surface. Therefore, in embodiments according to this disclosure, the filter element is not included in a sealing member downstream of the leak-proof joint.

[0032] In embodiments where the support device is a sealing device including a sealing member, the leak-proof connector is configured to perform a sealing function in parallel with the sealing member of the sealing device, so that the filtered fluid does not mix with the unfiltered fluid during operation.

[0033] In embodiments, the support device is a molded single-structure sealing device that includes a housing member and further includes a sealing member for sealing the filter element to the housing of the filter system. In these embodiments, the housing member can be understood as a sealing carrier for the sealing member.

[0034] In embodiments, the sealing member comprises a first material and the housing member, or at least the portion of the housing member welded to the circumferential surface of the filter media package, comprises a second material, wherein the second material is different from the first material. Preferably, in these embodiments, the glass transition temperature of the first material is higher than that of the second material.

[0035] Molded single-structure sealing devices are obtained, for example, by two-component injection molding or, more generally, multi-component injection molding processes. Advantageously, robust filter elements are obtained in a cost-effective manner by combining multi-component injection molding with a thermal welding process. In fact, a single-structure sealing device directly coupled to the filter media package is obtained without the use of any adhesive by first joining the seal and seal carrier through a two-component injection molding process and then further joining the seal carrier to the filter media package through a thermal welding process.

[0036] In the embodiments, the sealing member is made of or at least partially of any material or mixture or combination thereof from the following list of materials: rubber, thermoplastic elastomer, thermosetting elastomer, thermoplastic vulcanized rubber.

[0037] In the embodiments, the sealing member is made of or at least partially of any one of the following thermoplastic elastomers or mixtures or combinations thereof: polyamide thermoplastic elastomer, copolyester thermoplastic elastomer, olefin thermoplastic elastomer, styrene thermoplastic elastomer, urethane thermoplastic elastomer, or dynamically vulcanized thermoplastic elastomer.

[0038] As a result of thermal welding, the outer surface of the housing component that has been thermally welded to the circumferential surface of the filter media package includes imprints or indentations. These imprints or indentations visually reflect the location where thermal welding has occurred. Therefore, imprints or indentations on the housing component must be understood as weld marks or weld indentations.

[0039] In one embodiment, the outer surface of the housing component, which is thermally welded to the circumferential surface of the filter media package, includes a circumferential imprint.

[0040] In one embodiment, the outer surface of the housing member includes circumferential markings with a circumferential chamfer shape. In other embodiments, the outer surface of the housing member includes V-shaped or double V-shaped circumferential markings.

[0041] In an embodiment, the outer surface of the housing member that is thermally welded to the circumferential surface of the filter media package includes one or more individual indentations. Indentations may be, for example, notches, cuts, recesses, dividing lines, or partial dividing lines.

[0042] In another embodiment, the outer surface of the housing member includes both circumferential imprints and one or more individual indentations.

[0043] According to a second aspect of this disclosure, a method for manufacturing a filter element is provided, the filter element comprising a filter media package having a circumferential surface extending longitudinally from a fluid inlet flow surface to an opposing fluid outlet flow surface. The method includes: • Provides a support device including a housing member configured for at least a portion of the circumferential surface of an external filter media package. • At least a portion of the shell components should be heated. • Position the housing components around the circumferential surface of the filter media package. • The heated portion of the housing component, or at least a portion thereof, is pushed against the circumferential surface of the filter media package. • Allows the circumferential portion of the shell components to cool down.

[0044] In an embodiment of the method according to this disclosure, the heated portion is the circumferential portion of the housing member, such that when the heated portion of the housing member is pushed against the circumferential surface of the filter media pack, the circumferential gap between the housing member and the circumferential surface of the filter media pack becomes sealed.

[0045] The housing component is partially heated before positioning it around the circumferential surface of the filter media package, or alternatively, partially heated after positioning it around the circumferential surface of the filter media package.

[0046] In embodiments where the heated portion of the housing member corresponds to the circumferential edge of the housing member, pressing the heated portion of the housing member or at least a portion of the heated portion of the housing member against the circumferential surface of the filter media package includes: • A clamping element is provided, the clamping element including a circumferentially chamfered edge configured to surround the circumferential surface of the filter media package. • The positioning fixture element relative to the filter media package is such that the circumferential chamfered edge of the fixture element surrounds the circumferential surface of the filter media package and faces the circumferential edge of the housing member in the longitudinal direction. • Move the housing member relative to the clamping element in the longitudinal direction until the chamfered edge of the clamping element abuts against the heated circumferential edge of the housing member and at least a portion of the heated circumferential edge is guided toward the circumferential surface of the filter media pack and thereby fills the circumferential gap between the housing member and the circumferential surface of the filter media pack.

[0047] In another embodiment, pushing the heated portion or at least a portion of the heated portion of the housing member against the circumferential surface of the filter media package includes: • Position multiple plates around the shell member such that the plates are transverse relative to the longitudinal axis. • Move multiple plates so that the edge portions of the plates are pushed against the heated circumferential portion of the shell component. Attached Figure Description

[0048] These and other aspects of this disclosure will be explained in more detail by way of example and with reference to the accompanying drawings, in which: Figure 1a An isometric view schematically illustrating an embodiment of a filter media package having opposing inlet and outlet flow surfaces; Figure 1b An isometric view schematically illustrates an embodiment of a filter media package having an oblong shape; Figure 2 The cross-section of the grooved filter media layer is schematically shown. Figures 3a to 3g A cross-sectional view of an example filter element according to this disclosure is shown schematically; Figures 4a to 4c Isometric views, side views, and a portion of the projection in cross-section of a filter element according to this disclosure are shown, wherein the filter media package has a cylindrical shape. Figures 5a to 5c Isometric views, top views, and a portion of the projection in cross-section of a filter element according to this disclosure are shown, wherein the filter media package has an oblong shape. Figures 6a to 6c Isometric view, top view and partial projection in cross section of the filter element according to this disclosure are shown respectively, wherein two circumferential portions of the housing element are welded to the filter media package; Figures 7a to 7c Isometric views, side views, and a portion of the projection in cross-section of a filter element according to this disclosure are shown, wherein the housing component includes circumferential non-circular weld marks. Figures 8a to 8d Isometric views, side views, magnified isometric views, and a portion of the projection on a cross section of a filter element according to this disclosure are shown, wherein the housing component includes weld marks having a chamfered shape and one or more dividing lines; Figures 9a to 9c Isometric views, side views, and a portion of the projection in cross-section of a filter element according to this disclosure are shown, wherein the housing component includes V-shaped weld marks; Figures 10a to 10c Isometric view, top view and a portion of the projection on a cross section of the filter element according to this disclosure are shown, wherein a first portion of the housing member is welded to a second portion of the housing member; Figures 11a to 11cIsometric views, top views, and a portion of the projection in cross-section of the filter element according to this disclosure are shown, wherein the housing component includes double V-shaped weld marks; Figures 12a to 12c Isometric view, side view and a portion of the projection in cross section of a filter element according to this disclosure are shown, wherein the support of the filter element includes a flange covering the edge portion of the flow surface of the filter media package. Figures 13a to 13c Isometric view, side view and a portion of the projection on a cross section of a filter element according to this disclosure are shown, wherein the support of the filter element includes a flange member and four notches that connect to the edge portion of the flow surface of the filter media package. Figures 14a to 14c Isometric view, side view and a portion of the projection on a cross section of a filter element according to this disclosure are shown, wherein the support device for the filter element includes an anti-expansion member. Figures 15a to 15c Isometric view, side view and a portion of the projection in cross section of a filter element according to this disclosure are shown, wherein the support device of the filter element includes a flange having a retaining ring member extending in the longitudinal direction. Figures 16a to 16c Isometric views, side views and a portion of the projection on a cross section of a filter element according to this disclosure are shown, wherein the filter element includes a first support and a second support respectively welded to a first end and a second end of a filter media package. Figures 17a to 17c Isometric views, side views, and a portion of the projection on a cross section of a filter element according to this disclosure are shown, wherein the filter element includes a first support and a second support respectively welded to a first end and a second end of a filter media package, and wherein the first support includes a sealing member and the second support includes a handle. Figures 18a to 18c Isometric views, side views, and a portion of the projection in cross-section of a filter element according to this disclosure are shown, wherein the filter media package includes a plastic wrapping. Figures 19a to 19f An exemplary embodiment of the manufacturing method according to this disclosure is illustrated schematically; Figures 20a to 20e A method for manufacturing a filter element according to this disclosure is shown, wherein a sliding plate is used in the thermal welding process; Figures 21a to 21d A method for manufacturing a filter element is shown, wherein a first part of a housing component is welded to a second part of a housing component; Figure 22The diagram schematically illustrates a portion of the welding process according to this disclosure, wherein four rollers are configured to rotate around a filter media package; and Figure 23a and Figure 23b A cross-sectional view of an embodiment of a support device is shown, which includes a housing member and a flange member that forms an end cap for a filter media package.

[0049] The accompanying drawings are neither drawn to scale nor are they to scale. Generally, identical parts are indicated by the same reference numerals in the drawings. Detailed Implementation

[0050] This disclosure will be described in light of specific embodiments that illustrate it and should not be construed as limiting. Those skilled in the art will understand that this disclosure is not limited to what is specifically shown and / or described, and that alternative or modified embodiments may be developed in light of the overall teachings of this disclosure. The accompanying drawings are illustrative only and not restrictive.

[0051] The use of the verb "include" and its corresponding inflections does not exclude the existence of elements other than those stated. The use of the articles "a," "a kind," or "the" before an element does not exclude the existence of multiple such elements.

[0052] Furthermore, the terms "first," "second," etc., used in the specification and claims are used to distinguish similar elements and are not necessarily used to describe an order in time, space, ranking, or any other aspect. It should be understood that such terms are interchangeable where appropriate, and the embodiments of this disclosure described herein can operate in an order different from that described or shown herein.

[0053] Throughout this specification, references to "an embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in one or more embodiments of this disclosure. Therefore, the phrases "in one embodiment" or "in an embodiment" appearing in various places throughout this specification do not necessarily refer to the same embodiment, but may refer to the same embodiment. Furthermore, in one or more embodiments, particular features, structures, or characteristics may be combined in any suitable manner as will be apparent to those skilled in the art from this disclosure.

[0054] The terms "preferred" and "ideally" refer to embodiments of the invention that may provide certain benefits in certain circumstances. However, other embodiments may also be preferred in the same or other circumstances. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention. Filter media package

[0055] refer to Figure 1a and Figure 1b An example of an embodiment suitable for forming a filter media package 10 according to this disclosure is shown. As shown, the filter media package 10 is defined by a circumferential surface 15 extending in the longitudinal direction Z, a fluid inlet flow surface 11, and an opposing fluid outlet flow surface 12. Typically, the fluid inlet and outlet flow surfaces are transverse to the longitudinal direction Z.

[0056] The filter media pack 10 can be manufactured in various geometries, and this disclosure is not limited to any particular filter media pack geometry. For example, the filter media pack can have, for instance, a geometry such as... Figure 1a The cylindrical shape shown has a circular cross-section of the circumferential surface 15 having a plane transverse to the longitudinal direction. In other embodiments, the cross-section of the circumferential surface 15 having a plane transverse to the longitudinal direction is oblong or has a racetrack shape, such as... Figure 1b As shown, in another embodiment, the cross-sectional shape is a square or rectangle with rounded corners. In some embodiments, the filter media pack may have a conical shape.

[0057] Figure 1a The arrows above indicate the fluid inlet and outlet, and the direction of fluid flow. (For example...) Figure 1a and Figure 1b This arrangement of the filter media pack is also called a straight-through flow arrangement. When fluid flows through the filter media pack in a direction from the inlet flow surface at the first end of the filter media pack to the outlet flow surface at the opposite end of the filter media pack, the filter media filters the fluid.

[0058] Typically, the filter media is a relatively flexible material, usually a nonwoven fibrous material, such as cellulose fibers, synthetic fibers, or a combination of both. This material usually contains resin and is sometimes treated with additional materials.

[0059] In some embodiments, the filter media may include a wet-laid web media. In some embodiments, the filter media may include a dry-formed or dry-laid web media. The filter media may include any suitable combination of materials (including, for example, polymers, fibers, binders, and additives) selected by those skilled in the art.

[0060] In an exemplary embodiment, the filter medium may include a wet-laid nonwoven filter medium that primarily contains cellulose fibers.

[0061] In another exemplary embodiment, the filter medium may include a wet-laid nonwoven filter medium containing cellulose fibers and synthetic fibers, wherein the filter medium includes up to 10% or up to 20% synthetic fibers.

[0062] In yet another exemplary embodiment, the filter medium may include a dry web-forming medium containing spunbond fibers. Exemplary spunbond fibers include polyester fibers.

[0063] In another exemplary embodiment, the filter media may include a multilayer dry-laid media containing synthetic fibers. As described above, each of these media may include additional binders and / or additives. Additive compounds may enhance functionality, including but not limited to flame retardancy, oleophobicity, and / or hydrophobicity.

[0064] In a preferred embodiment, the filter media package includes grooved filter media, also known as Z-shaped filter media. An example of commercially available Z-shaped filter media is named Powercore. TM Known as such, as being manufactured by Donaldson Company Inc.

[0065] In this embodiment, the filter medium may be formed from a wound layer of filter material.

[0066] In an embodiment, a filter media package is obtained by winding a filter material layer, wherein the outer peripheral surface 15 of the filter media package is formed by the surface of the outer layer of the wound filter media.

[0067] In an embodiment, the filter medium may be formed from wound layers of grooved filter material, wherein each of these wound layers includes inlet grooves and outlet grooves oriented substantially parallel to the longitudinal direction Z. A filter medium package is formed by winding the grooved filter material layers, wherein the outer peripheral surface 15 of the filter medium package is formed by the surface of the outer layer of the wound grooved filter medium.

[0068] In another embodiment including a wound layer of filter material, the outer layer of the wound filter material is at least partially covered by a plastic wrapping. The plastic wrapping is understood as a protective cover. In this way, at least a portion of the circumferential surface of the filter media package is formed by the plastic wrapping. The plastic wrapping can be, for example, glued to the outer layer of the filter material, or the plastic wrapping can be adhesive tape. In embodiments, as further discussed below, the plastic wrapping can also be thermally welded to the outer layer of the wound layer of the filter material.

[0069] In embodiments including wound layers of grooved filter material, each wound grooved material layer includes a set of inlet grooves and a set of outlet grooves. The set of inlet grooves is open on the axial inlet side of the filter body to receive unfiltered fluid, and closed on the axial outlet side of the filter body. Conversely, the set of outlet grooves is closed on the axial inlet side and open on the axial outlet side to allow filtered fluid to exit the filter body. In this way, the fluid is forced to form a Z-shaped trajectory from the axial inlet side to the axial outlet side.

[0070] Exemplary grooved filter media and filter media packages including grooved filter media (including wound Z-shaped filter media) are disclosed in U.S. Patent Nos. 6,350,291 and 7,396,376 and European Patent Publication No. 3,680,002.

[0071] like Figure 2 Schematably illustrating a type of rolled Z-shaped filter media, this structure uses two sheets to form the filter media layer 5. The first sheet 5a is corrugated and is fixed to a second, non-corrugated sheet 5b, also known as a finishing sheet. When this type of media is used in a rolled structure, the media typically wraps around itself. In embodiments where the rolled layer is a layer formed by fixing corrugated and non-corrugated sheets, the outer peripheral surface 15 of the filter media package is the outer surface of the non-corrugated sheet of the outer layer of the rolled layer of the filter media.

[0072] As further described in U.S. Patent Nos. 6,350,291 and 7,396,376, regarding Z-shaped filter media, "wound" refers to a filter media package formed by winding a strip of grooved filter media into a filter media package. Filter element

[0073] refer to Figures 3a to 18c Various examples of embodiments of the filter element 1 according to this disclosure are shown. Figures 3a to 3g This is a cross-sectional view of filter element 1, wherein the cross-section includes the longitudinal axis Z of filter element 1. Figures 4a to 18c The diagram shows a combination of isometric views, side views, top views, and projections onto a cross-section including the longitudinal axis Z, of an example filter element according to this disclosure.

[0074] As shown in these figures, in addition to the filter media pack 10, the filter element 1 also includes a support device 20, which includes a housing member 25 extending longitudinally and externally contacting at least a portion of the circumferential surface 15 of the filter media pack. A common feature of these embodiments is that a portion 25a of the housing member is thermally welded to the circumferential surface 15 of the filter media pack, thereby attaching the support device 20 to the filter media pack. Therefore, no adhesive or glue is required to attach the support device 20 to the filter media pack 10. Figures 3a to 11c Above, the dashed circle schematically indicates the location where at least a portion 25a of the housing component is thermally welded to the circumferential surface 15 of the filter media package 10.

[0075] In the embodiments, the heat-welded portion 25a of the housing member 25 is a circumferential portion. In other words, in these embodiments, a circumferential weld is formed due to heat welding. In this way, by welding the circumferential portion of the housing member, a circumferential leak-proof joint is formed between the housing member 25 and the circumferential surface 15 of the filter media package. For example, in embodiments where the support device is a sealing device, the heat-welded portion 25a is a circumferential portion. In this way, a reliable radial and leak-proof attachment of the support device 20 to the filter media package is obtained without the use of any adhesive, and without any obstruction of fluid flow from the fluid inlet flow surface 11 to the fluid outlet flow surface 12.

[0076] The circumferential leak-proof joint must be understood as a sealing joint. In other words, during operation, fluid can only flow from the inlet flow surface to the outlet flow surface through the filter media package, and no fluid can flow between the housing member 25 and the circumferential surface of the filter media package.

[0077] In embodiments where the support device is a sealing device including a sealing member 29, the leak-proof connector is configured to perform a sealing function in parallel with the sealing member of the sealing device, so that the filtered fluid does not mix with the unfiltered fluid during operation.

[0078] In embodiments of the filter element according to this disclosure, wherein the support device is the sealing device 20, and the filter element does not include any additional sealing members coupled to the circumferential surface 15 of the filter media package for sealing against the housing of the filter system. In these embodiments of the filter element, the only sealing member of the filter element for sealing against the housing of the filter system is the sealing member of the sealing device 20. The sealing device 20 according to this disclosure is further discussed below.

[0079] In embodiments of the filter element according to this disclosure, the support device is a sealing device 20, and the filter element 1 does not include any additional sealing members downstream of the circumferential leak-proof joint. Downstream is defined relative to the flow direction from the inlet flow surface to the outlet flow surface.

[0080] In other embodiments, the heat-welded portion 25a of the housing member 25 is not necessarily a circumferential portion. In fact, in some embodiments, welding can only be performed at some discrete points or locations on the housing member. For example, if the support is an anti-expansion member or a support structure for supporting a handle, a leak-proof joint is not necessary, and therefore in these embodiments, it may be sufficient to perform heat welding at discrete points to attach the support to the filter media package.

[0081] refer to Figures 4a to 4c The image shows an isometric view, a side view, and a portion of a cross-sectional projection of an embodiment of a filter element according to this disclosure, wherein the filter media package has a cylindrical shape. Figure 4c In, it is shown that in Figure 4b The indicated cross-section A shows a portion of the projection, and the dashed circle schematically indicates the location where a portion 25a of the housing member is welded to the circumferential surface 15 of the filter media package. In this example, the support device 20 is a sealing device that includes a sealing member 29 in addition to the housing member 25. Figure 4c Above, use a dotted line to draw the support device 20.

[0082] refer to Figures 5a to 5c The image shows an isometric view, a top view, and a portion of a cross-sectional projection of a filter element according to this disclosure, wherein the filter media package has an oblong shape. Figure 5c In, it is shown that in Figure 5b A portion of the projection onto the indicated cross-section C. In Figure 5c Above, the support device 20 is circled with a dotted line. In this example, the support device 20 is also a sealing device that includes a sealing member 29 in addition to the housing member 25. The dashed circle schematically indicates the location where the circumferential portion 25a of the housing member is welded.

[0083] Welding the housing member to the filter media package is not limited to welding a single circumferential portion 25a to the filter media package. In some embodiments, more than one circumferential portion of the housing member is welded to the filter media package. For example, as... Figures 3e to 3g This schematically illustrates that two circumferential portions 25a and 25b are welded to the circumferential surface 15 of the filter media package. Welding more than one circumferential portion can make the filter element more robust. (Reference) Figures 6a to 6c The image shows an isometric view, a top view, and a portion of the projection onto cross-section C of the filter element, wherein two circumferential portions 25a and 25b of the housing element are welded to the filter media package. The locations where the two circumferential portions 25a and 25b of the housing element 25 are welded to the circumferential surface 15 of the filter media package are... Figure 6c It is indicated schematically by two dashed circles. Figure 6c Above, use a dotted line to draw the support device 20.

[0084] refer to Figure 3d and Figure 3g The housing member 25 completely surrounds the circumferential surface 15 of the filter media pack; that is, the housing member extends from the fluid inlet flow surface 11 to the opposite fluid outlet flow surface 12 and forms a protective cover for the filter media pack. In other embodiments, for example... Figures 3a to 3c As shown, housing component 25 only surrounds a portion of the filter media package.

[0085] refer to Figures 10a to 10c The diagram shows an isometric view, a top view, and a portion of the projection onto cross-section B of the filter element, wherein a first portion of housing member 26 is welded to a second portion of housing member 27. The two housing portions 26 and 27 form housing member 25. Figure 10c Above, it is shown in Figure 10b The projection onto the indicated cross section B. Figure 10c The dashed circles on the surface not only schematically indicate the positions where the first housing portion and the second housing portion are welded together, but also schematically indicate the positions where portion 25a of the housing member is simultaneously welded to the circumferential surface 15 of the filter media package. The welding method applied to this embodiment will be discussed in more detail below.

[0086] The precise location where the circumferential portion 25a of the housing component is welded to the circumferential surface 15 of the filter media package 10 can vary depending on the embodiment. For example, as Figure 3a This schematically illustrates welding in the middle of the filter media package. In other embodiments, such as... Figure 3d As shown, welding is performed closer to the fluid inlet flow surface of the filter media pack or closer to the fluid outlet flow surface.

[0087] In an embodiment, such as Figures 3a to 3b The diagram schematically illustrates that a circumferential welded portion forms a circumferential leak-proof joint between the housing member 25 and the circumferential surface 15 of the filter media package. This circumferential leak-proof joint is circular. In other words, the separation distance measured along the longitudinal direction Z between the leak-proof joint and the inlet flow surface is the same, regardless of the point on the leak-proof joint from which the distance is measured.

[0088] Figures 3a to 3d Reference S shown 入 and / or S 出 This corresponds to the separation distance measured along the longitudinal direction Z between the leak-proof joint and the inlet flow surface 11 and the outlet flow surface 12, respectively. For example, if welding is performed in the middle of the filter media package, such as... Figure 3a As shown, S 入 =S 出 Parameter S入 and / or S 出 It allows identification of welding locations relative to the inlet and outlet flow surfaces; that is, the parameters define the location of the weld.

[0089] In this embodiment, the circumferential leak-proof connector is spaced apart from the fluid inlet flow surface 11 and from the fluid outlet flow surface 12, wherein S 入 >0.05x H and S 出 >0.05x H, where H is the height of the filter media pack measured along the longitudinal direction Z between the inlet and outlet flow surfaces, such as Figure 3a As shown. In other embodiments, S 入 >0.10x H and S 出 >0.10x H.

[0090] In the embodiment, the portion 25a of the housing component that is welded to the circumferential surface of the filter media package is not necessarily a circular portion. Therefore, the circumferential welded portion forming the circumferential leak-proof joint is not necessarily circular. (Reference) Figures 7a to 7c The image shows an isometric view, a side view, and a portion of the projection onto cross-section A of an example filter element according to this disclosure. Figure 7a and Figure 7b As shown, the welded portion 25a of the shell member is not circular. Therefore, the visual weld marks on the outer surface of the shell member are also non-circular. Figures 7a to 7c In the illustrated embodiment, the sealing member 29 is not circular, and the welded portion 25a of the housing member follows the shape of the sealing member 29. Figure 7c Above, use a dotted line to draw the support device 20.

[0091] In an embodiment, such as Figure 7b As shown, the separation distance measured along the longitudinal direction Z from the fluid inlet flow surface 11 to the circumferential leak-proof joint varies depending on the azimuth position of the leak-proof joint on the filter media pack. Preferably, this separation distance is within a minimum S 最小 Separation distance and maximum S 最大 Variations in separation distances.

[0092] In an embodiment, such as Figure 3a As shown, the circumferential portion 25a of the housing member welded to the circumferential surface 15 of the filter media package corresponds to the circumferential edge of the housing member. In other embodiments, the welded circumferential portion 25a of the housing member is the central portion of the housing member, for example, as... Figure 3c This is shown schematically. In another embodiment, the entire circumferential surface of the housing component is welded to the filter media package.

[0093] Typically, as a result of the welding process, markings and / or one or more indentations can be seen on the outer surface of the housing member 25, indicating where or which part 25a of the housing member has been welded to the circumferential surface of the filter media package. The specific markings or indentations observed depend on the tools used in the manufacturing process for welding the housing member to the filter media package, as will be discussed further below. Therefore, markings or indentations can be understood as welding markings or welding indentations.

[0094] In one embodiment, the weld mark 50 completely surrounds the outer surface of the housing member 25. In other embodiments, the weld mark 50 only partially surrounds the outer surface of the housing member 25.

[0095] In one embodiment, the outer surface of the circumferential surface 15 of the housing component, which is thermally welded to the filter media package, includes one or more individual indentations.

[0096] In other embodiments, the outer surface of the housing member that is thermally welded to the circumferential surface 15 of the filter media package includes a circumferential imprint 50 or a partial circumferential imprint, for example, as... Figure 5c , Figure 6c , Figure 7c , Figure 8d , Figure 9c , Figure 10c and Figure 11c As shown.

[0097] In one embodiment, the outer surface of the housing component includes V-shaped or U-shaped markings that form grooves.

[0098] In other embodiments, for example, such as Figure 5c , Figure 6c , Figure 7c and Figure 8d As shown, the portion of the housing component that is welded to the circumferential surface 15 of the filter media package is the end portion of the housing component 25, and the mark 50 produced by the welding process has the shape of a circumferentially chamfered edge.

[0099] refer to Figures 9a to 9c The image shows an isometric view, a side view, and a portion of a projection onto a cross-section of a filter element according to this disclosure. Figure 9c Above, it is shown in Figure 9b A portion of the projection onto the indicated cross section A. Figure 9c The dashed circle indicates the location where the circumferential portion 25a of the housing member 25 is welded to the circumferential surface 15 of the filter media package. As shown, the weld mark 50 on the outer surface of the housing member 25 has a single V shape.

[0100] refer to Figures 11a to 11c The image shows an isometric view, a top view, and a portion of a projection onto a cross-section of a filter element according to this disclosure. Figure 11c Above, it is shown in Figure 11b A portion of the projection on the indicated cross section B. Figure 11c The dashed circle indicates the location where the circumferential portion 25a of the housing member 25 is welded to the circumferential surface 15 of the filter media package. As shown, the weld mark 50 on the outer surface of the housing member 25 has a double V shape.

[0101] refer to Figures 12a to 12c The image shows an isometric view, a side view, and a portion of a cross-sectional projection of a filter element according to this disclosure, wherein the support device 20 of the filter element includes a flange member 24 in addition to the housing member 25 and the sealing member 29. Figure 12c Above, it is shown that in such Figure 12b A portion of the projection onto the indicated cross-section A. In Figure 12c Above, the support device 20 is outlined with a dotted line, and the dashed circle indicates the location where the circumferential portion 25a of the housing member 25 is welded to the circumferential surface 15 of the filter media pack 10. As shown, the flange member 24 partially covers the edge portion of the flow surface of the filter media pack. This increases the robustness of the filter media pack. In an embodiment, Figure 12c The flange member 24 shown can receive a seal, for example, for sealing against a pre-filter or cover seal.

[0102] The support device 20, including the housing member 25 and the flange member 24, can also be referred to as an end cap. (See reference) Figure 23a and Figure 23b Two examples of embodiments of a support device 20 are shown, which includes a housing member 25 forming an end cap and a flange member 24.

[0103] refer to Figures 13a to 13c The image shows an isometric view, a side view, and a portion of a cross-sectional projection of a filter element according to this disclosure, wherein the support 20 of the filter element further includes a flange member 24 and four notches 23 that engage with the edge portion of the flow surface of the filter media package. Figure 13c Above, the support device 20 is outlined with a dotted line. The notch 23 makes the filter element more robust. In this way, protection is provided on the inflow surface, for example, when the bag is tapped during maintenance to empty dust.

[0104] refer to Figures 14a to 14c The image shows an isometric view, a side view, and a portion of a projection onto a cross-section of a filter element according to this disclosure, wherein the support 20 for the filter element further includes an anti-expansion member 22. Figure 14c Above, the support device 20, including the anti-stretch member 22, is outlined with a dashed line. The anti-stretch member 22 is configured to prevent the wound layer from moving in the longitudinal direction Z. Figure 14a As shown, the anti-expansion member includes one or more ribs attached to the flow surface of the filter media package.

[0105] refer to Figures 15a to 15c The image shows an isometric view, a side view, and a portion of a projection in a cross section of a filter element according to this disclosure, wherein the support of the filter element further includes a flange 24 having a retaining ring member extending in the longitudinal direction Z.

[0106] For a filter media package comprising a wound layer of filter media, the circumferential surface of the filter media package is the outer surface of the outer layer of the wound layer of filter media, and therefore, the circumferential portion 25a of the housing member is directly attached to the outer surface of the outer layer of the filter media by thermal welding. In other words, no additional plastic housing is required to further surround the filter media before the support device is attached to the filter media package.

[0107] In some embodiments, the filter media package includes a plastic wrapping for protecting the filter media, and in these embodiments, the outer surface of the plastic wrapping forms the circumferential surface 15 of the filter media package 10. The plastic wrapping surrounding the filter media makes the filter element more robust.

[0108] In one embodiment, the filter media package includes a wound layer 5 of filter material, and the outer layer of the wound layer is covered by a plastic wrapping 13. In these embodiments, the outer surface of the plastic wrapping 13 forms the circumferential surface 15 of the filter media package 10.

[0109] In embodiments that include a plastic wrapping, the plastic wrapping is glued to the filter material. In other embodiments, the plastic wrapping is welded to the filter material, as discussed further below.

[0110] about Figures 18a to 18c The image shows an isometric view, a side view, and a portion of a cross-sectional projection of a filter element according to this disclosure, wherein the filter media package 10 includes a plastic wrapping 13 surrounding the filter material, and wherein the outer surface of the plastic wrapping forms a circumferential surface 15 of the filter media package.

[0111] In an embodiment, the housing member, or at least the circumferential portion 25a of the housing member welded to the filter media package, is made of a thermoplastic material. This material may include any one of the following non-limiting materials: acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyamide (PA), polyethylene terephthalate (PET), polylactic acid (PLA), polyethylene (PE), polycarbonate (PC), polystyrene (PS), or polyvinyl chloride (PVC), or mixtures and combinations thereof.

[0112] In some embodiments, the material of the housing member or at least the circumferential portion 25a of the housing member may further comprise glass fiber or minerals or combinations thereof. Exemplary polyamides include polyamide 6 (PA6) and polyamide 66 (PA66). Additionally or alternatively, the material may include any other material suitable for thermal welding.

[0113] In embodiments where the housing member 25 or at least the circumferential portion 25a of the housing member comprises polypropylene, the housing member or at least the circumferential portion of the housing member may comprise a random copolymer of polypropylene, including, for example... QR 50AV (DUCOR Petrochemicals, Netherlands) or QR 76AV (DUCOR Petrochemicals, Netherlands); atactic polypropylene containing multiphase copolymer additives, including, for example... CL 50E (Carmel Olefins, Ltd., Israel); or P homopolymer (Laurent Engineering Plastics GmbH, Germany) Engineering Plastics).

[0114] In some embodiments, the materials or combinations of materials used to form the shell members and / or the circumferential portions of the shell members may be selected based on the expected Shore hardness of the materials.

[0115] In some embodiments, the Shore A value of the housing member or at least the circumferential portion of the housing member is at least 50, at least 60, at least 70, at least 80, or at least 90.

[0116] In some embodiments, the Shore A value of the housing member or at least the circumferential portion of the housing member is as high as 80, 90, 95 or 100.

[0117] In an exemplary embodiment, the Shore A value of the housing member or at least the circumferential portion of the housing member is in the range of 60 to 100.

[0118] In another exemplary embodiment, the Shore A value of the housing member and / or the circumferential portion of the housing member is in the range of 70 to 100.

[0119] In yet another exemplary embodiment, the Shore A value of the housing member or at least the circumferential portion of the housing member is in the range of 80 to 100.

[0120] For example, the Shore A value is determined as described in ASTM D2240-15e1, entitled "Standard Test Method For Rubber Property—Durometer Hardness". Example of a support device

[0121] In embodiments according to this disclosure, the support device 20 is a sealing device. In these embodiments, the housing member 25 or at least a portion of the housing member 25 forms a sealing carrier for supporting the sealing member. The sealing carrier is understood as a sealing frame for supporting the sealing member.

[0122] In embodiments where the support device is a sealing device, the sealing member may be, for example, a gasket that can be removably placed on the sealing carrier.

[0123] In a preferred embodiment, the support device 20 is a molded single-structure sealing device that includes a sealing member in addition to the housing member 25. In these preferred embodiments, the housing member 25, or at least a portion thereof, forms a sealing element carrier for the sealing member. This molded single-structure sealing device, including the sealing member and the sealing element carrier, is configured to separate filtered fluid from unfiltered fluid when the filter element is operably placed within the housing of the filter system.

[0124] For example Figure 4c , Figure 5c , Figure 6c , Figure 7c , Figure 8d and Figure 9c The embodiment of the support device 20 shown can be a molded single-structure sealing device including a housing member 25 and a sealing member 29. In these figures, the sealing device 20 is outlined with a dashed line.

[0125] In embodiments where the support device is a molded single-structure sealing device, the sealing member and the sealing carrier are made of a first material and a second material, respectively, wherein the second material is different from the first material. The sealing member is typically formed of a softer material, while the sealing carrier is typically formed of a harder material. Examples of each material are further described herein. Examples of the first material used for the sealing carrier have already been discussed above and correspond to the examples of the materials given for the housing member 25.

[0126] In some embodiments of a molded, single-structure sealing device, the sealing member and / or sealing carrier may be made of more than one material.

[0127] In embodiments, the sealing member is made of any of the following non-limiting materials: rubber, including unsaturated or saturated rubber; thermoplastic elastomers; thermosetting elastomers; thermoplastic vulcanized rubber; or mixtures or combinations thereof. Exemplary thermoplastic elastomers (TPEs) include polyamide TPEs, copolyester TPEs, olefin TPEs, styrene TPEs, urethane TPEs, or dynamically vulcanized TPEs, or mixtures or combinations thereof.

[0128] In some embodiments, the material used to form the sealing member may be selected based on the desired Shore hardness of the resulting seal. In some embodiments, the Shore A value of the sealing member is at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, or at least 60.

[0129] In some embodiments, the Shore A value of the sealing member is as high as 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90.

[0130] In an exemplary embodiment, the Shore A value of the sealing member is in the range of 30 to 90.

[0131] In another exemplary embodiment, the Shore A value of the sealing member is in the range of 40 to 70.

[0132] In yet another exemplary embodiment, the Shore A value of the sealing member is in the range of 50 to 70.

[0133] In some embodiments, the Shore A value is determined as described in ASTM D2240-15e1, entitled "Standard Test Method For Rubber Property—Durometer Hardness". The Shore A value of the seal carrier is preferably determined in the fully formed filter element (i.e., after the seal is attached to the seal carrier and after the seal carrier is thermally welded to the filter media package).

[0134] Compared to U.S. Patent Publication No. 2009 / 0320424 (which teaches the use of soft urethane foam for forming a mating joint between a filter element and a filter housing to prevent unfiltered fluid from passing through the fluid housing), the sealing member disclosed herein is formed via a multi-material injection molding process, as further described herein. Additionally, U.S. Patent Publication No. 2009 / 0320424 teaches that the sealing member has a Shore A value of less than 25. Furthermore, advantages in both manufacturing and use are gained when the sealing member comprises a thermoplastic polymer as described herein, rather than a urethane sealing member as described in U.S. Patent Publication No. 2009 / 0320424. The sealing member formed from a thermoplastic polymer via a multi-material injection molding process does not require curing, thus improving the efficiency of the manufacturing process, compared to urethane sealing members that must be cured. Furthermore, compared to urethane sealing components (which are typically stable only up to about 80°C), sealing components formed through a multi-material injection molding process can be stable at higher temperatures (e.g., up to 140°C), potentially providing greater stability during some periods of use when the filter element is exposed to thermal conditions. For example, some filter elements installed in engine compartments may be exposed to temperatures above 80°C (e.g., up to 90°C) during use.

[0135] Exemplary unsaturated rubbers include natural polyisoprene, including, for example, cis-1,4-polyisoprene natural rubber (NR) and trans-1,4-polyisoprene gutta-percha; synthetic polyisoprene (also known as isoprene rubber (IR)); polybutadiene (also known as butadiene rubber (BR)); chloroprene rubber (CR), including, for example, polychloroprene rubber, chloroprene rubber, Baypren, etc.; butyl rubber (also known as isobutylene-isoprene (IIR)); halogenated butyl rubber, including chlorinated butyl rubber (CIIR) and brominated butyl rubber (BIIR); styrene-butadiene rubber (SBR); nitrile rubber (also known as NBR, Buna N, or acrylonitrile butadiene rubber); hydrogenated nitrile rubber (HNBR); including, for example, Therban and Zetpol.

[0136] Exemplary saturated rubbers include ethylene propylene rubber (EPM), copolymers of ethylene and propylene; ethylene propylene diene (EPDM) rubber, terpolymers of ethylene, propylene, and diene components; epichlorohydrin rubber (ECO); polyacrylic rubber (ACM, ABR); silicone rubber (SI, Q, VMQ); fluorosilicone rubber (FVMQ); the FKM and FEPM series of fluororubbers, including, for example, VITON, TECNOFLON, FLUOREL, AFLAS, and DAI-EL; perfluoroelastomers (FFKM), including, for example, TECNOFLON PFR, KALREZ, CHEMRAZ, and PERLAST; polyether block amide (PEBA); chlorosulfonated polyethylene (CSM), including, for example, HYPALON; and ethylene-vinyl acetate (EVA).

[0137] Exemplary polyamide TPEs include polyamide TPEs comprising soft segments having ether and ester bonds (TPA-EE), polyamide TPEs comprising polyester soft segments (TPA-ES), or polyamide TPEs comprising polyether soft segments (TPA-ET), or mixtures or combinations thereof. Exemplary commercially available polyamide TPEs include... and E.

[0138] Exemplary copolyester TPEs include copolyester TPEs comprising soft segments having ether and ester bonds (TPC-EE), copolyester TPEs comprising polyester soft segments (TPC-ES), or copolyester TPEs comprising polyether soft segments (TPC-ET), or mixtures or combinations thereof. Exemplary commercially available copolyester TPEs include... and

[0139] Exemplary olefin TPEs include blends of polyolefins and conventional rubbers, wherein the rubber phase in the blend has little or no crosslinking (TPO). Exemplary commercially available olefin TPEs include... and ENFLEX-

[0140] Exemplary styrene-based TPEs include block copolymers of styrene and butadiene (TPS-SBS), polystyrene-poly(ethylene-butene)-polystyrene (TPS-SEBS), polystyrene-poly(ethylene-propylene)-polystyrene (TPS-SEPS), or block copolymers of styrene and isoprene (TPS-SIS), or mixtures or combinations thereof. Exemplary commercially available styrene-based TPEs include... KRATON TM , and

[0141] Exemplary urethane TPEs include urethane TPEs comprising aromatic hard segments and polyester soft segments (TPU-ARES), urethane TPEs comprising aromatic hard segments and polyether soft segments (TPU-ARET), urethane TPEs comprising aromatic hard segments and soft segments having ester and ether bonds (TPU-AREE), urethane TPEs comprising aromatic hard segments and polycaprolactone soft segments (TPU-ARCE), urethane TPEs comprising aromatic hard segments and polycaprolactone soft segments (TPU-ARCL), urethane TPEs comprising aliphatic hard segments and polyester soft segments (TPU-ALES), or urethane TPEs comprising aliphatic hard segments and polyether soft segments (TPU-ALET), or mixtures or combinations thereof. Exemplary commercially available urethane TPEs include... and

[0142] Exemplary dynamically vulcanized TPEs include: combinations of ethylene propylene diene monomer (EPDM) rubber and polypropylene, wherein the EPDM phase is highly crosslinked and finely dispersed in a continuous polypropylene phase (TPV-EPDM+PP); combinations of acrylonitrile-butadiene rubber (NBR) and polypropylene, wherein the NBR phase is highly crosslinked and finely dispersed in a continuous polypropylene phase (TPV-(NBR+PP)); combinations of natural rubber (NR) and polypropylene, wherein the NR phase is highly crosslinked and finely dispersed in a continuous polypropylene phase; combinations of epoxidized natural rubber (ENR) and polypropylene, wherein the ENR phase is highly crosslinked and finely dispersed in a continuous polypropylene phase (TPV-(ENR+PP)); or combinations of butyl rubber (also known as isobutylene-isoprene (IIR)) and polypropylene, wherein the butyl rubber phase is highly crosslinked and finely dispersed in a continuous polypropylene phase (TPV-(IIR+PP)); or mixtures or combinations thereof. Exemplary commercially available dynamically vulcanized TPEs include... SANTOPRENE TM , and In one exemplary embodiment, the seal may include TPV 4155B03 is a dynamically vulcanized TPE from Teknor Apex Company (Potakette, Rhode Island).

[0143] Other commercially available TPEs that may be suitable in some embodiments include BERGAFLEX. TM .

[0144] However, the support device welded to the filter media package according to this disclosure is not limited to a sealing device. In embodiments, the support device is, for example, an anti-stretch member configured to prevent the wound layer from moving in the longitudinal direction Z.

[0145] In other embodiments, the support device welded to the filter media pack is a support structure that includes one or more handles for carrying the filter media pack.

[0146] In one embodiment, the filter element 1 includes a first support device 20a and a second support device 20b, wherein the first and second support devices are thermally welded to the circumferential surface of the filter media package. The first and second support devices may be located at a first end and a second end of the filter media package, respectively. The first support device may be, for example, a sealing device, and the second support device may be, for example, an anti-expansion member.

[0147] refer to Figures 16a to 16c The image shows an isometric view, a side view, and a portion of a projection on a cross-section of a filter element 1, wherein the filter element 1 includes a first support 20a and a second support 20b respectively welded to a first end and a second end of a filter media package. Two dashed circles indicate the locations where a first portion 25a of the housing member 25 of the first support 20a and a second portion 25b of the housing member 25 of the second support 20a are welded to the circumferential surface 15 of the filter media package. In this embodiment, the first support 20a is a sealing device that includes a sealing member 29 in addition to the housing member 25. The second support 20b includes a flange member 24 in addition to the housing member 25.

[0148] refer to Figures 17a to 17c This illustrates another example of an embodiment of a filter element 1 including a first support device 20a and a second support device 20b. This embodiment is similar to... Figures 16a to 16c Similar to the example shown, except that in this embodiment the second support device 20b includes one or more handles 21, in this example two handles. These handles allow carrying the filter element and facilitate mounting the filter element in the housing. In this embodiment, the second support device 20b also includes a flange member 24, and the handles 21 are attached to the flange member, as shown. Figure 17a As shown.

[0149] As discussed above and, for example... Figure 23a and Figure 23b As shown, in addition to the housing member 25, the support device 20 may also include a flange member 24. This support device 20 forms an end cap for the filter media package.

[0150] exist Figure 23aIn the illustrated embodiment, the housing member 25 is a straight housing member, wherein the end portion 25a of the straight housing member is the portion of the housing member to be thermally welded to the filter media package. The housing member 25 has, for example, a hollow cylindrical shape, wherein the inner diameter of the housing member is selected to be larger than the outer diameter of the circumferential surface 15 of the filter media package, such that during the manufacturing process, after heating the portion 25a of the housing member 25 to be welded, as discussed below, the housing member 25 can slide on the filter media package 10.

[0151] In such Figure 23b In other embodiments shown, the housing member 25 is not entirely a straight housing member. For example... Figure 23b As shown, the housing member 25 includes a chamfered portion 25c, and this chamfered portion is chamfered relative to the longitudinal direction Z at an angle α (e.g., 30°). By providing a housing member 25 with a chamfered portion 25c, the internal dimensions (e.g., inner diameter) of the housing member can vary in the longitudinal direction, such as... Figure 23b As shown. In Figure 23b In the illustrated embodiment, the housing member includes a first portion, such as a first cylindrical portion having a first inner diameter D1, and a second portion, such as a second cylindrical portion having an inner diameter D2 larger than the inner diameter D1 of the first cylindrical portion. The second portion with the larger inner diameter D2 is the end portion of the housing member and is the portion 25a of the housing member 25 to be welded to the filter media package. In other words, the chamfered portion 25c allows for an increase in the internal dimensions of the end portion of the housing member, which is the portion 25a of the housing member to be welded to the filter media package. The end portion 25a of the housing member with a larger internal dimension (e.g., a larger inner diameter) facilitates a manufacturing process in which the housing member will slide on the filter media package, as discussed further below. Methods for manufacturing filter elements

[0152] This disclosure also describes a method of manufacturing a filter element 1, which includes a filter media package 10 having a circumferential surface 15 extending in the longitudinal direction Z from a fluid inlet flow surface 11 to an opposing fluid outlet flow surface 12. Using this manufacturing method, a support device 20 is welded to the circumferential surface 15 of the filter media package 10. As discussed above, the support device can be, for example, a seal carrier for supporting a sealing member, or the support device can be a molded single-structure sealing device including a seal carrier and a sealing member.

[0153] The method according to this disclosure includes: providing a support device 20 including a housing member 25 configured for connecting a circumferential surface 15 or at least a portion thereof to an external filter media package; heating at least a portion 25a of the housing member 25; positioning the housing member 25 around the circumferential surface 15 of the filter media package; pushing the heated portion 25a of the housing member or at least a portion thereof against the circumferential surface 15 of the filter media package; and allowing the circumferential portion 25a of the housing member to cool down.

[0154] Thermal welding is also known as plastic welding, thermal fusion, contact bonding, or direct bonding.

[0155] Typically, by first heating the circumferential portion to be welded and then pressing it against the circumferential surface of the filter media pack, the molecules of the circumferential portion and the molecules of the outer surface of the filter media pack entangle and bond together upon cooling. In this way, a strong and usually airtight attachment can be achieved between the circumferential surface of the filter media pack and the support device. Technicians will optimize parameters such as processing temperature and cooling time to obtain a strong attachment.

[0156] In embodiments where the weldable portion 25a of the housing member is a circumferential portion, when the heated portion 25a of the housing member is pushed against the circumferential surface 15 of the filter media package, the circumferential gap between the housing member 25 and the circumferential surface 15 of the filter media package becomes sealed. In practice, since the housing member 25 is positioned around the circumferential surface 15 of the filter media package, a circumferential gap 19 always exists between the housing member 25 and the circumferential surface 15 of the filter media package.

[0157] refer to Figures 19a to 19f This schematically illustrates an exemplary embodiment of a method for manufacturing a filter element according to this disclosure.

[0158] like Figure 19a As shown, a support device 20 is provided for attachment to the circumferential surface 15 of the filter media pack, and the support device 20 includes at least a housing member 25. In this exemplary embodiment, the support device 20 does not include any components other than the housing member 25 forming a support frame for a sealing member. A hot plate 30 is provided as a heating tool, and a chamfering clamp 40 is provided, which is configured to surround the circumferential surface 15 of the filter media pack. Figure 19a The chamfered clamp 40 shown is a hollow body that can be placed around the filter media package and includes a chamfered edge 40a.

[0159] exist Figure 19bIn the illustrated embodiments, the circumferential portion 25a to be welded of the housing member corresponds to the circumferential edge of the housing member 25. In these embodiments, the circumferential edge of the housing member 25 is heated by the hot plate 30 by placing the hot plate under the support device, such that the circumferential edge 25a of the housing member contacts and is heated by the hot plate 30.

[0160] like Figure 19b As further shown, the chamfered clamp 40 is positioned relative to the filter media package 10 such that the circumferential chamfered edge 40a of the clamp element surrounds the circumferential surface 15 of the filter media package and faces the circumferential edge 25a of the housing member in the longitudinal direction Z.

[0161] like Figure 19c As shown, after a predefined heating period, the hot plate 30 is removed and the housing member 25 is positioned along the longitudinal direction Z around the circumferential surface 15 of the filter media package, such that at least the circumferential portion 25a of the housing member to be welded surrounds the circumferential surface of the filter media package. Figure 19c The black arrow along the longitudinal direction indicates the direction of movement of the housing component 25.

[0162] In other words, and as Figure 19d and Figure 19e As further shown, the housing member 25 moves relative to the clamping element 40 along the longitudinal direction Z until the chamfered edge of the clamping element abuts against the heated circumferential edge of the housing member. Thus, at least a portion of the heated circumferential edge is guided toward the circumferential surface of the filter media package, thereby filling the circumferential gap 19 between the housing member and the circumferential surface 15 of the filter media package 10.

[0163] like Figure 19e As further shown, when the chamfered edge of the clamping element abuts against the heated circumferential edge 25a of the housing member, a radial force is generated, such as... Figure 19e It is indicated by two arrows perpendicular to the longitudinal direction Z.

[0164] After a cooling period that allows the circumferential portion 25a of the housing component to cool down, the clamping element 40 is removed from the filter media package, thus completing the manufacturing method of the filter element 1. Figure 19f As shown. Figure 19f The dashed circle on the top indicates the location where a portion 25a of the housing component is welded to the circumferential surface 15 of the filter media package.

[0165] In some embodiments, a clamping element comprising two chamfered edges is used. This allows for the formation of two leak-proof joints, for example, one at each end of the housing member 25.

[0166] In embodiments where the support device 20 is configured to support a seal carrier for a removable seal (such as a gasket), the seal carrier can be welded to the filter media package before the sealing member is placed on the seal carrier. Alternatively, the sealing member can be placed on the seal carrier before the welding process begins.

[0167] To heat the circumferential portion of the shell components, any suitable heating technique other than hot plate heating can be used.

[0168] Other applicable heating techniques include, for example, infrared heating, hot gas heating, laser beam heating, rotary welding heating, mirror heating, vibration heating, and friction heating. In some embodiments, a combination of different heating techniques may be used to heat the circumferential portion of the housing component.

[0169] In an embodiment, such as Figure 19b As shown, for example, the hot plate 30 is used to heat the circumferential portion 25a of the housing member, and the heating of the circumferential portion 25a of the housing member is performed before the housing member 25 of the support device is positioned around the circumferential surface 15 of the filter medium package.

[0170] In other embodiments, heating of the circumferential portion 25a of the housing member can be performed after the housing member 25 of the support device is positioned around the circumferential surface 15 of the filter media package, using another heating technique (such as heating with a laser beam or heating with hot air).

[0171] As discussed above, in some embodiments, the filter media package 10 includes a plastic wrapping for protecting the filter material and making the filter element more robust. In these embodiments, the outer surface of the plastic wrapping forms the circumferential surface 15 of the filter media package, or at least a portion of the circumferential surface 15 of the filter media package is formed by the outer surface of the plastic wrapping.

[0172] In embodiments where the filter media package includes a plastic wrapping, the filter element manufacturing method includes the step of wrapping the plastic wrapping around the filter material. In embodiments including a wound layer of filter material, the plastic wrapping is wrapped around the outer layer of the wound filter material.

[0173] In one embodiment, the plastic wrapping is glued to the filter material. In other embodiments, the plastic wrapping is an adhesive tape that can be directly attached to the outer surface of the filter material. Therefore, if the plastic wrapping is glued, or alternatively when adhesive tape is used, the wrapping with the plastic wrapping is performed before applying the heat welding process discussed above for welding the support device to the filter media package.

[0174] In another embodiment, the plastic package is welded to the outer surface of the filter material, for example, to the outer layer of a wound layer of the filter material. In these embodiments, the package is welded to the filter material simultaneously with the thermal welding of the support device to the filter media package as discussed above, after the plastic package has been positioned around the filter material. Typically, in these embodiments, the method includes heating the plastic package or at least a portion of the plastic package.

[0175] Heating of the circumferential portion of the shell component is typically performed until the circumferential portion becomes deformable and has reached a given processing temperature.

[0176] The processing temperature required for hot welding depends on the specific materials chosen for the shell component and / or the materials chosen for the circumferential portion of the shell component. "Processing temperature" is the temperature at which the circumferential portion of the shell component intended to be attached to the filter media package becomes deformable. The processing temperature is measured by measuring the temperature of the heated circumferential portion of the shell component.

[0177] The preferred processing temperature can be selected by those skilled in the art with reference to the material properties of the housing component and / or the circumferential portion of the housing component.

[0178] The processing temperature is preferably greater than the glass transition temperature of the material forming the shell component and / or the peripheral portion of the shell component intended to be attached to the filter media package.

[0179] In some embodiments, the processing temperature may be at least 100°C, at least 125°C, at least 150°C, at least 175°C, or at least 200°C. In some embodiments, the processing temperature may be as high as 200°C, as high as 225°C, as high as 250°C, as high as 300°C, as high as 325°C, or as high as 350°C. In an exemplary embodiment, the processing temperature may be in the range of 100°C to 300°C. In another exemplary embodiment, the processing temperature may be in the range of 150°C to 300°C. In yet another exemplary embodiment, the processing temperature may be in the range of 200°C to 300°C.

[0180] When a material or combination of materials comprises a single-phase polymer component in an amorphous state (including, for example, polystyrene (PS) or polycarbonate (PC)), the glass transition temperature of the material is understood as the midpoint temperature (T0). mgThe midpoint temperature was determined using differential scanning calorimetry (DSC) according to ASTM D3418-99, entitled "Standard Test Method for Transition Temperatures of Polymers by Differential Scanning Calorimetry". The midpoint temperature (T) mg ) is used as the glass transition temperature (T) g The representation is based on the fact that the glass transition is actually a temperature range. DSC can be performed using any suitable instrument; however, in an exemplary embodiment, a DSC3+ (Mettler-Toledo AG of Schwezenbach, Switzerland) with an FRS 6+ sensor can be used.

[0181] When one or more materials include semi-crystalline polymer materials or any other material exhibiting more than a single polymer phase (including, for example, polypropylene (PP) or polyethylene (PE)), the glass transition temperature of the material is defined as the final temperature at which the elastic modulus (G') and loss modulus (G”) intersect, wherein G' and G” are plotted relative to temperatures from 0°C to the temperature at which the polymer is in a molten state. G' and G" are defined according to ASTM D4092-01, entitled "Standard Terminology for Plastics: Dynamic Mechanical Properties". The rise in tanδ can be used to characterize a system transitioning to the melt flow region. In this document, G' and G" are determined using temperature-scanning dynamic mechanical analysis (DMA) by measuring forced constant-amplitude, fixed-frequency shear oscillations with a mechanical spectrometer, according to ASTM D4440-15, entitled "Standard Test Method for Plastics: Dynamic Mechanical Properties MeltRheology", as further described in ASTM D4065-12, entitled "Standard Practice for Plastics: Dynamic Mechanical Properties: Determination and Report of Procedures". Any suitable dynamic mechanical analyzer can be used; however, in the exemplary embodiment, the Q800 (TA Instruments, Newcastle, DE) can be used.

[0182] In order to push the heated circumferential portion of the housing member against the filter media package, various techniques can be applied in addition to the clamping elements with chamfered edges discussed above. This method is not limited to any specific technique for pushing the heated circumferential portion of the housing member against the circumferential surface 15 of the filter media package.

[0183] In one embodiment, in order to push the heated circumferential portion of the housing component against the circumferential surface 15 of the filter medium pack 10, a plurality of plates transverse to the longitudinal axis Z are used.

[0184] refer to Figures 20a to 20e An example of a welding process is shown, in which multiple plates 60a, 60b, 60c, and 60d are used to push the heated circumferential portion 25a of the housing component against the circumferential surface 15 of the filter media package. Figure 20a As shown, multiple plates 60a, 60b, 60c, and 60d are positioned around the shell member 25 such that these plates are transverse relative to the longitudinal axis Z. Figures 20b to 20e As further shown, by moving multiple plates, the edge portions of the plates are pushed against the heated circumferential portion 25a of the housing member 25, and the heated circumferential portion 25a of the housing member 25 is pushed against the circumferential surface 15 of the filter medium package 10.

[0185] In an embodiment, the contour shape of the edge portions of plates 60a, 60b, 60c, and 60d is configured to match the contour shape of the circumferential surface 15 of the filter media package.

[0186] exist Figures 20a to 20e In the illustrated embodiment, the two plates are configured to slide from a pull-out position toward a pull-in position in a plane transverse to the longitudinal direction Z. The pull-out position is as follows: Figure 20a and Figure 20b As shown, the pull-in position is as follows Figure 20c and Figure 20d As shown. In this embodiment, the first set of plates includes two plates 60a and 60b that are movable along a first axis, and the second set of plates 60c and 60d are movable along a second axis perpendicular to the first axis. Figure 20b The black arrows on the top indicate the direction of movement of each plate from the pull-out position to the pull-in position, and Figure 20d The black arrows indicate the direction of movement of each plate from the pull-in position to the pull-out position. Furthermore, the two sets of plates are axially positioned relative to the circumferential portion 15 of the housing member and configured such that when the plates are slid into the pull-in position, the edge portions of the plates contact the circumferential portion 25a of the housing member 25 to be welded. Therefore, by sliding the two sets of plates from the pull-out position to the pull-in position, the edge portions of the plates are pushed against the heated circumferential portion of the housing member, and at least a portion of the heated circumferential portion is guided toward the circumferential surface of the filter media package. The circumferential gap between the housing member and the circumferential surface is thus filled.

[0187] exist Figure 20e Above, it is shown in Figure 20d A portion of the projection onto the indicated cross-section B. In Figure 20e Above, plate 60b is shown resting against a portion 25a of the housing member 25 of the support device 20.

[0188] like Figure 20e As shown, the edge of the plate resting against the circumferential surface of the filter media pack has a blade, and therefore the weld mark 50 on the outer surface of the housing component is V-shaped. Similarly, in Figure 9c In the illustrated embodiment, the housing component 25 of the support device 20 is welded to the filter media package using a sliding plate with a blade.

[0189] refer to Figures 8a to 8d The image shows an isometric view, side view, magnified isometric view, and a portion of the projection on a cross-section of another example of a filter element, where welding is performed using a sliding plate. In this example, the edges of the sliding plate used to weld the housing member to the filter media package have a chamfered shape. Therefore, the weld marks on the outer surface of the housing member have a circumferential chamfered shape. Furthermore, as... Figure 8c As shown, the dividing lines 28 or partial dividing lines are visible due to the interface between the two sliding plates used during the welding process. If four plates are used, four dividing lines 28 or partial dividing lines are visible on the outer surface of the shell member. These dividing lines 28 or partial dividing lines can be understood as weld indentations.

[0190] In other embodiments, multiple plates form an iris-like aperture, which is another example, where the plates are used to push a portion of the housing member against the filter media pack during the welding process. In these embodiments, after the circumferential portion of the support housing member is heated, the iris-like aperture is positioned around the housing member 25 of 20 in the open position. Subsequently, the iris-like aperture is closed such that the edges of the plates of the iris-like aperture press against the circumferential portion 25a of the housing member to be welded.

[0191] In other embodiments, after the circumferential portion 25a of the housing member is heated, one or more rollers are configured to apply a radial force while rolling one or more rollers around the circumferential portion of the housing member, thereby pushing the heated portion of the housing member against the circumferential surface 15 of the filter medium package 10.

[0192] refer to Figure 22 The illustration schematically depicts an example of a thermal welding process according to this disclosure, wherein four rollers 65 rotate around the filter media package 10 to press the heated circumferential portion 25a of the housing member 25 against the circumferential surface of the filter media package. Figure 22 In the embodiment shown, the filter media pack 10 remains stationary while the roller 65 moves around the filter media pack while rotating about its axis of rotation. Figure 22 The solid arrows schematically show the direction of rotation of the roller about its axis of rotation, and the dashed arrows indicate the direction of movement of the roller about the filter media pack as it rotates about its axis of rotation. In other embodiments, the filter media pack 10 is configured to rotate when the roller is stationary.

[0193] As discussed above, in such Figures 10a to 10c In some embodiments shown, the housing member 25 of the support device 20 includes a first housing portion 26 and a second housing portion 27 welded together. Figures 21a to 21dThe method of welding the first housing portion and the second housing portion together is further illustrated such that a portion 25a of the housing member is also welded to the circumferential surface 15 of the filter media package. In this embodiment, the first housing portion 26 has a chamfered circumferential edge 26a, such as... Figure 21d As shown. The second housing portion 27 is positioned around the filter media package 10, as... Figure 21b As shown. During the welding process, the chamfered circumferential edge 26a of the first portion 26 and the edge of the second housing portion 27 are heated, and then the first and second housing portions are moved in the longitudinal direction Z until the chamfered edge 26a of the first housing portion 26 presses against the edge of the second housing portion. The direction of movement of the first and second portions is... Figure 21b and Figure 21c The above is illustrated by two black arrows. In this way, the first and second housing parts are welded together, and an internal plastic seam is formed between the housing members and the circumferential surface 15 of the filter media package, thereby creating a leak-proof connection.

[0194] exist Figure 10c Above, the dashed circle indicates the heat-welded area where the circumferential portion 25a of the housing member 25 is welded to the circumferential surface 15 of the filter media package. In this embodiment, the heat-welded area is located at the interface between the first housing portion 26 and the second housing portion 27 forming the housing member 25.

[0195] In other embodiments where the housing member is formed by welding the first housing member to the second housing member, the edges of both the first housing member 26 and the second housing member 27 are chamfered. In yet another embodiment, the edges of the first housing member 26 are not chamfered and only the edges of the second housing member 27 are chamfered. Method for molding and welding single-structure sealing devices

[0196] In the embodiments, as discussed above, the support device is a molded single-structure sealing device, wherein the housing component and the sealing component are formed simultaneously through a multi-material injection molding manufacturing process. In these embodiments, the housing component of the support device forms a sealing carrier for the sealing component, or at least a portion of the housing component forms a sealing carrier for the sealing component.

[0197] Since the filter media package may be damaged, resulting in reduced efficiency, the multi-material injection molding process for forming the seal is preferably performed before the seal is thermally welded to the filter media package if exposed to the high temperatures required for multi-material injection molding.

[0198] If a multi-material injection molding manufacturing process is performed before the welding process, the support device 20 already includes a sealing member during the heating of the circumferential portion of the housing member during the welding process used to weld the support device to the filter media package.

[0199] Multimaterial injection molding is a process of molding two or more different materials into a single structural part. Multimaterial injection molding can include, for example, multi-component injection molding (also known as co-injection molding); multiple injection molding; and overmolding. In multimaterial injection molding, at least a first material and a second material are used, wherein the sealing member includes at least the first material and the sealing carrier includes at least the second material. In some embodiments, the multimaterial injection molding manufacturing process may include molding only two materials, but in other embodiments, more than two materials may be used.

[0200] A variety of arrangements of molded single-structure sealing devices can be envisioned using multi-material injection molding manufacturing processes. For example, when a multi-material injection molding manufacturing process involves two materials, these two different materials can be injected into a single mold to form a molded single-structure sealing device. In this way, a molded single-structure sealing device with two different material regions is obtained. These two different materials can be injected into a single mold simultaneously (typically referred to as multi-component injection molding or co-injection molding) or sequentially (typically referred to as multiple injection molding). In exemplary embodiments, two different types of polymers can be used as two components, wherein one polymer forms the sealing member and the other polymer forms the sealing carrier or a portion thereof. Additional examples of various materials and combinations of materials that can be used for sealing members and sealing carriers are further discussed herein.

[0201] Alternatively or alternatively, overmolding can be used to form a molded single-structure sealing device, wherein one material is laminated on top of another material. If overmolding is used to form a sealing member or a portion thereof, or a sealing carrier or a portion thereof, the overmolding is performed using an injection molding manufacturing process. While overmolding can also be used for polyurethane seals or thixotropic seals, this embodiment is not an overmolding performed using an injection molding manufacturing process.

[0202] In some embodiments, the sealing device may include a third element comprising a third material different from the first and second materials. This third element may also be included in the sealing device in addition to the sealing member and the sealing carrier, or it may form, for example, only a portion of the sealing carrier (e.g., a portion of the sealing carrier not thermally welded to the filter media package). For example, this could be a portion of the housing member not welded to the filter media package. In this embodiment, a three-component injection molding process can be used to form the sealing device. Alternatively, a two-component injection molding process can be used to form a portion of the sealing device, and overmolding can be used to form the remainder of the sealing device.

[0203] Multi-material injection molding allows for the formation and / or bonding of sealing components and seal carriers without the use of curable adhesives. Curable adhesives require curing time, thus increasing manufacturing time. Therefore, multi-material injection molding allows for faster production of filter elements. Furthermore, using multi-material injection molding instead of curable adhesives (such as polyurethane) provides greater stability and dimensional stability to the sealing components, resulting in a lower risk of leakage during use and offering more potential configurations and geometries for the location and orientation of the sealing components.

[0204] In embodiments where the support device is a molded single-structure sealing device, the preferred processing temperature for welding the support device to the filter media package can be selected by those skilled in the art with reference to the glass transition temperature of the material forming the sealing member, the glass transition temperature of the material forming the shell member and / or the circumferential portion of the shell member to be attached to the filter media package, the heating technique for heating the circumferential portion of the shell member, and the configuration of the sealing device.

[0205] In some embodiments, the glass transition temperature of the first material or combination of materials used to form the sealing member may be greater than the glass transition temperature of the second material or combination of materials used to form the housing member and / or the circumferential portion of the housing member. In this way, the sealing member is less likely to deform when heat is applied to the housing member or the circumferential portion of the housing member during the thermal welding manufacturing process and the processing temperature is higher than the glass transition temperature of the second material.

[0206] The glass transition temperature difference between the materials of the sealing member and the sealing carrier can be selected by those skilled in the art based on the geometry of the sealing device, the heat source used, and the processing temperature. In some embodiments, the processing temperature may be at least 5°C, at least 10°C, at least 15°C, at least 20°C, at least 25°C, at least 30°C, at least 35°C, at least 40°C, at least 45°C, or at least 50°C higher than the glass transition temperature of the second material. In some embodiments, the processing temperature may be up to 50°C, up to 75°C, up to 100°C, up to 125°C, up to 150°C, up to 175°C, or up to 200°C higher than the glass transition temperature of the second material. Figure Labels 5 Filter material layer 5a First corrugated sheet 5b Second non-corrugated sheet 10 Filter media package 11 Fluid inlet flow surface 12 Fluid outlet flow surface 13 plastic wrapping 15 Circumferential surface of filter media pack 19 interval 20, 20a, 20b support device 21 handle 22 Anti-expansion components 23 Notch 24 Flange components 25 Shell components 25a, 25b Welded parts of shell components 25c Chamfered portion of shell components 26 First part of the shell component 26a, 40a chamfered edges 27 Second part of the shell component 28 Divider line 29 Sealing components 30 hot plate 40 chamfering fixture 50 Zhou Xiang Imprint 60a, 60b, 60c, 60d Sliding plate 65 roller

Claims

1. A filter element, comprising: • A filter media package, the filter media package comprising a circumferential surface extending in the longitudinal direction (Z) from the fluid inlet flow surface to the opposite fluid outlet flow surface; as well as • A support device comprising a housing member extending along the longitudinal direction (Z), wherein the housing member is external to at least a portion of the circumferential surface of the filter media package; The characteristic feature is that at least a portion of the housing component is thermally welded to the circumferential surface of the filter media package.

2. The filter element according to claim 1, wherein, The filter media package includes a wound layer of filter material, wherein the circumferential surface of the filter media package is the outer surface of the outer layer of the wound layer of filter material.

3. The filter element according to claim 1, wherein, The filter media package includes a wound layer of filter material, wherein the outer layer of the wound layer is covered by a plastic wrapping, and wherein the outer surface of the plastic wrapping forms the circumferential surface of the filter media package.

4. The filter element according to claim 2 or claim 3, wherein, The filter material includes cellulose fibers, synthetic fibers, or a combination of both.

5. The filter element according to claim 1, wherein, The filter media package includes a grooved filter media, wherein the grooves are formed by fixing a first corrugated sheet to a second non-corrugated sheet.

6. The filter element according to claim 1, wherein, The heat-welded portion of the housing component is the circumferential portion that forms a circumferential leak-proof joint between the housing component and the circumferential surface of the filter media package.

7. The filter element according to claim 1, wherein, The outer surface of the housing component includes a weld circumferential mark, a weld portion circumferential mark, one or more individual weld indentations, or a combination of one or more individual weld indentations and a weld circumferential mark or a weld portion circumferential mark.

8. The filter element according to claim 1, wherein, The thermal welding of the portion of the housing member includes: heating the portion of the housing member to be welded, pushing the heated portion or at least a portion of the heated portion against the circumferential surface of the filter media package, and allowing the heated portion of the housing member to cool down.

9. The filter element according to claim 1, wherein, The housing member, or at least the portion of the housing member that is thermally welded to the circumferential surface of the filter media package, is made of a thermoplastic material, which is any material or mixture and combination thereof from the following list: Acrylonitrile butadiene styrene, polypropylene, polyamide, polyethylene terephthalate, polylactic acid, polyethylene, polycarbonate, polystyrene, or polyvinyl chloride.

10. The filter element according to claim 6, wherein, The support device is a sealing device, and wherein the housing member or at least a portion thereof forms a sealing element carrier for supporting the sealing member in order to seal the filter element to the housing of the filter system.

11. The filter element according to claim 1, wherein, The support device is a molded single-structure sealing device, which includes the housing member and further includes a sealing member for sealing the filter element to the housing of the filter system, wherein the housing member or at least a portion thereof forms a sealing carrier for the sealing member.

12. The filter element according to claim 11, wherein, The sealing member includes a first material and the housing member, or at least the portion of the housing member welded to the circumferential surface of the filter media package, includes a second material, wherein the second material is different from the first material, and the glass transition temperature of the first material is higher than that of the second material.

13. The filter element according to claim 11 or claim 12, wherein, The sealing member is made of, or at least in part of, any material or mixture or combination thereof from the following list of materials: rubber, thermoplastic elastomer, thermosetting elastomer, thermoplastic vulcanized rubber.

14. The filter element according to claim 11 or claim 12, wherein, The sealing member is made of, or at least in part of, any of, a mixture or combination of, the following thermoplastic elastomers: Polyamide thermoplastic elastomers, copolyester thermoplastic elastomers, olefin thermoplastic elastomers, styrene thermoplastic elastomers, urethane thermoplastic elastomers, or dynamically vulcanized thermoplastic elastomers.

15. The filter element according to claim 11 or 12, in, The Shore A value of the sealing member is at least 25.

16. The filter element according to claim 11 or 12, wherein, The sealing component has a Shore A value as high as 90.

17. The filter element according to claim 1, wherein, The Shore A value of the housing member, or at least the portion of the housing member that is thermally welded to the circumferential surface of the filter media package, is at least 50.

18. The filter element according to claim 1, wherein, The Shore A value of the housing component, or at least the portion of the housing component that is thermally welded to the circumferential surface of the filter media package, is as high as 100.

19. The filter element according to claim 1, in, The Shore D value of the housing member, or at least the portion of the housing member that is thermally welded to the circumferential surface of the filter media package, is at least 10.

20. The filter element according to claim 1, wherein, The Shore D value of the housing component, or at least the portion of the housing component that is thermally welded to the circumferential surface of the filter media package, is as high as 100.

21. The filter element according to claim 10, wherein, The circumferential leak-proof joint is configured to provide a seal in parallel with the sealing member, so that the filtered fluid does not mix with the unfiltered fluid during operation.

22. The filter element according to claim 6, wherein, The circumferential leak-proof joint has a non-circular outline shape.

23. The filter element according to claim 6 or claim 22, wherein, The separation distance measured along the longitudinal direction (Z) from the fluid inlet flow surface to the circumferential leak-proof joint varies depending on the azimuth position of the circumferential leak-proof joint on the filter media package, and the separation distance varies between a minimum separation distance and a maximum separation distance.

24. The filter element according to claim 6, wherein, The circumferential leak-proof joint is spaced apart from the fluid inlet flow surface and from the fluid outlet flow surface, wherein... S 入 > 0.05 x H and S 出 > 0.05 x H, S 入 > 0.10 x H and S 出 > 0.10 x H Among them, S 入 and S 出 H is the separation distance measured along the longitudinal direction (Z) between the circumferential leak-proof joint and the fluid inlet flow surface and the fluid outlet flow surface, respectively, and wherein H is the height of the filter media pack measured along the longitudinal direction (Z) between the fluid inlet flow surface and the fluid outlet flow surface.

25. The filter element according to claim 1, wherein, The circumferential surface is formed by a plastic wrapping around the filter material encased in the filter media package.

26. The filter element according to claim 1, wherein, The filter media package includes a wound layer of filter material, wherein the outer layer of the wound layer is at least partially covered by a plastic wrapping, and the heat-welded portion of the housing member is heat-welded to a portion of the circumferential surface of the filter media package, including the plastic wrapping.

27. The filter element according to claim 1, wherein, The filter media package includes a wound layer of filter material.

28. The filter element according to claim 1, wherein, The support device includes anti-expansion components.

29. The filter element according to claim 9, wherein, The thermoplastic material further includes glass fiber, minerals, or combinations thereof.

30. A method of manufacturing a filter element, the filter element comprising a filter media package having a circumferential surface extending in a longitudinal direction (Z) from a fluid inlet flow surface to an opposing fluid outlet flow surface, the method comprising: • A support device is provided including a housing member configured for externally connecting the circumferential surface or at least a portion of the circumferential surface of the filter media package; • At least a portion of the housing component is heated; • Position the housing component around the circumferential surface of the filter media package; • The heated portion of the housing component or at least a portion of the heated portion of the housing component is pushed against the circumferential surface of the filter media package; as well as • Allows the heated portions of the housing component to cool down.

31. The method according to claim 30, wherein, The heating of the portion of the housing member is performed before positioning the housing member around the circumferential surface of the filter media package, or alternatively, the heating of the portion of the housing member is performed after positioning the housing member around the circumferential surface of the filter media package.

32. The method according to claim 30 or claim 31, wherein, The heated portion is the circumferential portion of the housing member, such that when the heated portion of the housing member is pushed against the circumferential surface of the filter media pack, the circumferential gap between the housing member and the circumferential surface of the filter media pack becomes sealed.

33. The method according to claim 32, wherein, The heated portion of the housing member corresponds to the circumferential edge of the housing member, and wherein pushing the heated portion of the housing member or at least a portion of the heated portion of the housing member against the circumferential surface of the filter media package includes: • Provide a clamping element including a circumferentially chamfered edge configured to surround the circumferential surface of the filter media package; • Position the clamping element relative to the filter media package such that the circumferential chamfered edge of the clamping element surrounds the circumferential surface of the filter media package and faces the circumferential edge of the housing member in the longitudinal direction (Z); and • Move the housing member relative to the clamping element along the longitudinal direction (Z) until the chamfered edge of the clamping element abuts against the heated circumferential edge of the housing member and at least a portion of the heated circumferential edge is guided toward the circumferential surface of the filter media pack and thereby fills the circumferential gap between the housing member and the circumferential surface of the filter media pack.

34. The method according to claim 32, wherein, The step of pushing the heated portion or at least a portion of the heated portion of the housing member against the circumferential surface of the filter media package includes: • Positioning multiple plates around the housing member such that the plates are transverse relative to the longitudinal direction (Z); and • Move the plurality of plates such that the edge portions of the plates rest against the heated circumferential portion of the housing member.

35. The method according to claim 33, wherein, Heating the circumferential edge includes: • Place the hot plate below the housing member such that the circumferential edge of the housing member contacts and is heated by the hot plate.

Images