Filter element and method of manufacturing a filter element

Abstract

A filter element for placement in a housing of a filter system comprises a filter media pack and a sealing arrangement comprising a seal and a seal carrier. The filter media pack includes, for example, pleated filter media or fluted filter media. The seal carrier includes an axial side coupled to at least a portion of the axial face of the filter media pack by a thermal weld manufacturing process. The coupling of the seal to the seal carrier may be obtained by manufacturing the sealing device using a multi-material injection molding manufacturing process. The disclosure further relates to a method for manufacturing a filter element comprising a hot welding step and a multi-material injection molding step.

Description

Cross-reference to related applications

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 62 / 878,941, filed July 26, 2019, which is incorporated herein by reference. Technical Field

[0002] This disclosure relates to a filter element for filtering fluids, and more specifically to a filter element that can be inserted into a housing of a filter system and can be removed for servicing. This disclosure also relates to a method for manufacturing the filter element. 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] In fact, in many cases, it is desirable to use filter elements to remove contaminant materials from fluid streams. For example, airflows to engines of motor vehicles, power generation equipment, construction equipment, or other equipment, gas flows to gas turbine systems, and airflows to various combustion furnaces carry particulate contaminants. For such systems, it is preferable to remove or at least reduce contaminant materials from the fluid.

[0005] Filter elements can be configured to be removed and replaced from the housing of the filter system at regular time intervals or when the filtration performance drops below a critical threshold level.

[0006] A filter element includes a filter media package containing filter media. When fluid flows through the filter media, the filter media removes contaminants. Commonly used and commercially available filter media are, for example, pleated or grooved media. Grooved media are also known as Z-shaped filter media.

[0007] U.S. Patent No. 7,396,376 describes an example of a filter media package comprising grooved media. The filter media package includes an outer circumferential surface forming the radial boundary of the filter media package. This outer circumferential surface generally extends longitudinally from a first axial surface to an opposite second surface.

[0008] In addition to the filter media pack, a filter element also includes a sealing device for separating the filtered fluid from the unfiltered fluid. In fact, for the filter element to operate properly, the filter media pack must be properly sealed to the housing into which it is inserted.

[0009] Various types of sealing devices have been proposed for filter elements. Typically, when using, for example, pleated media, the sealing device is formed from polyurethane foam (PU) obtained by molding technology. Advantageously, the foam PU sealing device not only seals the pleats at the first axial face of the filter media package, but the circumferential surface of the PU sealing device can also be used as a radial or axial seal to properly seal to the housing. End caps, typically also made of foam PU, are used to seal the pleats at the second axial face of the filter media package.

[0010] U.S. Patent No. 7,396,376 discloses a polyurethane foam (PU) sealing device used in conjunction with a grooved filter media pack. 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 upward process, a so-called foam PU overmolded part is formed. The reinforcing frame element provides strength to the seal and also compensates for irregular shapes of the filter media pack.

[0011] However, PU sealing devices have drawbacks: they are not well-suited for environments where temperatures can become very high, such as above approximately 80°C. Additionally, due to the manufacturing process of foamed PU, filter elements do not always have an aesthetically pleasing appearance.

[0012] Alternatives to foam sealing devices include sealing devices with mechanical gaskets (such as O-rings) that can withstand high temperatures and can be attached to the filter media package, for example, via a gasket carrier. These types of alternative sealing devices can also utilize adhesives, such as glue, to bond the gasket carrier to the filter media package.

[0013] The disadvantages of using sealing devices that include mechanical gaskets or involve the use of adhesives are that the manufacturing process may be more time-consuming, and sealing devices involving multiple parts may be less robust.

[0014] The specific configuration of the sealing device to be applied often depends on the type of filter media package used, and therefore there is not always a uniform manufacturing process available for manufacturing filter elements.

[0015] Therefore, it is desirable to provide more robust and cost-effective filter elements, and to provide an improved method for manufacturing filter elements. Summary of the Invention

[0016] The objective of this disclosure is to provide a robust and cost-effective filter element for filtering fluids. A further objective of this disclosure is to provide a cost-effective method for manufacturing the filter element, which is applicable to a wide variety of types of filter media packages.

[0017] In one aspect, this disclosure describes a filter element comprising a filter media package and a molded single-structure sealing device. The filter media package includes an outer circumferential surface extending in a longitudinal direction and a first axial surface transverse to the longitudinal direction. The molded single-structure sealing device includes a seal and a seal carrier, wherein the seal comprises a first material and the seal carrier comprises a second material, and wherein the second material is different from the first material. The seal carrier includes a first axial side, and the first axial side of the seal carrier is thermally welded to at least a circumferential portion of the first axial surface of the filter media package.

[0018] In another aspect, this disclosure describes a filter element for placement in a housing of a filter system. The filter element includes a filter media package for filtering fluid, and a sealing device for separating filtered fluid from unfiltered fluid when the filter element is operatively placed in the housing. The filter media package includes an outer circumferential surface extending in a longitudinal direction and a first axial surface transverse to the longitudinal direction. The sealing device includes a seal made of at least a first material and a seal carrier made of at least a second material, wherein the second material is different from the first material. The seal is coupled to the seal carrier, and the coupling between the seal and the seal carrier is achieved by manufacturing the sealing device using a multi-component injection molding process with the first and second materials. The seal carrier includes a first axial side coupled to at least a circumferential portion of the first axial surface of the filter media package by a thermal welding process.

[0019] In another aspect, this disclosure describes a method for manufacturing a filter element. The method includes: providing a filter media package having a circumferential surface extending in a longitudinal direction and a first axial surface transverse to the longitudinal direction; providing a sealing element carrier; and applying a thermal welding manufacturing process to attach a first axial side of the sealing element carrier to at least a circumferential portion of the first axial surface of the filter media package. In some embodiments, the sealing device includes a molded single-structure sealing device having a sealing element carrier. In some embodiments, the sealing device includes a molded single-structure sealing device having a seal and a sealing element carrier. In some embodiments, the method further includes: attaching the seal to the sealing element carrier using a multi-component injection molding manufacturing process. The seal may be attached to the sealing element carrier before or after the application of the thermal welding manufacturing process.

[0020] 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.

[0021] Where the term "comprising" and its variations appear in the specification and claims, these terms are not restrictive. Such terms should be understood to imply inclusion of the stated steps or elements or a group of steps or elements, but not to exclude any other steps or elements or any other group of steps or elements.

[0022] "Comprising of..." means including and limited to anything contained in the phrase "comprising of...". Therefore, the phrase "comprising of..." indicates that the listed element is necessary or mandatory, and that other elements may not be present. "Substantially comprising..." means including any element listed in the phrase, and is limited to other elements that do not impede or contribute to the function or role specified in this disclosure for the listed element. Therefore, the phrase "substantially comprising..." indicates that the listed element is necessary or mandatory, but other elements are optional and may or may not be present, depending on whether they substantially affect the function or role of the listed element.

[0023] Unless otherwise stated, “one / type”, “described” and “at least one / type” are used interchangeably and do not exclude the existence of more than one / type.

[0024] The term “and / or” means one or all of the listed elements or any combination of two or more of the listed elements.

[0025] Unless otherwise stated, any reference to standard methods (e.g., ASTM, TAPPI, AATCC, etc.) refers to the most recent available version of that method at the time of submission of this disclosure.

[0026] The terms “first,” “second,” and other similar terms used herein are used to distinguish similar elements and are not necessarily used to describe a temporal, spatial, ranking, or any other order. 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.

[0027] Furthermore, in this document, the numerical range described by endpoints includes all numbers falling within the range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0028] In this article, “up to” a certain number (e.g., up to 50) includes that number (e.g., 50).

[0029] The term "in the range" (and similar statements) includes the end values ​​of the stated range.

[0030] 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 disclosed herein. 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.

[0031] For any method disclosed herein that includes discrete steps, the steps can be performed in any feasible order. Furthermore, any combination of two or more steps can be performed simultaneously, where appropriate.

[0032] Unless otherwise stated, all figures indicating the quantity of components, molecular weight, etc., used in the specification and claims should be understood to be modified by the term "about" in all cases. When used herein in conjunction with the quantity measured, the term "about" refers to a variation in the measured quantity as would be expected by a person skilled in the art to perform the measurement and to operate with a level of care commensurate with the purpose of the measurement and the accuracy of the measuring equipment used. Therefore, unless otherwise indicated to the contrary, the numerical parameters set forth in this specification and claims are approximations, which may vary depending on the desired characteristics sought to be obtained by the invention. At least, and not in an attempt to limit the scope of the claims, each numerical parameter should be interpreted at least according to the number of significant digits reported and by applying general rounding methods.

[0033] While the numerical ranges and parameters illustrating the broad scope of the invention are approximate, the values ​​described in specific examples are reported as precisely as possible. However, all values ​​inherently contain ranges that are necessarily generated by the standard deviations found in their respective test measurements.

[0034] All headings are for the reader's convenience and should not be used to limit the meaning of the text following them, unless otherwise stated.

[0035] The above summary of the invention is not intended to describe every disclosed embodiment or implementation of the invention. The following description illustrates illustrative embodiments in more detail. Throughout this application, guidance is provided by a list of examples that can be used in various combinations. In each case, the enumerated list is intended only as a representative group and should not be construed as an exclusive list. 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 can be developed in light of the overall teachings of this disclosure. The described drawings are merely illustrative and not restrictive. Attached Figure Description

[0036] 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 1 An exploded elevation view of an example of a filter element according to this disclosure is shown, wherein the filter media package includes pleated filter media. Figure 2A An elevation view of a filter element according to this disclosure is shown, the filter element including an inwardly pointing radial seal. Figure 2B An elevation view of a filter element according to this disclosure is shown, the filter element including an axial seal. Figure 3 A cross-sectional view of an example filter element according to this disclosure is shown, wherein the filter media package includes pleated filter media. Figures 4A to 4F This is a cross-sectional view of an example of a sealing carrier, which is coupled to a filter media package comprising pleated filter media. Figure 5 An exploded elevation view of an example filter element according to this disclosure is shown, wherein the filter media package includes grooved filter media. Figure 6 An elevation view of a filter element according to this disclosure is shown, wherein the filter media package comprises a wound grooved filter media. Figure 7 An elevation view of a filter element according to this disclosure is shown, wherein the filter media package comprises wound grooved filter media, and wherein the sealing device comprises an axial seal. Figure 8 An elevation view of another example of a filter element according to this disclosure is shown, wherein the filter media package comprises wound grooved filter media, and wherein the filter element includes outwardly pointing radial seals. Figures 9A to 9C A cross-sectional view of an example filter element according to this disclosure is shown, wherein the filter media package includes grooved filter media. Figures 10A to 10E This is a cross-sectional view of an example of a sealing carrier, which is coupled to a filter media package including grooved filter media. Figure 11A and Figure 11B An example of a cross-section between the circumferential surface of a filter media pack and a plane perpendicular to the longitudinal direction of the filter media pack is shown. Figure 12A and Figure 12B This is a perspective view showing two additional examples of filter media packages, where the outer peripheral surface has a convex portion. Figures 13A to 13DA method for thermally welding a seal carrier to a filter media package is shown, as further described in the examples. Figure 14 An exemplary image is shown after a pleated filter media package has been heat-welded to a sealing carrier. Figure 15A and Figure 15B An exemplary image is shown of a grooved filter media package after it has been heat-welded to a sealing carrier, wherein... Figure 15A It shows Figure 15B A detailed view of a portion; these arrows indicate the location of the grooved embedding seal carrier of the filter media package.

[0037] The accompanying drawings are neither drawn to scale nor to scale. Typically, the same reference numerals will show the same or corresponding structures in different views. Detailed Implementation

[0038] In one aspect, this disclosure describes a filter element installed in a housing of a filter system. The filter element includes a filter media package containing filter media that captures particles and impurities present in an incoming fluid flow. The fluid can be a liquid or a gas (including, for example, air). When the filter element is installed in the housing and the filter system is in operation, the filtered fluid should remain separated from the incoming unfiltered fluid. Therefore, the filter element includes a sealing device configured to separate the filtered fluid from the unfiltered fluid when the filter element is installed in the housing and the filter system is in operation. The filter element can be configured to be removed and replaced from the housing of the filter system at regular time intervals or when the filtration performance degrades below a critical threshold level.

[0039] In another aspect, this disclosure describes methods for manufacturing filter elements. In some embodiments, this disclosure describes filter elements manufactured by a production process involving a multi-material injection molding process and a thermal welding process. As further described herein, the multi-material injection molding process is used to form a sealing device comprising both a seal carrier and a seal, while the thermal welding process is used to join the seal carrier to a filter media package.

[0040] In some embodiments, a multi-material injection molding process is used to form both the seal and the seal carrier before attaching the seal carrier to the filter media package using a thermal welding process. In such embodiments, the seal, the seal carrier, and the thermal welding process must each be designed in a way that the thermal welding does not damage the seal or the filter media package.

[0041] In some embodiments, the multi-material injection molding process can be used to form the seal carrier before attaching it to the filter media package using a thermal welding process, and to form the seal after attaching the seal carrier to the filter media package. Filter element

[0042] Referring now to the accompanying drawings, in different views, the same reference numerals represent the same or corresponding structures, for example in... Figure 1 , Figure 2A , Figure 2B , Figure 5 , Figure 6 , Figure 7 ,as well as Figure 8 Examples of embodiments of a filter element 100 according to the present invention are shown in the figures. As illustrated in these figures, the filter element 100 includes filter media packages 10, 110, and a sealing device. In some embodiments, the sealing device is preferably a molded, single-structure sealing device. The sealing device is adapted to separate filtered fluid from unfiltered fluid when the filter element 100 is operatively placed in a housing.

[0043] like Figures 1 to 1As shown in Figure 0, the sealing device includes sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, and sealing elements 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e. The sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e support the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e, and as further discussed below, the seals... The carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e form the interface between the filter media packages 10, 110 and the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e. In some embodiments, the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e may be circumferential seals. As shown in the exemplary embodiments discussed herein, seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e may be outward-pointing radial seals, inward-pointing radial seals, or axial seals.

[0044] As further described herein, seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e are joined to seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e via a multi-material injection molding manufacturing process to form a molded single-structure sealing device. This molded single-structure sealing device may have visual indicators (including, for example, visible feed points or visible injection points) indicating that the sealing device is formed by the multi-material injection molding manufacturing process. In some embodiments, the seam (also referred to as weld line or knitted line) between the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e may be visible. However, the absence of a visible feed point, injection point, or seam does not necessarily indicate that the molded single-structure sealing device was not formed by a multi-material injection molding manufacturing process.

[0045] The filter element according to this disclosure is not limited to any particular filter medium. For example, the filter element according to the first aspect of this disclosure may include a filter medium package comprising grooved filter media, pleated filter media, or any other filter media suitable for filtering fluids. Grooved filter media may include wound grooved filter media or stacked grooved filter media. Although a pleated filter media package 10 is shown in the figures (see, for example, see...), the filter element according to this disclosure may also include a grooved filter media package 10. Figure 1 , Figure 3 (and Figure 4) or grooved filter media package 110 (for example, see Figure 4). Figures 5 to 1 The specific embodiments of 0) are as follows, but unless otherwise specified, the teachings concerning the filter element 100 including the pleated filter media pack 10 apply to the grooved filter media pack 110, and the teachings concerning the filter element 100 including the grooved filter media pack 110 apply to the pleated filter media pack 10.

[0046] While many of the figures presented and discussed herein specifically illustrate embodiments of filter elements for filtering gases (such as air), the filter elements described herein are not limited to filtering any particular fluid.

[0047] In some embodiments, the filter medium may include a wet-laid medium. In some embodiments, the filter medium may include a dry-formed or dry-laid medium. The filter medium may include any suitable combination of materials (including, for example, polymers, fibers, binders, and additives) selected by those skilled in the art. In an exemplary embodiment, the filter medium may include a wet-laid nonwoven filter medium primarily containing cellulose fibers. 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. In yet another exemplary embodiment, the filter medium may include a dry-laid medium containing spunbond fibers. Exemplary spunbond fibers include polyester fibers. In yet another exemplary embodiment, the filter medium may include a multilayer dry-laid medium containing synthetic fibers. As described above, each of these media may include additional binders and / or additives. Additive compounds may increase functionality, including but not limited to flame retardancy, oleophobicity, and / or hydrophobicity.

[0048] The filter media package 10 or 110 includes at least i) an outer peripheral surface 6 extending in the longitudinal direction Z, and ii) a first axial surface 7 transverse to the longitudinal direction. Figures 1 to 1 In 0, the longitudinal direction is schematically indicated as the longitudinal axis Z. For example... Figure 3 and Figures 9A to 9C As further illustrated, the first axial surface 7 can be the side of the filter media package that is transverse to the longitudinal direction defined by the longitudinal axis Z. This first axial surface 7 can be the inlet side or the outlet side of the fluid. Figure 3 and Figures 9A to 9C In the illustrated embodiment, two arrows indicate the direction of fluid flow in and out. In other embodiments, the fluid flow indicated in these figures may be reversed, depending on how the filter elements are mounted in the housing of the filter system.

[0049] The filter element 100 may preferably be configured to be housed within the housing of the filter system. When the filter element 100 is operatively housed within the housing, the mating and / or interaction between the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e of the filter element 100 and the housing prevents leakage during the separation of filtered fluid from unfiltered fluid through the filter element 100.

[0050] For example Figure 1 and Figure 5In the illustrated embodiment, the outer peripheral surface 6 extends along the longitudinal direction Z from the first axial surface 7 to a second axial surface 8 opposite to the first axial surface 7. In these examples, the first axial surface 7 and the second axial surface 8 correspond to the fluid inlet and fluid outlet, respectively. This depends on the specific shape of the filter media package, and as... Figure 9C As illustrated schematically, the filter media package does not always include a second axial surface parallel to the first axial surface. In this example, the first axial surface 7 is the planar outlet side of the filtered fluid, while the unfiltered fluid enters via a non-planar side (e.g., a curved side) of the filter media package 10.

[0051] Seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e are made of at least a first material, while seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are made of at least a second material. Typically, the second material differs from the first material. Examples of various materials that can be used for seals and seal carriers are further discussed below.

[0052] when Figure 1 When the filter element 100 shown is placed in the housing of the filter system, fluid flows through the filter medium in a direction transverse to the longitudinal direction Z. For example, as Figure 3 As indicated by the arrows, the fluid to be filtered crosses the outer peripheral surface 6 of the filter media package 10 toward the hollow filter body formed of the pleated media, and the filtered fluid exits the filter media package 10 through a central opening in the first axial surface 7. This central opening in the first axial surface 7 corresponds to an opening at the first end of the hollow filter body. Therefore, these types of embodiments may include an open end cap (including or constituted by a sealing device) and a closed end cap 70 at the first and second ends of the hollow filter body formed of the pleated filter media, respectively.

[0053] The outer peripheral surface 6 of the filter media package can have various shapes, and this disclosure is not limited to any particular shape; in fact, the cross-section between the outer peripheral surface 6 of the filter media package and a plane perpendicular to the longitudinal axis Z can, for example, have the following shapes: circular, oval, elliptical, or with rounded corners (e.g., Figure 11A (As shown), oblong, rectangular, or any other shape suitable for the filter media package. Figure 8 The image shows an elevation view of an exemplary filter element 100, wherein the cross-section of the outer peripheral surface 6 and the plane perpendicular to the longitudinal direction Z has a rounded shape.

[0054] In some exemplary embodiments, the cross section between the outer peripheral surface 6 of the filter media package 10, 110 and the plane perpendicular to the longitudinal direction Z forms an outer peripheral periphery having one or more convex portions. Figure 11B The diagram illustrates two specific shapes of the outer peripheral surface 6 of filter media packages 10 and 110. The upper diagram shows a shape with peripheral convex portions, while the lower diagram shows a peanut-shaped shape with two peripheral convex portions. Figure 12A and Figure 12B Figure 12 shows a perspective view of a filter media package having an outer peripheral surface 6 with a convex portion. Although a grooved filter media package 110 is indicated in Figure 12, this configuration may also include a pleated filter media package 10.

[0055] exist Figures 5 to 8 In the illustrated embodiment, the filter media package 110 also has a second axial surface 8 opposite to the first axial surface 7. This type of configuration is sometimes referred to as a "straight-through flow configuration" or a "direct-flow configuration." Typically, in this context, the filter media package 110 of the filter element 100 includes an inlet surface that allows unfiltered fluid to flow into the filter media package 110, and an opposite outlet surface that allows filtered fluid to exit the filter media package 110. Therefore, the flow into and out of the filter media package is generally along the same straight-through direction.

[0056] In example Figures 5 to 8 In the illustrated embodiment, the first axial surface 7 and the second axial surface 8 of the filter media package 110 correspond to the fluid inlet surface and the fluid outlet surface, or vice versa. Typically, the fluid inlet surface and the fluid outlet surface are planar, with the two surfaces parallel to each other. However, variations of this configuration (e.g., non-planar surfaces) are possible.

[0057] exist Figures 9A to 9C The image shows a cross-sectional view of an exemplary embodiment of the filter element 100, wherein the filter media package 110 includes grooved filter media. Two arrows indicate exemplary flow directions of fluid into and out of the filter media package 110. Figure 9C The following example is shown: the first axial surface 7 is a planar side, but there is no second axial surface with an opposite plane.

[0058] In some embodiments, the outer surface of the outer layer of the wound grooved filter media may form the outer peripheral surface 6 of the filter media package 110. In other words, a portion of the surface sheet of the grooved filter material discussed above forms the outer peripheral surface 6.

[0059] In some embodiments, the width of the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e is preferably kept as small as possible, such that the circumferential edges of the first axial surface 7 that connect to the first axial sides 442a-442f, 1042a-1042e are as small as possible. In fact, since the axial surface 7 is the fluid inlet or outlet, the coverage of the first axial sides 442a-442f, 1042a-1042e of the sealing carriers by the inlet or outlet can affect fluid flow and / or limit the filtration capacity of the filter media packages 10, 110.

[0060] In example Figures 5 to 8 In the illustrated embodiment, the filter element 100 includes a grooved filter medium formed from layers of grooved filter material. Each layer of grooved filter material includes inlet grooves and outlet grooves, which are substantially oriented parallel to the longitudinal direction Z of the filter medium package. The groove inlet of the inlet groove or the groove outlet of the outlet groove of at least one outer layer of the grooved filter material layer is blocked by the first axial sides 1042a-1042e of the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e. In some embodiments, the groove inlet of the inlet groove or the groove outlet of the outlet groove of at least two outer layers of the grooved filter material layer is blocked by the first axial sides 1042a-1042e of the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e. If the first axial surface is an inlet surface for receiving unfiltered fluid, the inlet of the inlet groove is blocked by the first axial sides 1042a-1042e of the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e. On the other hand, if the first axial surface 7 is an outlet surface for discharging filtered fluid, the outlet of the outlet groove is blocked by the first axial sides 1042a-1042e of the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e.

[0061] The filter element 100 is characterized by using two different manufacturing processes for manufacturing the filter element 100: more specifically, a manufacturing process for connecting seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e to seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, and a manufacturing process for connecting seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e to filter media packages 10, 110. As further described herein, a multi-material injection molding process is used to attach seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e to seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e to provide molded single-structure sealing devices. As further described herein, a thermal welding process is used to attach seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e to filter media packages 10, 110.

[0062] In some embodiments, such as Figure 5 and Figure 9B As shown, the support frame 60 can be coupled to the second axial surface 8. When the filter media packs 10 and 110 are grooved filter media packs 110, the support frame 60 can be configured to prevent the winding layers of the filter media pack 110 from moving in the longitudinal direction Z. Typically, the support frame 60 includes ribs 62 that block movement of the winding layers in the longitudinal direction. As further described herein, a second thermal welding process can be used to join the support frame 60 to the filter media packs 10 and 110.

[0063] In some embodiments, such as Figure 6 and Figure 9A As shown, the sealing carriers 640, 940 may include one or more ribs 45 located in a plane substantially perpendicular to the longitudinal direction Z. When the filter media packs 10, 110 are grooved filter media packs 110, the one or more ribs 45 may be arranged to engage with the first axial surface 7 to prevent movement of the wound layer along the longitudinal direction Z. Advantageously, for these types of embodiments, no additional support frame is required to engage with the second axial surface 8 of the filter media packs 10, 110, as... Figure 5 and Figure 9B The situation is as shown in the embodiment.

[0064] In example Figure 5 and Figure 6 In the illustrated embodiment, the sealing carriers 540 and 640 include a radially circumferential side 41 extending in the longitudinal direction Z. Seals 520 and 620 surround this radially circumferential side 41 of the sealing carriers 540 and 640 to form outwardly pointing radial seals. In an exemplary embodiment, the seals 520 and 620 may be formed around the radially circumferential side 41 of the sealing carriers 540 and 640.

[0065] In some embodiments, such as Figure 7 and Figure 10E As shown, seals 720 and 1020e are axial seals. To form an axial seal, as shown in these figures, seals 720 and 1020e can be coupled to opposite circumferential boundaries 44 of the seal carrier. Figure 10E As schematically shown, the opposite circumferential boundaries 44 of the sealing carriers 740 and 1040e are typically the following boundary: this boundary is parallel to the circumferential boundary 1042e of the first axial surface 7 of the sealing carrier, which is joined to the filter media package 10 by thermal welding. In such a way... Figure 10E In the embodiments shown, the circumferential boundary 1042e and the opposite circumferential boundary 44 correspond, for example, to two parallel rings.

[0066] Figures 4A to 4E and Figures 10A to 10ESeveral different embodiments of the sealing carriers 440a-440f, 1040a-1040e connected to the filter media packages 10, 110 are schematically shown. In the cross-sectional view showing only a partial view of the filter element 100, the sealing carriers 440a-440f, 1040a-1040e are indicated by shaded areas, and the filter media packages 10, 110 are indicated by dashed lines. The sealing carriers 440a-440f, 1040a-1040e include multiple sides, which may differ in the various embodiments. As shown in these figures, the filter element 100 according to the first aspect of this disclosure is characterized in that the sealing carriers 440a-440f, 1040a-1040e include at least a first axial side 442a-442f, 1042a-1042e, which is axially connected to a first axial surface 7 of the filter media package 10. The first axial sides 442a-442f, 1042a-1042e can be joined to at least the circumferential portion of the first axial surface 7 of the filter media package via a thermal welding manufacturing process. In other words, the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 440a-440f, 1040a-1040e can be connection surfaces that are generally substantially parallel to the first axial surface 7 of the filter media package. The degree of connection between the circumferential portion of the axial surface 7 of the filter media package and the first axial sides 442a-442f, 1042a-1042e of the sealing carriers can depend on the type of filter media packages 10, 110. For example, a filter media package 10 including pleated media (e.g., Figure 1 , Figure 3 (as shown in Figure 4) and a filter media package 110 including grooved media (e.g., Figure 5 and Figures 8 to 1 0) Different circumferential portions of the first axial surfaces 7 of the filter media packages 10, 110, covered by the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. Similarly, only a portion of the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 440a-440f, 1040a-1040e can be the connecting surface; that is, only a portion of the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 440a-440f, 1040a-1040e can be connected to the first axial surface 7 of the filter media package.

[0067] In some embodiments, such as Figures 10A to 10CAs shown, the seal carriers 1040a-1040e, indicated by the shaded area, include a tubular extension 43 extending in the longitudinal direction Z, thereby forming an inlet channel for receiving unfiltered fluid. In these embodiments, the seals 1020a-1020e are coupled to the outer circumferential surface of the tubular extension 43 to form an outwardly pointing radial seal. The coupling of the seals 1020a-1020e to the outer circumferential surface of the tubular extension 43 can preferably be achieved by a multi-material injection molding manufacturing process to obtain a molded single-structure sealing device. Examples of embodiments with pleated filter media

[0068] In some embodiments, the filter element 100 includes a filter media package 10 having a pleated filter media.

[0069] exist Figure 1 The image shows an exploded view of an embodiment of a filter element 100 according to the first aspect of this disclosure. The filter element 100 shown includes a filter media package 10 comprising a pleated filter media having multiple pleats arranged in a closed loop (annular shape in this example) to form a hollow filter body extending in the longitudinal direction Z. Therefore, the hollow filter body has a first opening and a second opening at a first end and a second end, respectively. These pleats are formed, for example, by folding filter paper. Figure 1 In the illustrated embodiment, the hollow filter body is a hollow cylindrical body. Multiple external tips of the pleats form the outer circumferential periphery of the hollow filter body. In this embodiment, the outer circumferential surface 6 of the filter media package 10 corresponds to this circumferential periphery formed by the external tips of the pleats, and the first axial surface 7 and the second axial surface 8 of the filter media package 10 correspond to the first end and the second end of the hollow filter body, respectively.

[0070] exist Figure 1 and Figure 4A In the illustrated embodiment, the sealing carriers 140 and 440a only provide support for the seals 120 and 420a, but the first axial side 442a of the sealing carrier also provides an open end cap for the first end of the hollow filter body. In fact, by thermally welding the first axial side 442a of the sealing carriers 140 and 420a to one end of the hollow filter body, the pleats at the first end of the filter media package 10 are closed. Figure 3 As schematically shown, the closed end cap 70 can be further connected to the second end of the hollow filter body, thereby not only sealing the pleats of the filter media pack 10 at the second end, but also completely sealing the second opening at the second end of the hollow filter body, so that the filtered fluid can only leave the filter element 100 through the first opening at the first end of the hollow filter body.

[0071] In some embodiments, including when the pleated media forms the hollow filter body, for example... Figure 1 and Figure 3 As schematically shown, the filter element 100 includes a closed end cap 70. The closed end cap 70 can be attached to the second axial face 8 of the filter media package 10 via a second thermal welding manufacturing process. In addition to using thermal welding to attach the sealing device to the filter media package 10, thermal welding is also used to attach the closed end cap 70 to the filter media package 10, which can accelerate the entire manufacturing process. By using two thermal welding manufacturing processes, no additional non-thermal welding manufacturing processes, such as molding or gluing (which may require additional manufacturing equipment or curing time), are needed to attach the filter media package 10 of the filter element 100, which includes the closed end cap 70.

[0072] In other embodiments where the filter media package 10 includes a pleated filter media, an outer liner may be provided around the hollow filter body formed by the pleated filter media, and in these embodiments, the outer liner forms the outer peripheral surface 6 of the filter media package 10.

[0073] exist Figures 4A to 4E The figure shows a cross-sectional view of an example sealing device used in conjunction with a filter media package 10, which includes a pleated filter media. Reference numeral "W" in the figure indicates the region where the first axial sides 442a-442e of the sealing carriers 440a-440e are joined to the first axial surface 7 of the filter media package 10 by thermal welding. As discussed above, in embodiments including the pleated filter media package 10, the first axial surface 7 may correspond to the first end of the hollow filter body formed by the pleated filter media.

[0074] Figure 1 and Figure 4A The exemplary embodiment shown illustrates a filter element in which the sealing carriers 140, 440a, in addition to the first axial side 442a, also include a radial circumferential side 41, which encloses or at least partially encloses the outer circumferential surface 6 of the filter media package 10. In some embodiments, such as Figure 1 and Figure 4A As shown, seals 120 and 420a can surround the radial circumferential side 41 of seal carriers 140 and 440a to form outward-pointing radial seals; that is, the sealing surfaces of seals 120 and 420a face outwards. Seals 120 and 420a can preferably be connected to the radial circumferential side 41 of seal carriers 140 and 440a by a multi-material injection molding manufacturing process to form a molded single-structure sealing device.

[0075] exist Figure 4FThe image shows a cross-sectional view of an embodiment in which the seal 420 surrounds the radial circumferential side 41 of the seal carrier 440f to form an outwardly pointing radial seal. In this embodiment, as... Figure 4F As shown schematically, the seal carrier 440f has a T-shaped cross-section with the plane including the longitudinal axis Z.

[0076] In other embodiments, such as Figure 2B and Figure 4E As shown, the seals 220b and 420e of the seal carriers 240 and 440e form axial seals. In fact, in these embodiments, the seal carriers 240 and 440e include a second axial side 44 opposite to the first axial side 442e, which is connected to the first axial surface 7 of the filter media package 10. The seals 220b and 420e are connected to the second axial side 44 via a multi-material injection molding manufacturing process.

[0077] In some embodiments, the radial circumferential side 41 of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e completely encloses the outer circumferential surface 6 of the filter media package 10, thereby forming a protective shell around the filter media package 10.

[0078] exist Figure 4B The image shows a cross-sectional view of a portion of an embodiment of the filter element 100, wherein the sealing carrier 440b does not include the radially circumferential side circumferentially surrounding the outer circumferential surface 6 of the filter media package 10. Indeed, in this embodiment, the sealing carrier 440b includes a tubular extension 43 in addition to the first axial side 442b, which is coaxial with the central opening at the first end of the hollow filter body. Therefore, the tubular extension 43 forms an exit channel for filtered fluid to exit from the interior of the hollow filter body. Figure 4B As schematically shown, in this example, seal 420b is coupled to the inner circumferential surface of tubular extension 43. In this way, an inwardly pointing radial seal is formed. The coupling of seal 420b to the inner circumferential surface of tubular extension 43 can preferably be achieved by a multi-material injection molding process to obtain a molded single-structure sealing device.

[0079] exist Figure 4C In the middle, a similar example is shown. Figure 4B In one embodiment of the embodiment, the tubular extension 43 of the sealing carrier extends inside the hollow filter body, rather than as... Figure 4B In the embodiment shown, the hollow filter body extends to the outside.

[0080] In an alternative embodiment, the tubular extension 43 of the sealing carrier 440a-440f can form an inlet channel for bringing unfiltered fluid into the interior of the hollow filter body so that the fluid can then traverse the pleated media.

[0081] In having such Figure 4B In another embodiment of the shown seal carrier 440b, the seal 420b may also be coupled to the outer peripheral surface of the tubular extension 43 to form an outwardly pointing radial seal.

[0082] exist Figure 2A and Figure 4D Another embodiment is shown, in which seals 220a and 420d form inwardly pointing radial seals. In this embodiment, seal carriers 240 and 440d have a central opening configured for either allowing filtered fluid to exit or for receiving unfiltered fluid. In this embodiment, seals 220a and 420d can be coupled to the inner circumferential surface of the central opening of the seal carrier via a multi-component manufacturing process, thereby forming inwardly pointing radial seals.

[0083] In some embodiments, the filter medium may be embedded in the sealing carriers 140, 240, 340, 440a-440f for at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm, and / or the material of the sealing carriers 140, 240, 340, 440a-440f may be impregnated into the pleats of the filter medium package 10 for at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm. Examples of embodiments having grooved filter media

[0084] In some embodiments, filter element 100 includes filter media package 110 having grooved filter media (also referred to as Z-shaped filter media).

[0085] See the attached diagram. Figure 5 The image shows an exploded view of an embodiment of a filter element 100, which includes a filter media package 110 having a grooved filter medium. Figure 5 In the embodiment shown, the outer surface of the grooved filter medium forms the outer peripheral surface 6 of the filter medium package 110. Figures 6 to 8 The image shows elevation views of several different embodiments of filter elements, wherein the filter media package includes wound grooved filter media.

[0086] In some embodiments, the grooved filter media may be formed from grooved filter material winding layers. Each of these winding layers includes inlet grooves and outlet grooves oriented substantially parallel to the longitudinal direction Z. The groove inlet of at least the outermost layer of the winding layer or the groove outlet of the outlet groove is blocked at the first axial side 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e where they are coupled to the first axial surface 7 of the filter media package 110. In some embodiments, the groove inlet of the inlet groove or the groove outlet of the outlet groove of at least two outer layers of the winding layer is blocked at the first axial side 442a-442f, 1042a-1042e of the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e where they are connected to the first axial surface 7 of the filter media package 110.

[0087] Figures 9A to 9C The figures further illustrate example cross-sectional views of filter element configurations including grooved filter media. Two arrows in each figure indicate exemplary flow directions of the fluid. Sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e can be coupled to filter media package 110 in any suitable configuration. Figures 10A to 10C Several different examples of sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, and 1040a-1040e connected to a grooved filter media package 110 are shown. In these cross-sectional views, the slanted and dashed areas represent sealing carriers 1040a-1040e and filter media package 110, respectively. The reference numeral "W" indicates the heat-welded area.

[0088] Exemplary grooved filter media and filter media packages including grooved filter media (including rolled-up 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. One type of Z-shaped filter media uses two specific media components joined together to form a media structure. These two components are a grooved (typically corrugated) media sheet and a surface media sheet. The surface media sheet is typically non-corrugated. The grooved media sheet and the surface media sheet can be used to define a media having a set of parallel inlet grooves and a set of parallel outlet grooves. After the grooved sheet and the surface sheet are secured together, a grooved filter material layer is obtained, and the grooved filter material includes an inlet groove set and an outlet groove set.

[0089] A filter body is formed by winding layers of grooved filter media, the filter body having an outer circumferential surface formed by the outer layer of the wound grooved filter media, and having an axial inlet face for receiving unfiltered fluid and an axial outlet face for the exit of filtered fluid. The grooves in each wound layer are oriented substantially parallel to the longitudinal direction of the filter media package. As further described in U.S. Patent Nos. 6,350,291 and 7,396,376, with respect to Z-shaped filter media, "wound" refers to a filter media package 110 formed by winding strips of grooved filter media to form a filter media package 110. Such wound media can be made in a wide variety of shapes, including: round or cylindrical; oval, such as a racetrack; square; or rectangular with rounded corners; and wound media can even be configured in a conical or similar arrangement. Examples of selected shapes are described in U.S. Patent No. 6,350,291.

[0090] Alternatively or concurrently, all or part of the grooved filter media can be stacked to create a filter media package. Exemplary stacked grooved filter media devices are described in U.S. Patent Nos. 5,820,646 and 8,292,983. For example, when the filter media package comprises stacked grooved filter media, the outer circumferential surface of the filter body may be rectangular.

[0091] In some embodiments, the outer peripheral surface of the filter body forms the outer peripheral surface 6 of the filter media package 110. In other embodiments, a protective layer may be placed around the circumferential surface of the filter body, such that the outer surface of the protective layer forms the outer peripheral surface 6 of the filter media package 110. Figures 5 to 8 In the illustrated embodiment, the axial inlet and axial outlet of the filter body correspond to the first axial surface 7 and the second axial surface 8 of the filter media package 110, respectively.

[0092] Each grooved filter media layer includes a set of inlet grooves and a set of outlet grooves. The inlet grooves are 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 outlet grooves are 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.

[0093] exist Figure 5 and Figure 10BIn the illustrated embodiment, the circumferential portion of the first axial surface 7 of the filter media package 110 (the first axial side 1042b of which is thermally welded to the sealing carriers 540, 1040b) corresponds to the circumferential edge portion of the axial surface 7 of the filter media package 110. Typically, this circumferential edge portion includes at least the axial side of the outer layer of the grooved filter media. In other words, at least the outer layer of the wound filter media cannot be used for filtration purposes. In some embodiments, not only the outer layer of the wound filter media but also one or more successive layers may be sacrificed to allow a more fixed axial connection between the first axial side 1042b of the sealing carrier and the first axial surface 7 of the filter media package.

[0094] See further Figure 5 As shown in Figure 10, in some embodiments, the first axial sides 1042a-1042e of the sealing carriers 540, 1040a-1040e can be configured as axial circumferential boundaries. In fact, this portion of the first axial surface 7 of the filter media package 110 that connects to the first axial sides 1042a-1042e of the sealing carriers 540 can be kept as small as possible while providing a fixed connection to limit the reduction of fluid flow through the first axial surface 7 of the filter media package 110.

[0095] Due to the axial connection between the sealing carriers 540, 1040a-1040e and the filter media package 110, the groove inlet of the inlet groove or the groove outlet of the outlet groove of at least the outermost layer of the wound layer is blocked by the first axial side 1042a-1042e of the sealing carrier. Preferably, in order to achieve a fixed connection between the sealing carriers 540, 1040a-1040e and the filter media package 110, the groove inlet of the inlet groove or the groove outlet of the outlet groove of at least two outermost layers of the wound layer is blocked by the first axial side 1042a-1042e of the sealing carriers 540, 1040a-1040e. On the other hand, the number of successive layers blocked by the first axial side 1042a-1042e of the sealing carriers 540, 1040a-1040e should also be limited to ensure optimal operation of the filter element 100. When the filter media package 110 includes a wound grooved media layer, the number of successive layers blocked by the first axial sides 1042a-1042e of the sealing carriers 540, 1040a-1040e should be limited to less than ten layers, preferably less than eight layers, and more preferably less than six layers.

[0096] For example, Figure 6 and Figure 10AThe illustrated embodiment shows a filter element 100, wherein the sealing carriers 640, 1040a, in addition to a first axial side 1042a, also include a radially circumferential side 41 that circumferentially surrounds the outer circumferential surface 6 of the filter media package 110. In these embodiments, the seals 620, 1020a surround the radially circumferential side 41 of the sealing carriers 640, 1040a to form an outwardly pointing radial seal.

[0097] In other embodiments, such as Figure 7 and Figure 10E As shown, seals 720 and 1020e form an axial seal. Seals 720 and 1020e can be coupled to a second axial side 44 connected to the first axial side 1042e via a multi-material injection molding process to form a molded single-structure sealing device, as further described herein. Figure 10E As schematically shown, the second axial side 44 of the sealing carrier is typically the side parallel to the first axial side 1042e of the sealing carrier 1040e.

[0098] exist Figure 10B and Figure 10C The diagram shows a cross-sectional view of a sealing device, wherein sealing carriers 1040b and 1040c include tubular extensions 43 extending in the longitudinal direction Z, thereby forming inlet channels for receiving unfiltered fluid. In such an embodiment, seals 1020b and 1020c can be coupled to the outer peripheral surface of the tubular extensions 43 to form outwardly pointing radial seals. The coupling of seals 1020b and 1020c to the outer peripheral surface of the tubular extensions 43 can be obtained by a multi-material injection molding manufacturing process to obtain a sealing device, i.e., a molded single-structure sealing device.

[0099] exist Figure 10A The following embodiment is shown: wherein the sealing carrier includes a tubular extension 43 and a radially circumferential side 41 that circumferentially surrounds the outer circumferential surface 6 of the filter media package 110. The radially circumferential side 41 can serve as a protective surface for the filter media package 110.

[0100] exist Figure 10D The following embodiment is shown, wherein the seal 1020d forms an inwardly pointing radial seal. In fact, in this embodiment, the seal carrier 1040d has, for example, a ring shape, and the seal is positioned on the inner circumferential surface of the annular seal carrier 1040d.

[0101] In some embodiments, including wound grooved media, such as Figure 5As shown, the filter element 100 includes a support frame 60 coupled to a second axial surface 8 of the filter media package 10. The support frame 60 can be configured to prevent movement of the wound layers in a direction parallel to the longitudinal direction Z. In fact, during operation, these layers may begin to move in the longitudinal direction due to fluid flow. Figure 5 As shown, the support frame 60 includes, for example, a circumferential boundary 61 and ribs 62. Ribs 62 can be positioned such that the wound layer is blocked from moving along the longitudinal direction of the filter media package.

[0102] In some embodiments, the support frame 60 can be coupled to the second axial surface 8 of the filter media package 110 via a second thermal welding manufacturing process, as further described herein. By using two thermal welding manufacturing processes, no additional non-thermal welding manufacturing processes, such as molding or gluing (which may require additional manufacturing equipment or curing time), are required to join the filter media package 110 of the filter element 100, which includes the support frame 60.

[0103] See Figure 6 In some embodiments, the sealing carrier 640 may include one or more ribs 45. Figure 6 The illustrated embodiment includes a rib 45. If included, this one or more ribs 45 may be arranged to engage with a first axial surface 7 of the filter media package 110 to prevent movement of the wound layer in the longitudinal direction Z. The engagement of this one or more ribs 45 with the first axial surface 7 of the filter media package 110 may preferably be achieved by thermal welding, as further discussed herein.

[0104] and Figure 5 Compared to the embodiments shown, Figure 6 One advantage of the illustrated embodiment is that no additional support frame 60 is required to connect to the second axial surface 8 of the filter media package 110. It is desirable not to be bound by theory and to include one or more ribs 45 as an integral part of the seal carrier 640 to prevent media expansion and contraction. In the present invention, expansion and contraction are typically prevented by including a support frame 60 connected to the second axial surface 8. Therefore, if the one or more ribs 45 prevent media expansion and contraction without the need for an additional support frame, fewer plastic parts can be included, making the filter element 10 cheaper and easier to manufacture. Materials for seals, seal carriers, and end caps

[0105] The sealing device includes seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. Seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e are made of at least a first material, while seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are made of at least a second material. Typically, the second material is different from the first material. In some embodiments, the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e, and / or the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e may be made of more than one material.

[0106] Because the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e prevent leakage during the separation of filtered and unfiltered fluids through the filter element 100 when the filter element 100 is operatively placed in the housing, and because the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e must support the seal and connect it to the filter media packages 10, 110, the seals are typically formed of a softer material, examples of which are provided herein, and the seal carriers are typically formed of a harder material. Examples of each material are further described herein.

[0107] If the filter element 100 includes a closed end cap 70, the closed end cap may be made of at least a third material. In some embodiments, the closed end cap 70 may be made of more than one material. However, in some embodiments, the closed end cap may preferably be made of one or more materials that are the same as the sealing carrier. It is desirable to use the same material for both the sealing carrier and the closed end cap to improve the manufacturing efficiency of the filter element 100.

[0108] In some embodiments, the transition temperature of the first material (or combination of materials) used to form the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e can be higher than the transition temperature of the second material (or combination of materials) used to form the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. In this way, when heat is applied to the sealing device during the thermal welding manufacturing process (as further described herein) and the processing temperature is higher than the transition temperature of the second material, the seal is less likely to deform. The transition temperature difference between the material of the seal and the material of the seal 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.

[0109] 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 material's "transformation temperature" is the midpoint temperature (T0). mg The 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 of ) because T g In reality, it refers to the temperature range. Any suitable instrument can be used to perform DSC; however, in the exemplary embodiment, a DSC3+ (Mettler Toledo GmbH, Schwezenbach, Switzerland) with an FRS 6+ sensor can be used.

[0110] 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 material's "transformation temperature" is the final temperature at which the elastic modulus (G') and loss modulus (G") intersect, where 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 of tanδ can be used to characterize a system transitioning to the melt flow region. In this paper, G' and G" are determined according to ASTM D4440-15, entitled "Standard Test Method for Plastics: Dynamic Mechanical Properties MeltRheology", using temperature-sweep dynamic mechanical analysis (DMA), as further described in ASTM D4065-12, entitled "Standard Practice for Plastics: Dynamic Mechanical Properties: Determination and Report of Procedures", using a mechanical spectrometer to measure forced constant amplitude fixed frequency shear oscillations. Any suitable dynamic mechanical analyzer can be used; however, in the exemplary embodiment, the Q800 (TA Instruments, New Castle, DE) can be used.

[0111] In some embodiments, the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e are made of at least a first material, which includes any one of the following non-limiting material lists: 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.

[0112] In some embodiments, the material used to form the seal may be selected based on the desired Shore hardness of the resulting seal. In some embodiments, the seal has a Shore A value of 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. In some embodiments, the seal has a Shore A value as high as 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90. In an exemplary embodiment, the seal has a Shore A value in the range of 30 to 90. In another exemplary embodiment, the seal has a Shore A value in the range of 40 to 70. In yet another exemplary embodiment, the seal has a Shore A value in the range of 50 to 70. In some embodiments, the Shore A value is determined as described in ASTM D2240-15e1. The Shore A value of the seal 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).

[0113] Compared to U.S. Patent Publication No. 2009 / 0320424 (which teaches the use of soft urethane foam for a seal forming a butt joint between a filter element and a filter housing to prevent unfiltered fluid from passing through the fluid housing), the seal disclosed herein is formed using a multi-material injection molding manufacturing process, as further described herein. Furthermore, U.S. Patent Publication No. 2009 / 0320424 teaches that the seal has a Shore A value of less than 25. Additionally, advantages in both manufacturing and use are gained when the seal comprises a thermoplastic polymer as described herein, rather than a urethane seal as described in U.S. Patent Publication No. 2009 / 0320424. The seal formed from a thermoplastic polymer using a multi-material injection molding process does not require curing, thus improving the efficiency of the manufacturing process, compared to urethane seals that must be cured. Furthermore, compared to urethane seals (which are typically stable only up to about 80°C), seals formed by multi-material injection molding processes 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 100 is exposed to thermal conditions. For example, some filter elements 100 installed in engine compartments may be exposed to temperatures above 80°C (e.g., up to 90°C) during use.

[0114] 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.

[0115] 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).

[0116] 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.

[0117] 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

[0118] 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-

[0119] 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

[0120] 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

[0121] 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 (Potakette, Rhode Island).

[0122] Other commercially available TPEs that may be suitable in some embodiments include BERGAFLEX. TM .

[0123] In some embodiments, the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, or a portion thereof, are made of at least a second material. The second material may preferably be a thermoplastic. In some embodiments, the second material may include any one of the following non-limiting material lists: 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. In some embodiments, including, for example, when the second material includes PP, the sealing carrier may further include glass fiber or minerals, or combinations thereof. Exemplary polyamides include polyamide 6 (PA6), polyamide 66 (PA66), etc. Additionally or alternatively, the second material may include any other material suitable for thermal welding and multi-material injection molding.

[0124] In some embodiments, the entire sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e includes a second material; in other embodiments, only a portion of the sealing carrier includes the second material. For example, in some embodiments, the first axial sides 442a-442f, 1042a-1042e of the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e may include the second material, but other portions of the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e may include one or more other injection molding materials. In another example, in some embodiments, the first axial side 442a-442f, 1042a-1042e portions of the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e intended to be attached to the filter media packages 10, 110 may include a second material, but other portions of the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e may include one or more other injection molding materials.

[0125] In embodiments where the sealing carrier comprises polypropylene, the sealing carrier may comprise a random copolymer of polypropylene, including, for example... QR 50AV (Dukerol Petrochemicals, Netherlands) or QR 76AV (Dukerol Petrochemicals, Netherlands); atactic polypropylene containing multiphase copolymer additives, including, for example... CL 50E (Carmel Olefins Ltd., Israel); P homopolymer (Laurent Engineering Plastics GmbH, Germany).

[0126] In some embodiments, the material or combination of materials used to form the sealing carrier may be selected based on the desired Shore hardness of the resulting sealing carrier.

[0127] In some embodiments, the Shore A value of the seal carrier is at least 50, at least 60, at least 70, at least 80, or at least 90. In some embodiments, the Shore A value of the seal carrier is as high as 80, as high as 90, as high as 95, or as high as 100. In an exemplary embodiment, the Shore A value of the seal carrier is in the range of 60 to 100. In another exemplary embodiment, the Shore A value of the seal carrier is in the range of 70 to 100. In yet another exemplary embodiment, the Shore A value of the seal carrier is in the range of 80 to 100. 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).

[0128] In some embodiments, the Shore D value of the seal carrier is at least 10, at least 15, at least 20, at least 25, or at least 30. In some embodiments, the Shore D value of the seal carrier is as high as 80, 90, 95, or 100. In an exemplary embodiment, the Shore D value of the seal carrier is in the range of 15 to 100. In another exemplary embodiment, the Shore D value of the seal carrier is in the range of 30 to 100. In some embodiments, the Shore D value of the seal carrier is determined as described in ASTM D2240-15e1, entitled "Standard Test Method For Rubber Property—Durometer Hardness". The Shore D 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).

[0129] In some embodiments, as described above, the seal carrier may include one or more ribs 45. If included, the one or more ribs 45 may be formed of at least a portion of the seal carrier being the same material or combination of materials.

[0130] During the manufacture of the filter elements, the first axial sides 442a-442f and 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are heated and cooled twice, first as part of a multi-material injection molding manufacturing process and then during a thermal welding manufacturing process. Those skilled in the art can select materials or combinations of materials for the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, and more precisely select materials for the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, because they can withstand heating and cooling without degradation.

[0131] In some embodiments, the closed end cap 70 or support frame 60 located on the second axial surface 8 of the filter media package 10, 110 is made of at least a third material. The third material may preferably be a thermoplastic. As described above, in some embodiments, the third material may preferably be the same as the second material and / or the same as the material used for the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e or comprising a portion of the second material. When the material used for the closure end cap 70 or the support frame 60 is the same as the material used for the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e or the portion attached to the filter media package 10, 110, a similar thermal welding manufacturing process can be used to attach both the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e or a portion thereof and the closure end cap 70 or the support frame 60.

[0132] In some embodiments, the third material may include any one of the following non-limiting material lists: 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. In some embodiments, when the second material includes PP, the seal carrier may further include glass fiber or minerals, or combinations thereof. Exemplary polyamides include polyamide 6 (PA6), polyamide 66 (PA66), etc. Additionally or alternatively, the second material may include any other material suitable for thermal welding and multi-material injection molding.

[0133] In one exemplary embodiment, the closure end cap 70 or the support frame 60 may include polypropylene. Exemplary polypropylene-containing polymers include, for example... QR 50AV (Dukerol Petrochemicals, Netherlands) or QR 76AV (Dukerol Petrochemicals, Netherlands) CL 50E (Carmel Olefins Ltd., Israel), and P homopolymer (Laurent Engineering Plastics GmbH, Germany).

[0134] In some embodiments, the material used to form the closed end cap 70 or the support frame 60 is selected based on the desired Shore hardness of the resulting closed end cap 70 or support frame 60.

[0135] In some embodiments, the Shore A value of the closed end cap 70 or the support frame 60 is at least 50, at least 60, at least 70, at least 80, or at least 90. In some embodiments, the Shore A value of the closed end cap 70 or the support frame 60 is as high as 80, as high as 90, as high as 95, or as high as 100. In an exemplary embodiment, the Shore A value of the closed end cap 70 or the support frame 60 is in the range of 60 to 100. In another exemplary embodiment, the Shore A value of the closed end cap 70 or the support frame 60 is in the range of 70 to 100. In yet another exemplary embodiment, the Shore A value of the closed end cap 70 or the support frame 60 is in the range of 80 to 100. 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 closed end cap 70 or the support frame 60 is preferably determined in the fully formed filter element (i.e., after the closed end cap is attached to the filter media package).

[0136] In some embodiments, the Shore D value of the closure end cap 70 or support frame 60 is at least 10, at least 15, at least 20, at least 25, or at least 30. In some embodiments, the Shore D value of the closure end cap 70 or support frame 60 is as high as 80, 90, 95, or 100. In an exemplary embodiment, the Shore D value of the closure end cap 70 or support frame 60 is in the range of 15 to 100. In another exemplary embodiment, the Shore D value of the closure end cap 70 or support frame 60 is in the range of 30 to 100. In some embodiments, the Shore D value is determined as described in ASTM D2240-15e1, entitled "Standard Test Method For Rubber Property—Durometer Hardness". The Shore D value of the closure end cap 70 or support frame 60 is preferably determined in the fully formed filter element (i.e., after the closure end cap is attached to the filter media pack). Method for manufacturing filter elements

[0137] This disclosure also describes a method for manufacturing the filter element 100 described herein.

[0138] In one aspect, these methods include: connecting seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e to seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. In another aspect, the method includes simultaneously forming seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e to form a sealing device.

[0139] In another aspect, these methods include: thermally welding the sealing device (including the seal and the seal carrier) to the filter media package 10.

[0140] In another aspect, these methods include: heat-welding the closed end cap 70 to the filter media package 10. Formation and / or connection of seals and seal carriers

[0141] In some embodiments, seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e can be coupled to seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e by manufacturing the sealing device using a multi-material injection molding manufacturing process.

[0142] In some embodiments, seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e can be formed simultaneously using a multi-material injection molding manufacturing process. In some embodiments, this formation can be performed before the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are coupled to the filter media packages 10, 110.

[0143] In some embodiments, portions of seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e can be simultaneously formed by a multi-material injection molding manufacturing process. In some embodiments, this formation can be performed after different portions of the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are attached to the filter media packages 10, 110.

[0144] Alternatively, in some embodiments, seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e can each be formed by injection molding, but seal 1 20, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e can be formed, for example, by overmolding using an injection molding process after the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are connected to the filter media packs 10, 110.

[0145] Multimaterial injection molding is a process of molding two or more different materials into a single-structure part. Multimaterial injection molding can include, for example, multi-component injection molding (also known as co-injection molding), multiple injection molding, and overmolding. In a multimaterial injection molding process, at least a first material and a second material are used, wherein seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e comprise at least a first material, and seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e comprise at least a 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.

[0146] 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 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 called multi-component injection molding or co-injection molding) or sequentially (usually called multi-injection molding). In exemplary embodiments, two different types of polymers can be used as two components, wherein one polymer forms seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e, and the other polymer forms seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, or a portion thereof. Further examples of a wide variety of materials and combinations of materials that can be used for seals and seal carriers are discussed herein.

[0147] Alternatively or concurrently, overmolding can be used to form molded single-structure sealing devices, in which one material is stacked on top of another. If overmolding is used to form seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e or a portion thereof, or seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e or a portion thereof, then the overmolding is performed using an injection molding manufacturing process. While polyurethane seals or thixotropic seals can also be overmolded, such embodiments are not overmolded using an injection molding manufacturing process.

[0148] 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 seal and seal carrier, or it may form, for example, only a portion of the seal carrier (e.g., the portion of the seal carrier not thermally welded to the filter media packages 10, 110). In such embodiments, 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.

[0149] Multi-material injection molding allows for the formation and / or bonding of 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e and sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e without the use of curable adhesives. The use of curable adhesives requires curing time, thereby increasing manufacturing time. Therefore, multi-material injection molding allows for faster production of filter elements 10. Furthermore, using multi-material injection molding instead of curable adhesives (such as polyurethane) provides greater stability and dimensional stability for the seals, resulting in a lower risk of leakage during use and offering more potential configurations and geometries for the seal's location and orientation.

[0150] The filter media packs 10 and 110 may be damaged when exposed to the high temperatures required for multi-material injection molding, resulting in reduced efficiency. Therefore, in some embodiments, the seal may preferably be coupled to a seal carrier, and / or the seal may be formed by multi-material injection molding prior to thermally welding the seal to the filter media packs 10 and 110. Hot welding manufacturing process

[0151] The thermal welding manufacturing process uses thermal welding to join the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e and the filter media packages 10, 110. In some embodiments, as described above, the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are preferably already part of the sealing device during the thermal welding manufacturing process. Thermal welding is also referred to as plastic welding, thermal fusion, contact bonding, or direct bonding. In some embodiments, when the method for manufacturing the filter element 100 includes two thermal welding manufacturing processes, the thermal welding manufacturing process may be the first thermal welding manufacturing process.

[0152] The hot welding manufacturing process includes at least three steps, as further described below.

[0153] The first step includes providing filter media packages 10 and 110, the filter media including an outer peripheral surface 6 extending in the longitudinal direction Z and a first axial surface 7 transverse to the longitudinal direction Z. As discussed above, filter media packages 10 and 110 may include pleated filter media or grooved filter media, or any other filter media suitable for filtering fluids.

[0154] The second step includes providing a sealing element carrier. In the context of sealing devices including seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e, sealing element carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a- 1040e, wherein seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e are present on seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. In some embodiments, as further described herein, the sealing device is a molded single-structure sealing device formed by a multi-material injection molding manufacturing process. Seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e include first axial sides 442a-442f, 1042a-1042e.

[0155] The third step includes: performing a thermal welding manufacturing process to connect the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e to at least the circumferential portion of the first axial surface 7 of the filter media packages 10, 110.

[0156] Any suitable thermal welding manufacturing process can be used. Exemplary thermal welding processes include contact heating; hot air welding; hot gas welding; induction heating (i.e., heating with high-frequency electromagnetic waves); laser welding; mirror welding; vibration welding; spin welding; infrared welding; and friction welding, including, for example, ultrasonic welding. In some embodiments, combinations of different thermal welding processes may be used. In the exemplary embodiments described in the examples, a hot plate is used to heat the sealing carrier.

[0157] In some embodiments, the thermal welding manufacturing process utilizes a heat source or thermal welding process to locally heat the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. More specifically, the thermal welding manufacturing process can preferably only heat the first axial sides 442a-442f, 1042a-1042e, or a portion of the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, such that other components or other sides of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e do not deform or begin to melt. Particularly preferred is that, if present, the seals 120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e do not deform during heating of the seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e.

[0158] In some embodiments, the first axial sides 442a-442f, 1042a-1042e may be heated until a given layer thickness, a portion of the first axial side, or a specific volume of the first axial side becomes deformable. In some embodiments, a thickness of at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm on the first axial side becomes deformable. In some embodiments, a thickness of up to 2 mm, up to 3 mm, up to 4 mm, or up to 5 mm on the first axial side becomes deformable. In this manner, when at least the circumferential portion of the first axial surface 7 of the filter media packages 10 and 110 is pressed into the first axial sides 442a-442f and 1042a-1042e, at least the circumferential portion of the first axial surface 7 of the filter media packages 10 and 110 enters the first axial sides 442a-442f and 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, and 1040a-1040e by at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm.

[0159] In some embodiments, the thermal welding manufacturing process may include the following sub-steps: First, heating the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e until at least a portion of the first axial sides 442a-442f, 1042a-1042e becomes deformable. Second, the filter media packages 10 and 110 and the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are brought together, such that at least the circumferential portion of the first axial surface 7 of the filter media packages 10 and 110 is pressed into the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. Thirdly, the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are allowed to cool, thereby fixing the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e to at least the circumferential portion of the first axial surface 7 of the filter media package.

[0160] The processing temperature required for heat welding depends on the specific material selected for the portion of the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e or the portion of the sealing carrier to be attached to the filter media package 10, 110. "Processing temperature" is the temperature at which the first axial side 442a-442f, 1042a-1042e of the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e intended to be attached to the filter media package 10, 110 becomes deformable. When the entire volume of the sealing carrier is formed from the same material or combination of materials, the "processing temperature" is the temperature at which the first axial sides 442a-442f and 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e become deformable. The processing temperature is measured by measuring the temperature of the heated portion of the surface of the first axial sides 442a-442f and 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e.

[0161] The processing temperature is preferably higher than the transition temperature of the material forming the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, or the material forming the sealing carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e intended to be attached to the filter media package 10, 110.

[0162] As further discussed herein, when the seal carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, or a portion thereof comprises a single-phase polymer portion (including, for example, polystyrene (PS) or polycarbonate (PC)) as an amorphous state, the material's "transformation temperature" is 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 of ) because T g In reality, it refers to the temperature range. Any suitable instrument can be used to perform DSC; however, in the exemplary embodiment, a DSC3+ (Mettler Toledo GmbH, Schwezenbach, Switzerland) with an FRS 6+ sensor can be used.

[0163] When the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e, or a portion thereof, comprise semi-crystalline polymer materials or any other material exhibiting more than a single polymer phase (including, for example, polypropylene (PP) or polyethylene (PE)), the material's "transition temperature" is the final temperature at which the elastic modulus (measured in shear force) (G') and loss modulus (measured in shear force) intersect, where G' and G' are plotted relative to temperatures from 0°C to the temperature at which the polymer is in a molten state. The increase in tanδ can be used to characterize the system's transition to the melt flow region. G', G”, and tanδ are defined according to ASTM D4092-01, entitled "Standard Terminology for Plastics: Dynamic Mechanical Properties". In this document, G' and G” are determined according to ASTM D4440-15, entitled "Standard Test Method for Plastics: Dynamic Mechanical Properties Melt Rheology", using temperature-sweep dynamic mechanical analysis (DMA), i.e., measured using a mechanical spectrophotometer to measure forced constant-amplitude fixed-frequency shear oscillations. Any suitable dynamic mechanical analyzer can be used; however, in the exemplary embodiment, a Q800 (TA Instruments, Newcastle, DE) can be used.

[0164] Those skilled in the art can select a preferred processing temperature by referring to the transition temperature of the seal, the transition temperature of the material forming the seal carrier 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e or the material forming the seal carrier to be attached to the filter media package 10, 110, the heat welding method used, and the configuration of the sealing device. 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 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 transition temperature of the second material.

[0165] In some embodiments, the processing temperature can 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 can 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 can be in the range of 100°C to 300°C. In another exemplary embodiment, the processing temperature can be in the range of 150°C to 300°C. In yet another exemplary embodiment, the processing temperature can be in the range of 200°C to 300°C.

[0166] In some embodiments, when the connection prevents leakage during the separation of filtered fluid from unfiltered fluid through the filter element 100, the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e are fixedly connected to at least a circumferential portion of the first axial surface 7 of the filter media package.

[0167] In some embodiments, including when the filter media packs 10 and 110 are pleated filter media packs 10, when the filter media is embedded in the sealing carriers 140, 240, 340, 440a-440f by at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm, and / or when the sealing carriers 140, 240, 340, 440a-440f are impregnated into the pleats of the filter media pack 10 by at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm, the filter media pack 10 can be fixedly connected. That is, the end portions of the pleats are sealed by impregnating the material of the first axial sides 442a-442f and 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e into the filter medium.

[0168] In some embodiments, when the filter media packs 10 and 110 are wound grooved filter media packs 110, the filter media packs 110 can be fixedly connected when at least one grooved layer is fully embedded in the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e, and / or the material of the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e is impregnated into at least one grooved layer. Not wanting to be bound by theory, although at least one grooved layer embedded in the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e is considered sufficient to prevent leakage during the separation of filtered fluid from unfiltered fluid through the filter element 100, in some embodiments it may be desirable to embed additional grooved layers in the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e, or partially in the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e, or both, to increase the adhesive strength between the filter media package 110 and the sealing carriers 540, 640, 740, 840, 940, 1040a-1040e. Figure 6 In the exemplary embodiment shown, the adhesive strength between the filter media package 110 and the sealing carrier 640 can be increased by including a rib 45 that is pressed into the first axial surface 7 of the filter media package 110. Additional embodiments are also envisioned where the rib 45 does not extend across the width of the first axial surface 7 of the filter media package 110. For example, a plurality of ribs 45 (with or without extending the width of the first axial surface 7) can be arranged around the circumference of the first axial surface 7. When these ribs 45 do not extend the width of the first axial surface, they can form a configuration similar to the scale lines on an analog clock.

[0169] When the filter element 100 includes one or more ribs 45, heating the first axial sides 442a-442f, 1042a-1042e of the heating seal carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040 may further include heating one or more ribs 45 until they become deformable. Additionally, during the second step of bringing the circumferential edge of the first axial surface 7 of the filter media package 10, 110 together with the first axial sides 442a-442f, 1042a-1042e of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040, the ribs 45 may be simultaneously pressed into the first axial surface 7.

[0170] In some embodiments, the thermal welding manufacturing process may further include heating at least a portion of the filter media packages 10, 110 before bringing them together with the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e. Not wanting to be bound by theory, it is rejected that heating at least a portion of the filter media packages 10, 110 before bringing them together with the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e can improve the bonding, because contact with the filter media packages 10, 110 does not drastically or rapidly reduce the temperature of the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e and thus reduce their deformability, thereby making the bond between the two materials stronger. In an exemplary embodiment, the filter media packages 10, 110 may be heated to the same temperature as the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e before being brought together with them. Those skilled in the art can determine, at least in part, whether and to what extent, the filter media packages 10, 110 should be heated based on the composition of the filter media packages 10, 110. For example, some media (including filter media containing synthetic components, for example) may deform when heated or heated to a temperature above a certain level before being brought into contact with the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e.

[0171] In practice, when filter media packages 10 and 110 and sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040 are brought together, at least the circumferential portion of the first axial surface 7 of the filter media packages 10 and 110 is pressed against the sealing carriers 140, 240, 340, 440a-440f. When the filter media packages 10 and 110 are in the first axial sides 442a-442f and 1042a-1042e of 540, 640, 740, 840, 940, 1040a-1040, relative movement occurs between them and the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040. Various options exist for enabling this relative movement. For example, the filter media packages 10 and 110 can be held in a stationary position while the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040 move. The sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, and 1040a-1040 are preferably movable in a direction parallel to the longitudinal axis Z of the filter media packages 10 and 110. In an alternative embodiment, the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, and 1040a-1040 can be held in a stationary position, while the filter media packages 10 and 110 can be movable. Alternatively, it is conceivable that both the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, and 1040a-1040 and the filter media packages 10 and 110 can be movable. A component that is kept in a stationary position can be held in that position by any suitable means, including, for example, a vacuum, a clamp, etc.

[0172] Not wanting to be bound by theory, it is believed that using a thermal welding manufacturing process to join the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e and the filter media package 10 offers advantages over, for example, using adhesive materials (such as glue, hot melt adhesive, etc.). Several advantages of using thermoplastics (Sika Corporation) and / or polyurethane (PU) for the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e) can be provided compared to adhesive materials (such as PU). Secondly, the use of a thermal welding manufacturing process can increase manufacturing speed because no curing time is required. Finally, using thermoplastics for the sealing carriers can improve the ability to recycle filter elements; for example, by reheating, the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e can be removed from the recycled filter media package 10, and the components can be recycled separately. Second hot welding manufacturing process

[0173] When the filter element 100 includes a support frame 60, the connection between the support frame 60 and the second axial surface 8 can be achieved through a second thermal welding manufacturing process.

[0174] The second hot welding manufacturing process is similar to the first hot welding manufacturing process, but the support frame 60 replaces the sealing carriers 140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e.

[0175] The second hot welding manufacturing process includes: heating the support frame 60 or a portion thereof until a temperature is reached that makes the support frame 60 or a portion thereof deformable; bringing the filter media packages 10, 110 and the support frame 60 together such that the second axial surface 8 of the filter media packages 10, 110 is pressed into the support frame 60 or a portion thereof; and allowing the support frame 60 or a portion thereof to cool such that the support frame 60 is fixedly connected to the second axial surface 8 of the filter media packages 10, 110.

[0176] The present invention is illustrated by the following examples. It should be understood that specific examples, materials, quantities, and procedures should be interpreted broadly in accordance with the scope and spirit of the invention as set forth herein. Exemplary component aspects Aspect 1. A filter element comprising: A filter media package, wherein the filter media package includes an outer peripheral surface extending in a longitudinal direction and a first axial surface transverse to the longitudinal direction; and A molded single-structure sealing device, the sealing device comprising a seal and a seal carrier, wherein the seal comprises a first material and the seal carrier comprises a second material, and wherein the second material is different from the first material; The sealing element carrier includes a first axial side, and the first axial side of the sealing element carrier is thermally welded to at least a circumferential portion of the first axial surface of the filter medium package. Aspect 2. The filter element as described in aspect 1, wherein the filter element is configured to be placed in the housing of the filter system. Aspect 3. The filter element as described in aspect 2, wherein the molded single-structure sealing device is configured to separate filtered fluid from unfiltered fluid when the filter element is operatively placed in the housing. Aspect 4. The filter element as described in any of the preceding aspects, wherein the transition temperature of the first material is higher than the transition temperature of the second material. Aspect 5. The filter element as described in any of the preceding aspects, wherein, The first material includes rubber, thermoplastic elastomer, thermosetting elastomer, thermoplastic vulcanized rubber, or mixtures or combinations thereof; and / or The second material includes thermoplastics. Aspect 6. The filter element as described in any of the preceding aspects, wherein the first material comprises a thermoplastic elastomer, and the thermoplastic elastomer comprises a polyamide thermoplastic elastomer, a copolyester thermoplastic elastomer, an olefin thermoplastic elastomer, a styrene thermoplastic elastomer, a urethane thermoplastic elastomer, or a dynamically vulcanized thermoplastic elastomer, or a mixture or combination thereof. Aspect 7. The filter element as described in any of the preceding aspects, Wherein, the Shore A value of the seal 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; and / or The Shore A value of the seal is as high as 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90. Aspect 8. The filter element as described in any of the preceding aspects, wherein the Shore A value of the seal is in the range of 30 to 90, in the range of 40 to 70, or in the range of 50 to 70. Aspect 9. The filter element as described in any of the preceding aspects, Wherein, the Shore A value of the sealing carrier is at least 50, at least 60, at least 70, at least 80, or at least 90; and / or The Shore A value of the sealing carrier is as high as 80, 90, 95, or 100. Aspect 10. The filter element as described in any of the preceding aspects, wherein the Shore A value of the sealing carrier is in the range of 60 to 100, in the range of 70 to 100, or in the range of 80 to 100. Aspect 11. The filter element as described in any of the preceding aspects, wherein the second material comprises a thermoplastic, and said thermoplastic comprises 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. Aspect 12. The filter element as described in any of the preceding aspects, Wherein, the Shore A value of the sealing carrier is at least 50, at least 60, at least 70, at least 80, or at least 90; and / or The Shore A value of the sealing carrier is as high as 80, 90, 95, or 100. Aspect 13. The filter element as described in any of the preceding aspects, wherein the Shore A value of the sealing carrier is in the range of 60 to 100, in the range of 70 to 100, or in the range of 80 to 100. Aspect 14. The filter element as described in any of the preceding aspects, Wherein, the Shore D value of the sealing carrier is at least 10, at least 15, at least 20, at least 25, or at least 30; and / or The Shore D value of the sealing carrier is as high as 80, 90, 95, or 100. Aspect 15. The filter element as described in any of the preceding aspects, wherein the Shore D value of the sealing carrier is in the range of 15 to 100, or in the range of 30 to 100. Aspect 16. The filter element as described in any one of Aspects 1 to 15, The sealing carrier includes a radial circumferential side that extends along the longitudinal direction and at least partially encloses the outer circumferential surface of the filter media package. The seal surrounds the radial circumferential side to form an outward-pointing radial seal. Aspect 17. The filter element as described in any one of Aspects 1 to 15, The sealing carrier includes a tubular extension that extends along the longitudinal direction to form a fluid inlet channel or a fluid outlet channel for the filter media package. Wherein, the sealing element surrounds the outer peripheral surface of the tubular extension to form an outwardly pointing radial seal, or The seal is positioned around the inner circumferential surface of the tubular extension to form an inwardly pointing radial seal. Aspect 18. The filter element as described in any one of Aspects 1 to 15, The sealing carrier includes a central opening configured to allow filtered fluid to exit or to receive unfiltered fluid. The seal is connected to the inner circumferential surface of the central opening to form an inwardly pointing radial seal. Aspect 19. The filter element as described in any one of Aspects 1 to 15, The sealing carrier includes a second axial side opposite to the first axial side, and The seal is connected to the second axial side to form an axial seal. Aspect 20. The filter element as described in any of the preceding aspects, wherein the filter media package comprises grooved filter media or pleated filter media. Aspect 21. The filter element as described in any of the preceding aspects, The filter media package includes a second axial surface opposite to the first axial surface, and The filter element further includes a closed end cap, which is connected to the second axial surface of the filter media package. Aspect 22. The filter element as described in aspect 21, wherein the closed end cap is thermally welded to the second axial surface of the filter media package. Aspect 23. The filter element of any one of Aspects 16 to 22, wherein the filter media package comprises a pleated filter media, and wherein the pleated filter media is embedded in the sealing carrier for a distance of at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm. Aspect 24. The filter element of aspect 20, wherein the filter medium package includes a grooved filter medium, the grooved filter medium including a grooved filter material winding layer. Aspect 25. The filter element as described in aspect 24, wherein each of the grooved filter material winding layers includes an inlet groove and an outlet groove, the grooves being oriented substantially parallel to the longitudinal direction, and wherein the groove inlet of the inlet groove or the groove outlet of the outlet groove of at least the outermost layer of the winding layer is blocked by a first axial side of the sealing carrier. Aspect 26. The filter element as described in aspects 20, 24 or 25, wherein the filter media package comprises a grooved filter media having a wound grooved media layer. Wherein, the number of successive grooved media layers blocked by the first axial side of the sealing element carrier is less than ten layers, less than eight layers, or less than six layers; and / or The number of successive grooved media layers blocked by the first axial side of the sealing element carrier is at least one or at least two layers. Aspect 27. The filter element as described in any one of Aspects 20 or 24 to 26, the filter element further comprising a support frame coupled to a second axial surface of the filter media package, wherein the second axial surface is opposite to the first axial surface. Aspect 28. The filter element of aspect 27, wherein the filter media package comprises a grooved filter media having a wound grooved media layer, and wherein the support frame is configured to prevent the wound grooved media layer from moving along the longitudinal direction. Aspect 29. The filter element as described in any one of Aspects 20, 24 to 28, wherein the sealing carrier includes one or more ribs arranged in a plane substantially parallel to the first axial surface, and wherein the one or more ribs are coupled to the first axial surface of the filter media package. Aspect 30. The filter element of aspect 29, wherein the filter media package comprises a grooved filter media having a wound grooved media layer, wherein the one or more ribs are configured to prevent the wound grooved media layer from moving along the longitudinal direction. Aspect 31. The filter element as described in any of the preceding aspects, wherein the molded single-structure sealing device is formed by a multi-material injection molding manufacturing process. Aspect 32. The filter element as described in any of the preceding aspects, wherein the molded single-structure sealing device includes a feed point, a spray point, or a seam. Aspect 33. The filter element as described in any of the preceding aspects, wherein the outer peripheral surface is circular, oval, elliptical, rounded square, oblong, or rectangular. Exemplary methods define product aspects Aspect 1. A filter element for placement in a housing of a filter system, comprising: A filter media package, wherein the filter media package includes an outer peripheral surface extending in a longitudinal direction and a first axial surface transverse to the longitudinal direction; and A molded single-structure sealing device for separating filtered fluid from unfiltered fluid when the filter element is operatively placed in the housing, wherein the molded single-structure sealing device includes a seal and a seal carrier, wherein the seal includes a first material and the seal carrier includes a second material, and wherein the second material is different from the first material; The seal is connected to the seal carrier, and the connection between the seal and the seal carrier is achieved through a multi-component injection molding process, using the first material and the second material to manufacture the sealing device; and The sealing carrier includes a first axial side, which is connected to at least a circumferential portion of the first axial surface of the filter medium package by a thermal welding manufacturing process. Aspect 2. The filter element as described in aspect 1, wherein the transition temperature of the first material is higher than the transition temperature of the second material. Aspect 3. The filter element as described in any of the preceding aspects, wherein, The first material includes rubber, thermoplastic elastomer, thermosetting elastomer, thermoplastic vulcanized rubber, or mixtures or combinations thereof; and / or The second material includes thermoplastics. Aspect 4. The filter element as described in any of the preceding aspects, wherein the filter media package comprises grooved filter media or pleated filter media. Aspect 5. The filter element as described in any one of Aspects 1 to 4, The sealing carrier includes a radial circumferential side that extends along the longitudinal direction and at least partially encloses the outer circumferential surface of the filter media package. The seal surrounds the radial circumferential side to form an outward-pointing radial seal. Aspect 6. The filter element as described in any one of Aspects 1 to 4, The sealing carrier includes a tubular extension that extends along the longitudinal direction to form a fluid inlet channel or a fluid outlet channel for the filter media package. Wherein, the sealing element surrounds the outer peripheral surface of the tubular extension to form an outwardly pointing radial seal, or The seal is positioned around the inner circumferential surface of the tubular extension to form an inwardly pointing radial seal. 7. The filter element as described in any one of aspects 1 to 4, The sealing carrier includes a central opening configured to allow filtered fluid to exit or to receive unfiltered fluid. The seal is connected to the inner circumferential surface of the central opening to form an inwardly pointing radial seal. Aspect 8. The filter element as described in any one of Aspects 1 to 4, The sealing carrier includes a second axial side opposite to the first axial side, and The seal is connected to the second axial side to form an axial seal. Aspect 9. The filter element as described in any of the preceding aspects, The filter media package includes a second axial surface opposite to the first axial surface, and The filter element further includes a closed end cap, which is connected to the second axial surface of the filter media package by a second thermal welding manufacturing process. Aspect 10. The filter element of any one of Aspects 4 to 9, wherein the filter media package comprises a pleated filter media, and wherein the pleated filter media is embedded in the sealing carrier for a distance of at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm. Aspect 11. The filter element as described in any one of Aspects 1 to 6, The filter media package includes a grooved filter media, which comprises a grooved filter material winding layer. Wherein, the circumferential portion of the first axial surface of the filter medium pack, which is connected to the first axial side of the sealing carrier, corresponds to the circumferential edge of the first axial surface of the filter medium pack. Aspect 12. The filter element of aspect 11, wherein each of the grooved filter material winding layers includes an inlet groove and an outlet groove, the grooves being oriented substantially parallel to the longitudinal direction, and wherein the groove inlet of the inlet groove or the groove outlet of the outlet groove of at least the outermost layer of the winding layer is blocked by a first axial side of the sealing carrier. Aspect 13. The filter element as described in aspect 11 or 12, wherein, for a given number of successive layers of the grooved filter material winding, a first axial side of the sealing carrier blocks the inlet of the inlet groove or blocks the outlet of the outlet groove; and Wherein, the number of successive grooved media layers blocked by the first axial side of the sealing element carrier is less than ten layers, less than eight layers, or less than six layers; and / or The number of successive grooved media layers blocked by the first axial side of the sealing element carrier is at least one or at least two layers. Aspect 14. The filter element of any one of Aspects 11 to 13, the filter element further comprising a support frame coupled to a second axial surface of the filter media package, wherein the second axial surface is opposite to the first axial surface. Aspect 15. The filter element as described in aspect 14, wherein the support frame is configured to prevent the winding layer from moving along the longitudinal direction. Aspect 16. The filter element as described in aspect 14 or 15, wherein the connection between the support frame and the second axial surface of the filter media package is obtained by a second thermal welding manufacturing process. Aspect 17. The filter element of any one of Aspects 11 to 16, wherein the sealing carrier includes one or more ribs arranged in a plane substantially parallel to the first axial surface, and wherein the one or more ribs are coupled to the first axial surface of the filter media package. Aspect 18. The filter element as described in aspect 17, wherein the one or more ribs are configured to prevent the wound layer from moving along the longitudinal direction. Aspect 19. The filter element as described in Aspect 17 or 18, wherein the connection of the one or more ribs to the first axial surface of the filter media package is obtained as part of the thermal welding manufacturing process. Aspect 20. The filter element as described in any of the preceding aspects, wherein the thermal welding manufacturing process comprises the following steps: The first axial side of the sealing carrier is heated until at least a portion of the first axial side becomes deformable; Bring the filter media package and the sealing carrier together such that at least a circumferential portion of the first axial surface of the filter media package is pressed into the first axial side of the sealing carrier; and The first axial side of the sealing carrier is allowed to cool, such that the first axial side is fixedly connected to at least a circumferential portion of the first axial surface of the filter medium package. Aspect 21. The filter element as described in any of the preceding aspects, Wherein, the Shore A value of the seal 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; and / or The Shore A value of the seal is as high as 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90. Aspect 22. The filter element as described in any of the preceding aspects, wherein the Shore A value of the seal is in the range of 30 to 90, in the range of 40 to 70, or in the range of 50 to 70. Aspect 23. The filter element as described in any of the preceding aspects, Wherein, the Shore A value of the sealing carrier is at least 50, at least 60, at least 70, at least 80, or at least 90; and / or The Shore A value of the sealing carrier is as high as 80, 90, 95, or 100. Aspect 24. The filter element as described in any of the preceding aspects, wherein the Shore A value of the sealing carrier is in the range of 60 to 100, in the range of 70 to 100, or in the range of 80 to 100. Aspect 25. The filter element as described in any of the preceding aspects, Wherein, the Shore D value of the sealing carrier is at least 10, at least 15, at least 20, at least 25, or at least 30; and / or The Shore D value of the sealing carrier is as high as 80, 90, 95, or 100. Aspect 26. The filter element as described in any of the preceding aspects, wherein the Shore D value of the sealing carrier is in the range of 15 to 100, or in the range of 30 to 100. Aspect 27. The filter element as described in any of the preceding aspects, wherein the first material comprises a thermoplastic elastomer, and the thermoplastic elastomer comprises a polyamide thermoplastic elastomer, a copolyester thermoplastic elastomer, an olefin thermoplastic elastomer, a styrene thermoplastic elastomer, a urethane thermoplastic elastomer, or a dynamically vulcanized thermoplastic elastomer, or a mixture or combination thereof. Aspect 28. The filter element as described in any of the preceding aspects, wherein the second material comprises a thermoplastic, and said thermoplastic comprises 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. Aspect 29. The filter element as described in any of the preceding aspects, wherein the outer peripheral surface is circular, oval, elliptical, rounded square, oblong, or rectangular. Exemplary manufacturing method aspects Aspect 1. A method for manufacturing a filter element, the method comprising: A filter media package is provided, the filter media package having a circumferential surface extending in a longitudinal direction and a first axial surface transverse to the longitudinal direction; Provide sealing carriers; and A thermal welding manufacturing process is used to connect the first axial side of the sealing element carrier to at least the circumferential portion of the first axial surface of the filter medium package. Aspect 2. The method as described in aspect 1, wherein the thermal welding manufacturing process includes: The first axial side of the sealing carrier is heated until at least a portion of the first axial side becomes deformable; Bring the filter media package and the sealing carrier together such that at least a circumferential portion of the first axial surface of the filter media package is pressed into the first axial side of the sealing carrier; and The first axial side of the sealing carrier is allowed to cool, such that the first axial side of the sealing carrier becomes fixedly connected to at least a circumferential portion of the first axial surface of the filter medium package. Aspect 3. The method as described in any of the preceding aspects, wherein the sealing device comprises a molded single-structure sealing device having a sealing element carrier. Aspect 4. The method as described in any of the preceding aspects, wherein the sealing device comprises a molded single-structure sealing device having a seal and a seal carrier. Aspect 5. The method as described in aspect 3 or 4, wherein the method further comprises: attaching the seal to the seal carrier by a multi-component injection molding manufacturing process. Aspect 6. The method of aspect 5, wherein the seal is attached to the seal carrier prior to the application of the thermal welding manufacturing process. Aspect 7. The method of aspect 5, wherein the seal is coupled to the seal carrier after the application of the thermal welding manufacturing process. Aspect 8. The method of any one of Aspects 3 to 7, wherein the sealing device is adapted to separate the filtered fluid from the unfiltered fluid when the filter element is operatively placed in the housing. Aspect 9. The method as described in any of the preceding aspects, wherein the processing temperature of the thermal welding process is higher than the transition temperature of a portion of the first axial side of the heated sealing carrier. Aspect 10. The method of any one of Aspects 1 to 9, wherein the filter media package comprises a pleated filter media package, and wherein the method comprises: embedding a first axial surface of the filter media package into a first axial side of the sealing carrier by at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 2 mm. Aspect 11. The method of any one of Aspects 1 to 9, wherein the filter media package comprises a grooved filter media package having a wound groove; and The method includes: impregnating at least one grooved layer with a material on the first axial side of the sealing element carrier; and / or The method includes: impregnating at least six grooved layers, at least eight grooved layers, or at least ten grooved layers with a material on the first axial side of the sealing carrier. Aspect 12. The method as described in any of the preceding aspects, wherein the method further comprises: embedding a rib in a first axial side of the sealing carrier. Aspect 13. The method of any one of Aspects 2 to 12, wherein the method further comprises: heating a first axial surface of the filter medium package, and then bringing the filter medium package and the sealing carrier together such that at least a circumferential portion of the first axial surface of the filter medium package is pressed into a first axial side of the sealing carrier. Aspect 14. The method of any of the preceding aspects, wherein the method further comprises a second thermal welding manufacturing process, the second thermal welding manufacturing process comprising connecting a support frame to a second axial surface of the filter media package. Aspect 15. A filter element obtained by the method of any one of the preceding aspects. Example

[0177] All reagents, starting materials, and solvents used in the following examples were purchased from commercial suppliers (e.g., Sigma-Aldrich, St. Louis, Missouri) and, unless otherwise specified, can be used without further purification. Hot welding method

[0178] The end cap (also referred to herein as the seal carrier), with or without a seal, is positioned in the fixture and held in place by vacuum. The filter media package is positioned in another fixture.

[0179] Set the heat source (or hot plate) to 350°C and position it between the end cap and the filter media pack. Figure 13A ).

[0180] Press the end cap against the hot plate for 20 seconds. Figure 13B Optionally, depending on the distance between the filter media pack and the hot plate, the hot plate also heats the filter media pack.

[0181] Lift the end cap off the hot plate and remove the hot plate.

[0182] The end cap was moved toward the filter media pack at a set speed (tested at 1 mm / s and 3 mm / s). Figure 13CThe distance is set (e.g., 1.5mm) as indicated by the arrow in the image. Once the set distance is reached, hold the endplate in place for 15 seconds. Figure 13D ).

[0183] Remove the resulting connected parts from the fixing device. Example 1

[0184] This example describes the welding of a cellulose pleated medium to a sealing carrier.

[0185] Using the methods described above and shown in Figure 13, the corrugated dielectric envelope is fused to the... P homopolymer (Laurent Engineering Plastics GmbH, Germany) The sealing carrier is made of Engineering Plastics (Germany). The filter media pack is heated to a temperature in the range of 100°C to 200°C (more preferably 100°C to 150°C) by a hot plate. Figure 14 An exemplary result is shown. The filter media is embedded approximately 1 mm into the seal carrier. Example 2

[0186] This example describes the welding of a synthetic grooved medium to a sealing carrier.

[0187] Using the method described above, the grooved dielectric package is fused to the... The sealing carrier is made of P homopolymer (Laurent Engineering Plastics AG, Germany). Prior to welding, the filter media pack was either not heated by a hot plate or heated very gently. Figure 15 shows exemplary results. Figure 15A At the location indicated by the arrow, approximately two grooved layers are embedded in the sealing carrier. Figure Labels

Claims

1. A filter element (100), comprising: A filter media pack (10, 110), wherein the filter media pack (10, 110) comprises an outer circumferential face (6) extending in a longitudinal direction and a first axial face (7) transverse to the longitudinal direction; and A molded, single-structure seal device comprising a seal (120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e) and a seal carrier (140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e), wherein the seal comprises a first material and the seal carrier comprises a second material, and wherein the second material is different from the first material; wherein the seal carrier includes a first axial side (442a-442f, 1042a-1042e), and wherein the first axial side of the seal carrier is heat welded to at least a circumferential portion of a first axial face (7) of the filter media pack (10, 110); wherein the seal (120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e) is coupled to a seal carrier (140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e), characterised in that the coupling of the seal to the seal carrier is obtained by manufacturing the seal from a first material and a second material using a multi-component injection moulding manufacturing process; And the transition temperature of the first material is higher than the transition temperature of the second material.

2. The filter element (100) according to claim 1, wherein The first material comprises rubber, a thermoplastic elastomer, a thermoset elastomer, a thermoplastic vulcanizate, or a mixture or combination thereof; and / or The second material includes a thermoplastic.

3. The filter element (100) according to any one of the preceding claims, wherein The first material includes a thermoplastic elastomer, and the thermoplastic elastomer includes a polyamide thermoplastic elastomer, a copolyester thermoplastic elastomer, an olefin thermoplastic elastomer, a styrenic thermoplastic elastomer, a urethane thermoplastic elastomer, or a dynamically vulcanized thermoplastic elastomer, or a mixture or combination thereof.

4. The filter element (100) according to any of the preceding claims, in, The seal carrier comprises a radial circumferential side (41) which extends in the longitudinal direction and at least partially envelops an outer circumferential face (6) of the filter medium pack (10, 110), and Therein, the seal surrounds the radial circumferential side (41) to form an outwardly directed radial seal.

5. The filter element (100) according to any one of claims 1 to 3, in, The seal carrier comprises a tubular extension (43) extending in a longitudinal direction to form a fluid inlet passage or a fluid outlet passage of the filter media pack (10, 110), and wherein the seal surrounds the outer circumferential surface of the tubular extension (43) to form an outwardly directed radial seal, or Therein, a seal is positioned around the inner circumferential surface of the tubular extension (43) to form an inwardly directed radial seal.

6. The filter element (100) according to any one of claims 1 to 3, in, The seal carrier includes a central opening configured for exiting filtered fluid or for receiving unfiltered fluid, and Therein, a seal is coupled to an inner circumferential surface of the central opening to form an inwardly directed radial seal.

7. A method of manufacturing a filter element (100), the method comprising: A filter media pack (10, 110) is provided, the filter media pack (10, 110) having a circumferential surface extending in a longitudinal direction and a first axial surface (7) transverse to the longitudinal direction; coupling the seal to the seal carrier by a multi-component injection molding manufacturing process, wherein the second material is different from the first material and the first material has a higher transition temperature than the second material; A molded, single-structure seal device is provided that includes a seal (120, 220a, 220b, 320, 420a-420f, 520, 620, 720, 820, 920, 1020a-1020e) and a seal carrier (140, 240, 340, 440a-440f, 540, 640, 740, 840, 940, 1040a-1040e); wherein the seal includes a first material and the seal carrier includes a second material; Applying a heat welding manufacturing process to couple a first axial side (442a-442f, 1042a-1042e) of the seal carrier to at least a circumferential portion of a first axial face (7) of a filter media pack (10, 110); The processing temperature of the thermal welding process is higher than the transformation temperature of a portion of the first axial side (442a-442f, 1042a-1042e).

8. The method according to claim 7, wherein: Thermal welding manufacturing processes include: heating the first axial side of the seal carrier until at least a portion of the first axial side (442a-442f, 1042a-1042e) becomes deformable; bringing the filter media pack (10, 110) and the seal carrier together such that at least a circumferential portion of the first axial face (7) of the filter media pack (10, 110) is pressed into the first axial side of the seal carrier; and The first axial side of the seal carrier is allowed to cool such that the first axial side of the seal carrier becomes fixedly coupled to at least a circumferential portion of the first axial face (7) of the filter media pack.

9. The method according to any one of claims 7 to 8, wherein: The method also includes embedding a rib (45) into the first axial side (442a-442f, 1042a-1042e) of the seal carrier.

10. The method according to any one of claims 7 to 9, wherein: The method also includes heating a first axial face (7) of the filter media pack (10, 110), and then bringing the filter media pack (10, 110) and the seal carrier together so that at least a circumferential portion of the first axial face (7) of the filter media pack (10, 110) is pressed into a first axial side (442a-442f, 1042a-1042e) of the seal carrier.

11. The method according to any one of claims 7 to 10, wherein: The method also includes a second heat welding manufacturing process including coupling the support frame (60) to a second axial face (8) of the filter media pack (10, 110).

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