U.S. patent application number 13/118971 was filed with the patent office on 2011-12-01 for cast formed filter and method of making the same.
Invention is credited to Christopher P. Montelauro, Philip P. Treier.
Application Number | 20110291314 13/118971 |
Document ID | / |
Family ID | 39136871 |
Filed Date | 2011-12-01 |
United States Patent
Application |
20110291314 |
Kind Code |
A1 |
Treier; Philip P. ; et
al. |
December 1, 2011 |
CAST FORMED FILTER AND METHOD OF MAKING THE SAME
Abstract
A cast formed filter and a method for making the filter is
provided. The method includes disposing a liquid filter media in a
cavity of a molding tool, the molding tool having a plurality of
features configured so that the filter media is formed about the
plurality of features to form a plurality of inlet openings and a
plurality of outlet openings in the filter media; applying at least
one of pressure and heat to the filter media disposed in the
molding tool to cure the liquid filter media and obtain a cast
formed filter media defined by the cavity of the molding tool; and
removing the cast formed filter media from the molding tool,
wherein the cast formed filter media maintains a configuration
having a three-dimensional periphery and the plurality of inlet
openings extend from an inlet end of the cast filter media into the
cast formed filter media so a first portion of the cast formed
filter media is disposed between each of the plurality of inlet
openings and an outlet end, and the plurality of outlet openings
extend from the outlet end into the cast formed cast filter media
so a second portion of the cast formed filter media is disposed
between each of the plurality of outlet openings and the inlet
end.
Inventors: |
Treier; Philip P.;
(Bloomdale, OH) ; Montelauro; Christopher P.;
(Bowling Green, OH) |
Family ID: |
39136871 |
Appl. No.: |
13/118971 |
Filed: |
May 31, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11847627 |
Aug 30, 2007 |
7951219 |
|
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13118971 |
|
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60824128 |
Aug 31, 2006 |
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Current U.S.
Class: |
264/46.4 |
Current CPC
Class: |
B01D 2046/2492 20130101;
B01D 46/2474 20130101; B01D 2046/2488 20130101; B01D 46/247
20130101; F02M 35/024 20130101 |
Class at
Publication: |
264/46.4 |
International
Class: |
B29C 67/20 20060101
B29C067/20 |
Claims
1. A method of making a cast formed filter, comprising: disposing a
liquid filter media in a cavity of a molding tool, the molding tool
having a plurality of features configured so that the filter media
is formed about the plurality of features to form a plurality of
inlet openings and a plurality of outlet openings in the filter
media; applying at least one of pressure and heat to the filter
media disposed in the molding tool to cure the liquid filter media
and obtain a cast formed filter media defined by the cavity of the
molding tool; and removing the cast formed filter media from the
molding tool, wherein the cast formed filter media maintains a
configuration having a three-dimensional periphery and the
plurality of inlet openings extend from an inlet end of the cast
filter media into the cast formed filter media so a first portion
of the cast formed filter media is disposed between each of the
plurality of inlet openings and an outlet end, and the plurality of
outlet openings extend from the outlet end into the cast formed
cast filter media so a second portion of the cast formed filter
media is disposed between each of the plurality of outlet openings
and the inlet end.
2. The method as in claim 1, further comprising curing the cast
formed filter media disposed in the molding tool.
3. The method as in claim 2, wherein the filter media is synthetic
fiber.
4. The method as in claim 3, wherein the synthetic fiber is
polyester fiber.
5. The method as in claim 1, wherein the filter media is synthetic
fiber.
6. The method as in claim 5, wherein the synthetic fiber is
polyester fiber.
7. The method as in claim 1, wherein the plurality of inlet
openings are a plurality of rows of inlet openings.
8. The method as in claim 1, wherein the plurality of inlet
openings are a plurality of columns of inlet openings.
9. The method as in claim 1, wherein the plurality of inlet
openings are a plurality of rows of inlet openings and a plurality
of columns of inlet openings.
10. The method as in claim 1, wherein the plurality of outlet
openings are a plurality of rows of outlet openings.
11. The method as in claim 1, wherein the plurality of outlet
openings are a plurality of columns of outlet openings.
12. The method as in claim 1, wherein the plurality of outlet
openings are a plurality of rows of outlet openings and a plurality
of columns of outlet openings.
13. The method as in claim 1, wherein at least one of the plurality
of inlet openings has a hexagonal cross-sectional shape.
14. The method as in claim 1, wherein at least one of the plurality
of outlet openings has a circular cross-sectional shape.
15. The method as in claim 1, wherein at least one of the plurality
of inlet openings has a configuration that is not the same as a
configuration of at least one of the plurality of outlet openings.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 11/847,627 filed Aug. 30, 2007, which claims the benefit
of U.S. Provisional Patent Application Ser. No. 60/824,128 filed
Aug. 31, 2006 the contents each of which are incorporated herein by
reference thereto.
BACKGROUND
[0002] The present application relates to a cast formed filter and
a method for making the same.
[0003] Air induction housing systems are continually being
challenged to become smaller and unique in shape without loss of
system performance. In particular and referring to vehicular
applications, this is due in part to the reduction in available
real estate in the engine compartment. As vehicle profiles are
reduced and engine systems become more complex there is very little
available space for the air induction system, which is a critical
component of the engine. The air induction system in an internal
combustion engine of a vehicle that provides at least two important
functions; providing a means for delivery of air into the
combustion chambers of the engine and providing a means for
filtering the air prior to its delivery to the combustion chambers.
Due to its filtering function, the filter itself needs to be
replaced after an extended period of use thus, accessibility to the
filter is also a requirement imposed upon the air induction system
as well as the housing.
[0004] In some designs the air induction system is not designed
until the engine design is completed thus, the designers of the air
induction system are typically faced with the problem of providing
a predetermined amount of airflow to the engine while also being
presented with a limited or unique amount of space between the
engine and the vehicle hood, front grill etc. Accordingly, the air
induction housing typically has a unique configuration that is
optimized for flow and space requirements, which may be
contradictory to design requirements for the filter to be located
within the air induction system.
[0005] Furthermore, reducing the housing size and creating unique
shapes limits the overall size of the filter capable of being
disposed therein. Accordingly, and based upon conventional airflow
technology, smaller filters typically result in less capacity thus,
reduced performance. Additionally, making filters having unique
configurations can require many manufacturing steps in producing
the filter.
[0006] Accordingly, it is desirable to provide a filter and
simplified method of manufacturing the same, wherein the filter
accommodates imposed size and shape limitations yet the filter
provides a high capacity for filtration.
SUMMARY OF THE INVENTION
[0007] A method of making a cast formed filter in accordance with
an exemplary embodiment is provided. The method includes disposing
a liquid filter media in a cavity of a molding tool, the molding
tool having a plurality of features configured so that the filter
media is formed about the plurality of features to form a plurality
of inlet openings and a plurality of outlet openings in the filter
media; applying at least one of pressure and heat to the filter
media disposed in the molding tool to cure the liquid filter media
and obtain a cast formed filter media defined by the cavity of the
molding tool; and removing the cast formed filter media from the
molding tool, wherein the cast formed filter media maintains a
configuration having a three-dimensional periphery and the
plurality of inlet openings extend from an inlet end of the cast
filter media into the cast formed filter media so a first portion
of the cast formed filter media is disposed between each of the
plurality of inlet openings and an outlet end, and the plurality of
outlet openings extend from the outlet end into the cast formed
cast filter media so a second portion of the cast formed filter
media is disposed between each of the plurality of outlet openings
and the inlet end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective and partial cross-sectional view of
a portion of a cast formed filter in accordance with an exemplary
embodiment of the present invention;
[0009] FIG. 2 is a perspective view and partial cross-sectional of
a portion of a cast formed filter in accordance with an alternative
exemplary embodiment;
[0010] FIG. 3 is a perspective view and partial cross-sectional of
a portion of a cast formed filter in accordance with another
alternative exemplary embodiment;
[0011] FIG. 4 is a cross sectional view of a portion of a tool used
to make a cast formed filter in accordance with an exemplary
embodiment;
[0012] FIG. 5 is a cross sectional view of a portion of a first
tool used to make a cast formed filter in accordance with an
exemplary embodiment;
[0013] FIG. 6 is a cross sectional view of a portion of a second
tool to be utilized with the first tool of FIG. 5 to make the cast
formed filter in accordance with an exemplary embodiment; and
[0014] FIG. 7 is a cross sectional view of the first tool of FIG. 5
being utilized with the second tool of FIG. 6 to make the cast
formed filter in accordance with an exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0015] Reference is made to the following United States patent
applications, U.S. Ser. No. 11/241,245 and U.S. Pat. No. 6,673,136
the contents of which are incorporated herein by reference
thereto.
[0016] In accordance with an exemplary embodiment of the present
invention, a cast formed filter and a method of making the same is
disclosed herein. In an exemplary embodiment, a configuration of
the cast formed filter is made by forming or shaping filter media
using a casting or molding process. The cast formed filter filters
a fluid flowing therethrough. Non-limiting examples of the fluid to
be filtered include gases and combinations thereof (e.g. air),
water, fuels, oils, coolants, etc.
[0017] It is contemplated that a molding or casting tool used in
the manufacturing process is configured to produce a particular
configuration of the cast formed filter media. Exemplary
embodiments of the configuration of the cast formed filter include
exterior features as well as interior features. Due to the
flexibility of the molding process, the particular configuration of
the cast formed filter media accommodates an application that
requires a unique exterior shape and size to satisfy a restricted
space limitation for the cast formed filter media and or an
application that requires a non-uniform periphery.
[0018] In an exemplary embodiment, an exterior periphery may be
defined by a geometric shape, a non-uniform or non-geometric shape,
or a combination thereof. For example and in a non-limiting
exemplary embodiment, a configuration of the cast formed filter has
an outer periphery that is configured to engage a complementary
periphery of a housing that receives the cast formed filter media.
In an exemplary embodiment, a cross sectional shape of an opening
and or a shape of a length of the opening in the cast formed filter
media may be defined by a geometric shape, a non-uniform or
non-geometric shape, or a combination thereof. For example, in an
exemplary embodiment, a periphery or an opening may have a shape
that is circular, oval, hexagon, triangular, diamond, square,
elliptical, non-geometric, or any combination thereof.
[0019] In an exemplary embodiment, a number of openings and their
configuration within the cast formed filter can increase surface
filter area through the cast formed filter without restricting
fluid flow, thereby providing a high capacity for filtration. In an
exemplary embodiment, in accordance with a particular application,
a configuration of openings in the cast formed filter media
satisfies a unique fluid flow path requirement, an increase of
filtration paths through the formed filter media, and or a
predetermined filtration rate. Thus, a configuration of the cast
formed filter can be created to provide a high capacity for
filtration even for an application that has a restricted space
requirement or requires a non-uniform exterior shape for the cast
formed filter.
[0020] In a non-limiting exemplary embodiment, a configuration of
the cast formed filter includes a plurality of inlet openings
extending into the cast formed filter media from an inlet end. The
cast formed filter media further includes a plurality of outlet
openings extending into the cast formed filter media from an outlet
end. Each of the plurality of inlet openings and each of the
plurality outlet openings do not extend completely through the cast
formed filter media. Each of the plurality of inlet openings and
each of the plurality of the outlet openings is formed within the
cast formed filter media so that a portion of formed filter media
separates an inlet opening from an outlet opening. In an exemplary
embodiment, a configuration of at least one of the inlet openings
may differ from a configuration of at least one of the outlet
openings, wherein the configuration may include a cross sectional
shape of the opening and or a length or shape of a length of the
opening.
[0021] In an exemplary embodiment, a fluid flow path extends
through at least one of the plurality of inlet openings and through
at least one of the plurality of outlet openings, wherein fluid
flowing along the flow path is filtered by a portion of the formed
filter media of the cast formed filter media. Of course, fluid can
be filtered by the cast formed filter media when the fluid flows
through a portion of the formed filter media without flowing
through an inlet or an outlet opening. In an exemplary embodiment,
media or material used to make the cast formed filter media is
selected, for example, in accordance with the fluid to be filtered,
a fluid flow rate through the filter, manufacturing considerations,
a predetermined fluid filtration rate, an operational temperature
of the fluid being filtered, and or a filter replacement interval.
In a non-limiting exemplary embodiment, media used to make the cast
formed filter media includes synthetic fiber, such as for example
polyester fiber.
[0022] Referring now to FIGS. 1-3, examples of exemplary
embodiments of configurations of a cast formed filter will be
discussed. As illustrated in FIGS. 1-3, a partial cross-sectional
view is provided wherein an interior portion of the cast formed
filter is shown in each of the figures to illustrate a
configuration of inlet openings and outlet openings arranged within
the cast formed filter media. Outer peripheries of the cast formed
filter are not to be limited to those shown in FIGS. 1-3. In
accordance with an exemplary embodiment of the present invention,
the side walls of the cast formed filter not comprising the inlet
openings or the outlet openings will consist of the filter media
thus having no inlet or outlet openings therein. In some exemplary
embodiments the cast formed filter media will be surrounded on the
side walls not having the inlet and outlet openings by a filter
housing having an inlet opening corresponding to the inlet openings
and an outlet opening corresponding to the outlet openings. In one
exemplary embodiment, the housing will be part of a conduit system
or the housing will surround the cast formed filter media and is
configured to be received within a conduit system.
[0023] Referring now to FIG. 1 and in an exemplary embodiment, a
cast formed filter 10 includes a cast formed filter media 12, an
inlet end 14, an outlet end 16, a plurality of inlet openings 18,
and a plurality of outlet openings 20. Each of the plurality of
inlet openings extends into formed filter media 12 from inlet end
14 such that formed filter media 15 is disposed between each of the
plurality of inlet openings and outlet end 16. Each of the
plurality of outlet openings extends into formed filter media 12
from outlet end 16 such that formed filter media 17 is disposed
between each of the plurality of outlet openings and inlet end 14.
Formed filter media 19 is disposed between each of the plurality of
inlet openings and an adjacent outlet opening. Formed filter media
15, 17 and 19 are portions of formed filter media 12. Depending on
a configuration of cast formed filter 10, portions of formed filter
media 15, 17 and 19 may blend into each other.
[0024] Each of plurality of inlet openings 18 and each of plurality
of outlet openings 20 has a substantially hexagon cross sectional
shape. Of course, other configurations are considered to be within
the scope of exemplary embodiments of the present invention.
Plurality of inlet openings 18 are arranged within formed filter
media 12 as spaced substantially parallel rows and spaced
substantially parallel columns, as shown in FIG. 1. Although not
fully shown in FIG. 1, plurality of outlet openings 20 are arranged
within formed filter media 12 as spaced substantially parallel rows
and spaced substantially parallel columns, wherein the rows and
columns of the outlet openings are also substantially parallel with
respect to the rows and columns of the inlet openings.
[0025] In an exemplary embodiment, a fluid flow path extends
through at least one of plurality of inlet openings 18 and through
at least one of plurality of outlet openings 20, wherein fluid is
filtered by at least a portion of formed filter media 12 along the
flow path. In a non-limiting example, fluid enters cast formed
filter 10 through at least one of plurality of inlet openings 18
along a flow path 22 in a direction toward outlet end 16. The fluid
in the inlet opening flows through formed filter media 19 along a
flow path 24 into at least one of plurality of outlet openings 20,
wherein the fluid is filtered by formed filter media 19 along flow
path 24. The fluid then flows through at least one of the outlet
openings out of cast formed filter 10 along a flow path 26. Of
course in another application, the flow path could be reversed such
that fluid flows into at least one of the plurality of outlet
openings at the outlet end and exits the cast formed filter media
by flowing through at least one of the plurality of inlet openings
at the inlet end, the fluid being filtered by passing through at
least a portion of the cast formed filter media along the flow
path.
[0026] In other applications, fluid may be filtered by formed
filter media 12 by flowing along alternative flow paths. For
example, fluid is filtered by formed filter media 17 when the fluid
enters at least one plurality of outlet openings 20 by first
passing through formed filter media 17. In another application,
fluid is filtered by formed filter media 15 when the fluid enters
at least one plurality of inlet openings 18 by first passing
through formed filter media 15. Of course, fluid is filtered by
formed filter media 15 if the fluid entering an inlet opening flows
through formed filter media 15 at outlet end 16, rather than
flowing through another portion of formed filter media 12.
Similarly, fluid is filtered by formed filter media 17 if the fluid
entering an outlet opening flows through formed filter media 17 at
inlet end 14, rather than flowing through another portion of formed
filter media 12. And in another application, fluid is filtered by a
portion of formed filter media 12 when the fluid passes only
through the formed filter media and does not pass through one of
the inlet or outlet openings.
[0027] Referring now to FIG. 2, a portion of a cast formed filter
media 30 in accordance with another exemplary embodiment is
illustrated. Cast formed filter media 30 includes formed filter
media 32, an inlet end 34, an outlet end 36, a plurality of inlet
openings 38, and a plurality of outlet openings 40. Each of the
plurality of inlet openings extends into formed filter media 32
from inlet end 34 such that formed filter media 35 is disposed
between each of the plurality of inlet openings and outlet end 36.
Each of the plurality of outlet openings extends into formed filter
media 32 from outlet end 36 such that formed filter media 37 is
disposed between each of the plurality of outlet openings and inlet
end 34. Formed filter media 39 is disposed between each of the
plurality of inlet openings and an adjacent outlet opening. Formed
filter media 35, 37 and 39 are portions of formed filter media 32.
Depending on a configuration of cast formed filter media 30,
portions of formed filter media 35, 37 and 39 may blend into each
other.
[0028] Each of plurality of inlet openings 38 and each of plurality
of outlet openings 40 has an approximate oval cross sectional
shape. Of course, other configurations are considered to be within
the scope of exemplary embodiments of the present invention. The
plurality of inlet openings 38 are arranged within formed filter
media 32 as spaced substantially parallel rows and spaced
substantially parallel columns, as shown in FIG. 2. Although not
fully shown in FIG. 2, plurality of outlet openings 40 are arranged
within formed filter media 32 as spaced substantially parallel rows
and spaced substantially parallel columns, wherein the rows and
columns of outlet openings are also substantially parallel with
respect to the rows and columns of inlet openings. The rows of the
inlet openings and the outlet openings are further arranged with
respect to each other so that the openings of one row are disposed
between the openings of an adjacent row of openings. The columns of
the inlet openings and the outlet openings are further arranged
with respect to each other so that the openings of one column are
disposed between the openings of an adjacent column of
openings.
[0029] In an exemplary embodiment, a fluid flow path extends
through at least one of plurality of inlet openings 38 and through
at least one of plurality of outlet openings 40, wherein fluid is
filtered by at least a portion of formed filter media 32 along the
flow path. For example, fluid enters formed filter media 32 through
at least one of plurality of inlet openings 38 along a flow path 42
in a direction toward outlet end 36. The fluid in the inlet opening
flows through formed filter media 39 along a flow path 44 into at
least one of plurality of outlet openings 40, wherein the fluid is
filtered by formed filter media 39 along flow path 44. The fluid
then flows through at least one of plurality of outlet openings 40
out of cast formed filter media 30 along a flow path 46. In other
exemplary embodiments, fluid is filtered by cast formed filter
media 30 by flowing along alternative flow paths similar to those
discussed for cast formed filter media 10.
[0030] Referring now to FIG. 3, a portion of a cast formed filter
media 50 in accordance with another exemplary embodiment is
illustrated. Cast formed filter media 50 includes formed filter
media 52, an inlet end 54, an outlet end 56, a plurality of inlet
openings 58, and a plurality of outlet openings 60. Each of the
plurality of inlet openings extends into formed filter media 52
from inlet end 54 such that formed filter media 55 is disposed
between each of the plurality of inlet openings and outlet end 56.
Each of the plurality of outlet openings extends into formed filter
media 52 from outlet end 56 such that formed filter media 57 is
disposed between each of the plurality of outlet openings and inlet
end 54. Formed filter media 59 is disposed between each of the
plurality of inlet openings and an adjacent outlet opening. Formed
filter media 55, 57 and 59 are portions of formed filter media 52.
Depending on a configuration of cast formed filter media 50,
portions of formed filter media 55, 57 and 59 may blend into each
other.
[0031] Each of plurality of inlet openings 58 and each of plurality
of outlet openings 60 has an elongated zig-zag cross sectional
shaped opening. Of course, other configurations are considered to
be within the scope of exemplary embodiments of the present
invention. Plurality of inlet openings 58 are arranged within
formed filter media 52 as spaced substantially parallel rows, as
shown in FIG. 3. Although not fully shown in FIG. 3, plurality of
outlet openings 60 are arranged within formed filter media 52 as
spaced substantially parallel rows, wherein the rows of outlet
openings are also substantially parallel with respect to the rows
of inlet openings.
[0032] In an exemplary embodiment, a fluid flow path extends
through at least one of plurality of inlet openings 58 and through
at least one of plurality of outlet openings 60, wherein fluid is
filtered by a least a portion of formed filter media 52 along the
flow path. For example, fluid enters formed filter media 52 through
at least one of plurality of inlet openings 58 along a flow path 62
in a direction toward outlet end 56. The fluid in the inlet opening
flows through formed filter media 59 along a flow path 64 into at
least one of plurality of outlet openings 60, wherein the fluid is
filtered by formed filter media 59 along flow path 64. The fluid
then flows through at least one of plurality of outlet openings 60
out of cast formed filter media 50 along a flow path 66. In other
exemplary embodiments, fluid is filtered by cast formed filter
media 50 by flowing along alternative flow paths similar to those
discussed for cast formed filter media 10.
[0033] Referring now to FIGS. 4-7, an exemplary embodiment of how
molding or casting tools are used for making a configuration of the
cast formed filter media will be briefly described. It is
contemplated that the molding tools used to produce the
configuration of the cast formed filter media have features to form
an exterior periphery as well as interior features of the cast
formed filter media. In an exemplary embodiment, the molding tools
include features to form an exterior periphery that is defined by a
geometric shape, a non-uniform or non-geometric shape, or a
combination thereof.
[0034] For example and in an exemplary embodiment, an exterior of
the cast formed filter media is defined by a length and a width,
wherein the width defines an outer periphery of the cast formed
filter media. In another exemplary embodiment, an exterior of the
cast formed filter media has a three-dimensional shape defined by a
non-uniform length, a non-uniform width, and a non-uniform height,
wherein the non-uniform width and the non-uniform height define an
outer periphery of the cast formed filter media. Due to the
flexibility of the molding process, the cast formed filter media
can have a unique exterior shape and size that accommodates a
restricted space limitation for the cast formed filter media and or
an application that requires a non-uniform periphery. For example,
a housing the cast formed filter media is inserted into. Moreover,
and as discussed above the sides of the cast formed filter media
not having the inlet openings and the outlet openings may be
received within an outer housing that fluidly seals the side wall
of the cast formed filter media not having the inlet openings and
the outlet openings.
[0035] In an exemplary embodiment, the molding tools also include
features to form an interior configuration of the cast formed
filter media. For example, the interior configuration can include
cross sectional shapes of openings and shapes of lengths of the
openings. In an exemplary embodiment, the tools are configured to
form openings having a configuration defined by a geometric shape,
a non-uniform or non-geometric shape, or a combination thereof.
Thus, due to the flexibility of the molding process, a cast formed
filter media can have a unique configuration of openings to
accommodate an application that requires unique flows paths for the
fluid to flow therethrough. Additionally, the molding tools can be
configured to create a plurality of openings in the cast formed
filter media, thereby increasing the surface filter area to provide
a cast formed filter media having a high capacity for
filtration.
[0036] Referring now to FIG. 4, a portion of a casting or molding
tool 70 contemplated for use in manufacturing a configuration of
the cast formed filter media in accordance with an exemplary
embodiment of the present invention is illustrated. Tool 70
includes a surface 72 that defines a cavity 74. A periphery of
surface 72 corresponds to an outer periphery of the cast formed
filter media after the molding process is completed. In an
exemplary embodiment, two or more tools may be combined to then
form the cavity and surface within the combined tools for forming a
configuration of cast formed filter media.
[0037] For example and in an exemplary embodiment, one
configuration of cast formed filter media made by a molding tool
that includes an arrangement of inlet and outlet openings as
illustrated in FIG. 1, 2 or 3 and an outer periphery wherein at
least a portion of the outer periphery has a circular, rectangular,
square, oval, or any other a geometric shape. In another exemplary
embodiment, a configuration of cast formed filter media made by a
molding tool includes an arrangement of inlet and outlet openings
as illustrated in FIG. 1, 2 or 3 and an outer periphery wherein at
least a portion of the outer periphery has a non-uniform or
non-geometric shape. Of course, in an alternative exemplary
embodiment, a configuration of the cast formed filter media made by
a molding tool includes inlet openings and outlet openings that
have a configuration different from those shown in FIGS. 1-3 and
the cast formed filter media has an exterior periphery defined by a
geometric shape, a non-geometric shape, or a combination
thereof.
[0038] In an exemplary embodiment, the surface defined by the
molding tool can be configured to produce an outer periphery of the
cast formed filter media that is substantially similar to an
interior surface of a housing configured to receive the cast formed
filter media. For example and in an exemplary embodiment, a
non-uniform configuration of the cast formed filter media is a
three-dimensional shape configured to be received in a housing
having a non-uniform periphery therein, wherein the non-uniform
configuration is defined by a non-uniform length, a non-uniform
width, and a non-uniform height. In another exemplary embodiment, a
surface of the tool defines a protrusion configured to form a
recess in a portion of an outer periphery of the cast formed filter
media, wherein the recess is configured to engage a complementary
protrusion of the housing. In another exemplary embodiment, a
surface of the tool defines a recess configured to form a
protrusion in a portion of an outer periphery of the cast formed
filter media, wherein the protrusion is configured to engage a
complementary recess of the housing. Due to the molding process, it
is possible to produce a cast formed filter media that has an outer
periphery configured for the geometry of the environment the cast
formed filter media will be used therewith.
[0039] Referring now to FIGS. 5-7, a non-limiting example of
molding tools used to make a configuration of cast formed filter
media having an arrangement of inlet openings and outlet openings
substantially similar to that of cast formed filter 10 is
illustrated. Only a portion of the mold tools are illustrated in
FIGS. 5-7 for discussing how a configuration of openings are formed
within the cast formed filter media. Although not shown and in an
exemplary embodiment, when tool 80 is assembled with tool 90
interior surfaces of tools 80, 90 define a cavity therein for
forming an outer periphery of the cast formed filter media. In an
alternative exemplary embodiment, any number of tools may be
combined to define surfaces and cavities to form a configuration of
the cast formed filter media.
[0040] In an exemplary embodiment, tool 80 includes a base portion
82 and a plurality of pins 84 extending from base portion 82. Pins
84 have a configuration that corresponds to the configuration of
inlet openings 18 of cast formed filter 10 as illustrated in FIG.
1. Tool 90 includes a base portion 92 and a plurality of pins 94
extending from base portion 92. Pins 94 have a configuration that
corresponds to the configuration of outlet openings 20 of cast
formed filter 10 as illustrated in FIG. 1. In an alternative
exemplary embodiment, any pin of the tools may have a unique
configuration to form a corresponding unique configuration of an
inlet opening or an outlet opening that extends into the cast
formed filter media. In exemplary embodiments, the configuration of
the pin includes its cross sectional shape, length of the pin, and
a shape of the length of the pin. For example, a length of the pin
may be shaped to form an inlet opening or an outlet opening wherein
at least a portion of the opening's length is substantially
straight, curved, a non-uniform shape, or any combination
thereof.
[0041] In an exemplary embodiment, when tool 80 is assembled with
tool 90 plurality of pins 84 and plurality of pins 94 substantially
overlap one another in a spaced manner, as illustrated in FIG. 7. A
quantity of filter media 102, which is in a liquid, semi-liquid or
non-solid state is then disposed or poured within the cavities of
tools 80, 90 so that filter media 102 substantially surrounds the
peripheries of each of plurality of pins 84 and 94 and
substantially fills the cavities of tools 80, 90. After the liquid,
semi-liquid or non-solid filter media 102 has cured, or formed into
a solid or semi-solid state and into the configuration defined by
tools 80, 90, the cast formed filter media is separated from tools
80, 90, wherein the cast formed filter media has the configuration
of inlet openings and outlet openings as that of cast formed filter
10 shown in FIG. 1. In exemplary embodiments of the cast formed
filter media, the filter media is selected so the cast formed
filter media filters fluid passing therethrough in accordance with
predetermined filtration criteria. In an exemplary embodiment,
filter media 102 includes synthetic fiber, such as for example
polyester fiber.
[0042] Exemplary embodiments described herein provide a cast formed
filter media having unique exterior as well as interior features to
accommodate specific application requirements, including restricted
space and or non-uniform shape requirements, and the cast formed
filter media provides a high capacity for filtration.
[0043] While the invention has been described with reference to an
exemplary embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the present
application.
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