Abstract: A roll forming method may be used to provide a pleated filter media pack and filter cartridges with channels formed. The pack includes a strip of a filter media extending opposed edges and opposed front and back sides. The strip is pleat tips with spacer structure such as integrally formed embossments maintaining a spacing between pleat panels. The inlet and outlet flow faces are created by the edges of the filter media rather than the pleat tips. Alternating pairs of pleat panels are closed such as by seal beads at the inlet and outlet flow faces.

Abstract: A method and apparatus for reinforcing a tubular-shaped sealing collar, extending from a filter cartridge are provided, by embedding, or substantially encapsulating, a reinforcement element within the tubular-shaped sealing collar, for resisting a change in circumference of at least a portion of the tubular-shaped collar. The collar may be formed from a resiliently compressible foam material, and the reinforcement element may be formed from a substantially non-compressible material.

Abstract: A method and apparatus for reinforcing a tubular-shaped sealing collar, extending from a filter cartridge are provided, by embedding, or substantially encapsulating, a reinforcement element within the tubular-shaped sealing collar, for resisting a change in circumference of at least a portion of the tubular-shaped collar. The collar may be formed from a resiliently compressible foam material, and the reinforcement element may be formed from a substantially non-compressible material.

Abstract: A method and apparatus are provided for constructing a filter element, having enhanced structural capabilities, through use of a molded end cap having first and second foam portions of differing physical properties meeting at a common juncture of the first and second foam portions and simultaneously cured with one another.

Abstract: A method and apparatus are provided, for forming a filter element including a media pack in the form of a coiled fluted filter media, by winding the web of fluted filter media around a pair of tools of a mandrel. The tools engage the sides of the filter media. The tools define a major to provide the media pack with a oblong or elongated shape. The web may be fed at constant linear speed, and/or a motor may be controlled in a manner to provide constant driving torque to maintain a constant tension on the web. The winding apparatus and methods may include apparatus or methods to modify the feed path of the web to adjust the tension of the web as it is being wound. Further, the coiled media packs can be fixtured to prevent relaxation. A method may form various shaped media packs with the same apparatus.

Abstract: A method and apparatus are provided for constructing a filter element, having enhanced structural capabilities, through use of a molded end cap having first and second foam portions of differing physical properties meeting at a common juncture of the first and second foam portions and simultaneously cured with one another.

Abstract: A method and apparatus for reinforcing a tubular-shaped sealing collar, extending from a filter cartridge are provided, by embedding, or substantially encapsulating, a reinforcement element within the tubular-shaped sealing collar, for resisting a change in circumference of at least a portion of the tubular-shaped collar. The collar may be formed from a resiliently compressible foam material, and the reinforcement element may be formed from a substantially non-compressible material.

Abstract: An air filter element having an inner metal liner, an outer metal liner, a filter media, an annular end cap, and a composite end cap is provided. The annular end cap is formed over the metal liners such that the metal liners are secured and at least a portion of the filter media is sealed. The composite end cap has an annular plastic insert and a foamed urethane portion. The annular plastic insert is tapered upwardly from an outer insert periphery toward a central aperture. The foamed urethane portion is molded about the annular plastic insert such that the metal liners are secured, at least a portion of the filter media is sealed, and an annular groove is formed on an underside of the composite end cap. The annular groove has a plurality of transverse ribs therein. Urethane flashing occurs proximate the central aperture and/or the outer liner periphery.

Abstract: The air filter element may include an inner metal liner, an outer metal liner, a filter media, an annular end cap, and a composite end cap The annular end cap is formed over the metal liners such that the metal liners are secured and at least a portion of the filter media is sealed. The composite end cap has a foamed urethane portion and a rigid urethane portion. The foamed urethane portion, which has a central aperture and stand-off apertures, is molded about the central aperture and the stand-off apertures such that the metal liners are secured, at least a portion of the filter media is sealed, and urethane flashing occurs proximate one or more of the central aperture and an outer liner periphery. The rigid urethane portion is molded over the foamed urethane portion such that the stand-off apertures are filled, blocked, and/or sealed.