Co-molded and cured filter cartridge end using different durometer plastisols
A filter cartridge includes a filter media having opposed edges. Annular end discs include first and second surfaces defined by spaced apart planes. The end discs has an integrated gasket, and is formal from includes first and second plastisol materials that have different durometers. The durometer of the second plastisol material makes it more rigid than the first plastisol material. The first plastisol material provides a flexible gasket. During manufacture, each edge of the filter media is embedded into the second material on an end disc. The second plastisol material is arranged between the planes, and the first plastisol material extends axially away from the second surface.
1 . A filter cartridge comprising:
a filter media having an edge; and
an end disc and an integrated gasket formed by first and second polymer materials, the second polymer material being more rigid than the first polymer material, the end disc formed by the second polymer material and including first and second surfaces defined by spaced apart planes, the edge in contact with the end disc at the first surface, and the first polymer material providing the integrated gasket extending axially away from the second surface.
2 . The filter cartridge according to claim 1 , wherein the edge is embedded in the second polymer material.
3 . The filter cartridge according to claim 1 , wherein the end disc includes inner and outer circumferential surfaces extending between the first and second surfaces, the inner circumferential surface providing a central opening in the end disc.
4 . The filter cartridge according to claim 3 , wherein the integrated gasket is spaced substantially radially inward of the outer circumferential surface.
5 . The filter cartridge according to claim 3 , wherein an exterior of the filter media is arranged radially inboard of the outer circumferential surface.
6 . The filter cartridge according to claim 1 , wherein the integrated gasket provides a sealing surface generally parallel to and outside of the second surface.
7 . The filter cartridge according to claim 1 , wherein the filter media is a pleated paper filter element.
8 . The filter cartridge according to claim 1 , wherein the first polymer material is spaced from the edge.
9 . The filter cartridge according to claim 1 , wherein the first and second polymer materials are plastisol.
10 . A method of manufacturing a filter cartridge comprising the steps of:
a) dispensing a first polymer material in a first cavity;
b) dispensing a second polymer material in a second cavity communicating with the first cavity;
c) embedding a filter media in the second polymer material; and
d) curing the first and second polymer materials.
11 . The method according to claim 10 , wherein the first polymer material provides a gasket and the second polymer material provides an end disc.
12 . The method according to claim 10 , wherein the second polymer material flows radially outwardly during step b) forming inner and outer circumferential surfaces, the first polymer material arranged radially outward of the inner circumferential surface.
13 . The method according to claim 10 , wherein the second polymer material provides first and second surfaces defining spaced apart planes, the filter media extending through the first surface, the first polymer material extending axially outward from the second surface.
14 . The method according to claim 10 , comprising the steps of:
e) dispensing the first polymer material in a third cavity;
f) dispensing the second polymer material in a fourth cavity communicating with the third cavity;
g) reorienting the filter media;
h) embedding the filter media in the second polymer material in the fourth cavity; and
i) curing the first and second polymer materials in the third and fourth cavities.
15 . The method according to claim 10 , wherein the first and second polymer materials are plastisol.
16 . The method according to claim 10 , wherein the second cavity is arranged axially above the first cavity.