Process of bonding fluted filter media to end caps

Claim 2

A process for bonding a fluted filter media to an end cap in the manufacture of a fluid filter, which comprises the steps of: (a) forming, between one end cap having a bonding surface and an edge of a fluted filter medium, an effective bonding amount of a coating of a bonding composition, the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an amount of ungelatinized granular starch effective to complex a major portion of the latex water; (b) heating the bonding composition coating to or above the gel point of the bonding composition to coalesce the bonding composition and form a continuous filter media to end cap bond; and (c) drying the bonding composition coating.

Claim 3

The process of claim 1 wherein the effective bonding amount of the bonding composition is about 0.02 to 0.045 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 4

The process of claim 1 wherein the effective bonding amount of the bonding composition is about 0.023 to 0.040 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 5

The process of claim 1 wherein the effective bonding amount of the bonding composition is about 0.025 to 0.031 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 6

The process of claim 1 wherein the bonding composition coating is dried at ambient temperature.

Claim 7

The process of claim 5 wherein the bonding composition coating is dried at an elevated temperature.

Claim 8

The process of claim 6 wherein the bonding composition coating is dried at a temperature between about 175° to 230° C. for about 10 to 30 seconds.

Claim 9

The process of claim 1 wherein the bonding composition comprises about 1-25% by weight starch, based on the bonding composition.

Claim 10

The process of claim 8 wherein the starch is selected from the group consisting of corn starch, barley starch, wheat starch, and mixtures thereof.

Claim 11

The process of claim 8 wherein the bonding composition comprises about 30-99% by weight of a thermoplastic polymer suspension, based on the bonding composition.

Claim 12

The process of claim 10 wherein the aqueous bonding composition comprises about 25 to 75 wt-% solids.

Claim 13

The process of claim 10 wherein the thermoplastic polymer is selected from the group consisting of polychloroprene-methacrylic acid copolymers, ethylene-vinyl acetate copolymers, styrene-butadiene rubber and mixtures thereof.

Claim 14

The process of claim 1 wherein the bonding composition further comprises: (a) an effective amount of a surfactant to enhance the ability of the bonding composition to wet the filter media and end cap; (b) an effective amount of a foam controlling compound to reduce foaming of the bonding composition; (c) an effective amount of a plasticizer to enhance the flexibility of the bonding composition after curing; (d) an effective amount of a thickener to control the rheology of the bonding composition so that the bonding composition coating remains substantially in place before curing; (e) an effective amount of a tackifier to obtain sufficient green bond strength to prevent substantial slippage of the end cap relative to the filter media; and (f) an effective amount of a compatible antioxidant to prevent substantial oxidation of the thermoplastic resin.

Claim 15

The process for bonding a fluted filter media to two end caps, each end cap having a bonding surface, in the manufacture of a fluid filter which comprises the steps of: (a) forming on the two end caps a coating of an effective bonding amount of a bonding composition, the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an amount of ungelatinized granular starch effective to complex a major portion of the latex water; (b) contacting the two coated end caps to opposite fluted edges of the fluted filter media; (c) heating the bonding composition coating to above the gel point of the bonding composition to set the bonding composition and form continuous filter media to end cap bonds; and (d) drying the bonding composition coating.

Claim 16

The process for bonding a fluted filter media to two end caps, each end cap having a bonding surface, in the manufacture of a fluid filter which comprises the steps of: (a) forming on the two end caps a coating of an effective bonding amount of a bonding composition, the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an amount of ungelatinized granular starch effective to complex a major portion of the latex water; (b) contacting the two coated end caps to opposite fluted edges of the fluted filter media; (c) heating the bonding composition coating to above the gel point of the bonding composition to set the bonding composition and form continuous filter media to end cap bonds; and (d) drying the bonding composition coating.

Claim 17

The process of claim 14 wherein the effective bonding amount of the bonding composition is about 0.023 to 0.040 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 18

The process of claim 14 wherein the bonding composition coating is dried at an elevated temperature.

Claim 19

The process of claim 16 wherein the bonding composition coating is heated to a temperature between about 175° to 230° C. for about 10-30 seconds.

Claim 20

The process of claim 14 wherein the bonding composition comprises about 1 to 25% by weight starch, based on the aqueous bonding composition.

Claim 21

The process of claim 14 wherein the bonding composition comprises about 30-99% by weight thermoplastic polymer suspension, based on the aqueous bonding composition.

Claim 22

The process of claim 14 wherein the thermoplastic polymer is selected from the group consisting of polychloroprene, ethylene-vinyl acetate copolymers, styrene-butadiene rubber and mixtures thereof.

Claim 23

A process as recited in claim 14 wherein the bonding composition further comprises: (a) an effective amount of a surfactant to enhance the ability of the bonding composition to wet the filter media and end cap; (b) an effective amount of a foam controlling compound to reduce foaming of the bonding composition; (c) an effective amount of a plasticizer to enhance the flexibility of the bonding composition after curing; (d) an effective amount of a thickener to control the rheology of the bonding composition so that the bonding composition coating remains substantially in place before curing; (e) an effective amount of a tackifier to obtain sufficient green bond strength to prevent substantial slippage of the end cap relative to the filter media; and (f) an effective amount of a compatible antioxidant to prevent substantial oxidation of the thermoplastic resin.

Claim 24

A process for bonding a fluted filter media to two end caps, each end cap having a bonding surface, in the manufacture of a fluid filter, which comprises the steps of: (a) forming, on the two end caps, a coating of an effective bonding amount of a bonding composition, the bonding composition consisting essentially of adhesive latex: (i) 60 to 90 wt-% neoprene latex comprising about 45 to 49 wt-% solids; (ii) 10 to 20 wt-% starch selected from the group consisting of corn starch, barley starch, wheat starch, and mixtures thereof; (iii) 0.05 to 2.5 wt-% surfactant; (iv) 0.05 to 2.0 wt-% diethylene glycol butylether; (v) 0.05 to 0.30 wt-% thickener selected from the group consisting of guar gum, guar gum derivatives, xanthan gum and mixtures thereof; (vi) 10 to 30 wt-% tackifier dispersion; (vii) 1 to 3 wt-% antioxidant dispersion; (viii) 0.07 to wt-1% defoamer; and (ix) 1 to 3 wt-% zinc oxide dispersion; (b) indexing the two end caps; (c) contacting, under pressure, the two coated end caps to opposite fluted edges of the fluted filter media; (d) heating the bonding composition coating to a temperature between about 175° to 220° C. for about 10 to 30 seconds to set the bonding composition and form continuous filter media to end cap bonds; (e) allowing the bonding composition coating to cool to ambient temperature.

Claim 25

A process for bonding a fluted filter media to two end caps, each end cap having a bonding surface, in the manufacture of a fluid filter, which comprises the steps of: (a) forming, on the two end caps, a coating of an effective bonding amount of a bonding composition, the bonding composition consisting essentially of adhesive latex: (i) 60 to 90 wt-% neoprene latex comprising about 45 to 49 wt-% solids; (ii) 10 to 20 wt-% starch selected from the group consisting of corn starch, barley starch, wheat starch, and mixtures thereof; (iii) 0.05 to 2.5 wt-% surfactant; (iv) 0.05 to 2.0 wt-% diethylene glycol butylether; (v) 0.05 to 0.30 wt-% thickener selected from the group consisting of guar gum, guar gum derivatives, xanthan gum and mixtures thereof; (vi) 10 to 30 wt-% tackifier dispersion; (vii) 1 to 3 wt-% antioxidant dispersion; (viii) 0.07 to wt-1% defoamer; and (ix) 1 to 3 wt-% zinc oxide dispersion; (b) indexing the two end caps; (c) contacting, under pressure, the two coated end caps to opposite fluted edges of the fluted filter media; (d) heating the bonding composition coating to a temperature between about 175° to 220° C. for about 10 to 30 seconds to set the bonding composition and form continuous filter media to end cap bonds; (e) allowing the bonding composition coating to cool to ambient temperature.

Claim 26

A process for bonding a fluted edge of a fluted filter media to an end cap having a bonding surface in the manufacture of a fluid filter which comprises the steps of: (a) forming, on at least one edge of the filter media, a coating of an effective bonding amount of a bonding composition to form a coated fluted edge, the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an amount of ungelatinized granular starch effective to complex a major portion of the latex water; (b) contacting the coated fluted edge of the fluted filter media with the end cap; (c) heating the bonding composition coating to or above the gel point of the bonding composition to set the bonding composition and form a continuous filter media to end cap bond; and (d) drying the bonding composition coating.

Claim 27

A process for bonding a fluted edge of a fluted filter media to an end cap having a bonding surface in the manufacture of a fluid filter which comprises the steps of: (a) forming, on at least one edge of the filter media, a coating of an effective bonding amount of a bonding composition to form a coated fluted edge, the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an amount of ungelatinized granular starch effective to complex a major portion of the latex water; (b) contacting the coated fluted edge of the fluted filter media with the end cap; (c) heating the bonding composition coating to or above the gel point of the bonding composition to set the bonding composition and form a continuous filter media to end cap bond; and (d) drying the bonding composition coating.

Claim 28

The process of claim 23 wherein the effective bonding amount of the bonding composition is about 0.02 to 0.045 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 29

The process of claim 23 wherein the effective bonding amount of the bonding composition is about 0.023 to 0.040 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 30

The process of claim 23 wherein the effective bonding amount of the bonding composition is about 0.025 to 0.031 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 31

The process of claim 23 wherein the bonding composition coating is dried at ambient temperature.

Claim 32

The process of claim 27 wherein the bonding composition coating is heated to a temperature between about 100° to 250° C.

Claim 33

The process of claim 27 wherein the bonding composition coating is heated to a temperature between about 175° to 230° C. for about 10 to 30 seconds.

Claim 34

The process of claim 23 wherein the bonding composition comprises about 1-25% by weight starch, based on the aqueous adhesive composition.

Claim 35

The process of claim 30 wherein the starch is selected from the group consisting of corn starch, barley starch, wheat starch and mixtures thereof.

Claim 36

The process of claim 30 wherein the bonding composition comprises about 30-99% by weight thermoplastic polymer suspension based on the aqueous bonding composition.

Claim 37

The process of claim 32 wherein the aqueous bonding composition comprises about 25 to 75% solids.

Claim 38

The process of claim 32 wherein the thermoplastic polymer is selected from the group consisting of polychloroprene, ethylene-vinyl acetate copolymers, styrene-butadiene rubber and mixtures thereof.

Claim 39

The process of claim 23 wherein the bonding composition further comprises: (a) an effective amount of a surfactant to enhance the ability of the bonding comopsition to wet the filter media and end cap; (b) an effective amount of a foam controlling compound to reduce foaming of the bonding composition; (c) an effective amount of a plasticizer to enhance the flexibility of the bonding composition after curing; (d) an effective amount of a thickener to control the rheology of the bonding composition so that the bonding composition coating remains substantially in place before curing; (e) an effective amount of a tackifier to obtain sufficient green bond strength to prevent substantial slippage of the end cap relative to the filter media; and (f) an effective amount of a compatible antioxidant to prevent substantial oxidation of the thermoplastic resin.

Claim 40

A process for bonding a fluted filter media having two opposite fluted edges to two end caps, each end cap having a bonding surface, in the manufacture of a fluid filter, which comprises the steps of: (a) forming, on the two ends of the fluted filter media, a coating of an effective bonding amount of a bonding composition forming coated fluted edges the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an ungelatinized granular starch effective to complex a major portion of the latex water; (b) contacting each coated fluted edge of the filter media to an end cap; (c) heating the bonding composition coating to or above the gel point of the bonding composition to set the bonding composition and form a continuous filter media to end cap bond; and (d) drying the bonding composition coating.

Claim 41

A process for bonding a fluted filter media having two opposite fluted edges to two end caps, each end cap having a bonding surface, in the manufacture of a fluid filter, which comprises the steps of: (a) forming, on the two ends of the fluted filter media, a coating of an effective bonding amount of a bonding composition forming coated fluted edges the bonding composition comprising, in adhesive latex, an effective bonding amount of a thermoplastic resin and an ungelatinized granular starch effective to complex a major portion of the latex water; (b) contacting each coated fluted edge of the filter media to an end cap; (c) heating the bonding composition coating to or above the gel point of the bonding composition to set the bonding composition and form a continuous filter media to end cap bond; and (d) drying the bonding composition coating.

Claim 42

The process of claim 36 wherein the effective bonding amount of the bonding composition is about 0.023 to 0.040 wet grams of bonding composition per square centimeter of end cap bonding surface.

Claim 43

The process of claim 36 wherein the bonding composition coating is dried at an elevated temperature.

Claim 44

The process of claim 38 wherein the bonding composition coating is heated to a temperature between about 175° to 230° C. for about 10 to 30 seconds.

Claim 45

The process of claim 36 wherein the bonding composition comprises about 1 to 25% by weight starch, based on the aqueous bonding composition.

Claim 46

The process of claim 36 wherein the bonding composition comprises about 30-99% by weight thermoplastic polymer suspension, based on the aqueous bonding composition.

Claim 47

The process of claim 36 wherein the thermoplastic polymer is selected from the group consisting of polychloroprene, ethylene-vinyl acetate copolymers, and styrene-butadiene rubber.

Claim 48

A process for bonding an end cap having a bonding surface to each opposite fluted edge of a fluted filter media in the manufacture of a fluid filter, which comprises the steps of: (a) forming, on the opposite fluted edges of the fluted filter media, a coating of an effective bonding amount of a bonding composition, the bonding composition comprising, in adhesive latex: (i) 60 to 90 wt-% neoprene latex having about 45 to 49 wt % solids; (ii) 10 to 20 wt-% starch selected from the group consisting of corn starch, barley starch, wheat starch, and mixtures thereof; (iii) 0.05 to 2.5 wt-% surfactant; (iv) 0.05 to 2.0 wt-% diethylene glycol butylether; (v) 0.05 to 0.30 wt-% thickener selected from the group consisting of guar gum, guar gum derivatives, xanthan gum and mixtures thereof; (vi) 10 to 30 wt-% tackifier dispersion; (vii) 0.07 to 1 wt-% defoamer; (viii) 1 to 3 wt-% antioxidant dispersion; and (ix) 1 to 3 wt-% zinc oxide dispersion; (c) contacting, under pressure, each edge of the filter media to each end cap; (d) heating the bonding composition coating to a temperature between about 175° to 220° C. for about 10 to 30 seconds to set the bonding composition and form a continuous filter media to end cap bond; and (e) allowing the bonding composition to cool to ambient temperature.

Claim 49

A process for bonding an end cap having a bonding surface to each opposite fluted edge of a fluted filter media in the manufacture of a fluid filter, which comprises the steps of: (a) forming, on the opposite fluted edges of the fluted filter media, a coating of an effective bonding amount of a bonding composition, the bonding composition comprising, in adhesive latex: (i) 60 to 90 wt-% neoprene latex having about 45 to 49 wt % solids; (ii) 10 to 20 wt-% starch selected from the group consisting of corn starch, barley starch, wheat starch, and mixtures thereof; (iii) 0.05 to 2.5 wt-% surfactant; (iv) 0.05 to 2.0 wt-% diethylene glycol butylether; (v) 0.05 to 0.30 wt-% thickener selected from the group consisting of guar gum, guar gum derivatives, xanthan gum and mixtures thereof; (vi) 10 to 30 wt-% tackifier dispersion; (vii) 0.07 to 1 wt-% defoamer; (viii) 1 to 3 wt-% antioxidant dispersion; and (ix) 1 to 3 wt-% zinc oxide dispersion; (c) contacting, under pressure, each edge of the filter media to each end cap; (d) heating the bonding composition coating to a temperature between about 175° to 220° C. for about 10 to 30 seconds to set the bonding composition and form a continuous filter media to end cap bond; and (e) allowing the bonding composition to cool to ambient temperature.