Bonded fluted filter media to end cap

Claim 2

A fluid filter manufactured by bonding a fluted filter media to an end cap, 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

A fluid filter manufactured by bonding a fluted filter media to two end caps, each end cap having a bonding surface, 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 (c) drying the bonding composition coating.

Claim 4

A fluid filter manufactured by bonding a fluted filter media to two end caps, each end cap having a bonding surface, 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 (c) drying the bonding composition coating.

Claim 5

A fluid filter manufactured by bonding a fluted filter media to two end caps, each end cap having a bonding surface, 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 2.05 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 1 wt % 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° and 220° C. for about 10 to 30 seconds to set the bonding composition and form continuous filter media to end cap bonds; and (e) allowing the bonding composition coating to cool to ambient temperature.

Claim 6

A fluid filter manufactured by bonding a fluted filter media to two end caps, each end cap having a bonding surface, 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 2.05 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 1 wt % 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° and 220° C. for about 10 to 30 seconds to set the bonding composition and form continuous filter media to end cap bonds; and (e) allowing the bonding composition coating to cool to ambient temperature.

Claim 7

A fluid filter manufactured by bonding a fluted edge of a fluted filter media to an end cap having a bonding surface, 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 8

A fluid filter manufactured by bonding a fluted edge of a fluted filter media to an end cap having a bonding surface, 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 9

A fluid filter manufactured by bonding a fluted filter media having two opposite fluted edges to two end caps, each end cap a bonding surface, 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 10

A fluid filter manufactured by bonding a fluted filter media having two opposite fluted edges to two end caps, each end cap a bonding surface, 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 11

A fluid filter manufactured by bonding an end cap having a bonding surface to each opposite fluted edge of a fluted filter media, 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; (b) contacting, under pressure, each edge of the filter media to each end cap; (c) heating the bonding composition coating to a temperature between about 175° and 220° C. for about 10 to 30 seconds to set the bonding composition and form a continuous filter media to end cap bond; and (d) allowing the bonding composition to cool to ambient temperature.

Claim 12

A fluid filter manufactured by bonding an end cap having a bonding surface to each opposite fluted edge of a fluted filter media, 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; (b) contacting, under pressure, each edge of the filter media to each end cap; (c) heating the bonding composition coating to a temperature between about 175° and 220° C. for about 10 to 30 seconds to set the bonding composition and form a continuous filter media to end cap bond; and (d) allowing the bonding composition to cool to ambient temperature.

Claim 13

The fluid filter of claim 1 wherein the fluid filter is an oil filter.

Claim 14

The fluid filter claim 1 wherein the fluid filter is a fuel filter.

Claim 15

The fluid filter of claim 1 wherein the fluid filter is an air filter.

Claim 16

The fluid filter of claim 2 wherein the fluid filter is an oil filter.

Claim 17

The fluid filter of claim 2 wherein the fluid filter is a fuel filter.

Claim 18

The fluid filter of claim 2 wherein the fluid filter is an air filter.

Claim 19

The fluid filter of claim 3 wherein the fluid filter is an oil filter.

Claim 20

The fluid filter of claim 3 wherein the fluid filter is a fuel filter.

Claim 21

The fluid filter of claim 3 wherein the fluid filter is an air filter.

Claim 22

The fluid filter of claim 4 wherein the fluild filter is an oil filter.

Claim 23

The fluid filter of claim 4 wherein the fluid filter is a fuel filter.

Claim 24

The fluid filter of claim 4 wherein the fluid filter is an air filter.

Claim 25

The fluid filter of claim 5 wherein the fluid filter is an oil filter.

Claim 26

The fluid filter of claim 5 wherein the fluid filter is a fuel filter.

Claim 27

The fluid filter of claim 5 wherein the fluid filter is an air filter.

Claim 28

The fluid filter of claim 6 wherein the fluid filter is an oil filter.

Claim 29

The fluid filter of claim 6 wherein the fluid filter is a fuel filter.

Claim 30

The fluid filter of claim 6 wherein the fluid filter is an air filter.