Z-filter media pack arrangement; and, methods

A method of forming an air filter cartridge;

• the method comprising:
• (a) coiling a strip of fluted media secured to facing media to define a media combination comprising:
• (i) inlet and outlet flutes;
• (ii) a coil center;
• and,
• (iii) a media combination lead end positioned in the coil center;
• and,
• (b) molding a molded-in-place center within an end of the coil center;
• (i) the step of molding comprising putting a sealant material in an end of the coil center, after the step of coiling, and molding the sealant material to seal at least a portion of a lead end and to seal the center against air flow therethrough.

An air filter cartridge comprising:

• (a) a coiled media combination comprising a fluted sheet secured to a facing sheet and defining a set of inlet flutes and a set of outlet flutes and defining first and second, opposite, media combination flow ends;
• the coiled media combination defining a coil having a center extending between the first and second, opposite, media combination flow ends and an outer sidewall extending between the first and second, opposite, media combination flow ends;
• and,
• (b) a mold-in-place center resulting from putting at least a portion of sealant material through an open end of the center of the coil and allowing the sealant to seal and close the center against air flow therethrough.

A method of forming an air filter cartridge;

• the method comprising:
• (a) coiling a strip of fluted media secured to facing media to define a media combination comprising:
• (i) inlet and outlet flutes;
• and
• (ii) a coil center;
• and
• (b) molding a molded-in-place center within an end of the coil center;
• (i) the step of molding being conducted after the step of coiling and comprising putting at least a portion of sealant material through an open end of the coil center and molding the sealant material to seal the center against air flow therethrough.

An air filter cartridge comprising:

• (a) a coiled media combination comprising fluted media secured to facing media and defining a media combination inlet flow end and an opposite media combination outlet flow end;
• the media combination defining:
• (i) a coil having a center extending between the opposite flow ends;
• (ii) a media combination lead end positioned inside of the coil center;
• and,
• (b) a mold-in-place center resulting from putting a sealant material into an open end of the center of the coil and allowing the sealant to seal at least a portion of the lead end and to close the center against air flow therethrough.

A method of manufacturing an air filter cartridge constructed for use in an air cleaner comprising steps of:

• (a) applying a curable resin circumscribing a filter media pack and extending at least 80% of a length of the filter media pack between an inlet flow face of the filter media pack and an outlet flow face of the filter media pack, wherein:
• (i) the filter media pack comprises a combination of a fluted sheet and a facing sheet arranged in a coiled arrangement and having the inlet flow face and the outlet flow face, and defining a plurality of flutes extending from the inlet flow face to the outlet flow face;
• (ii) the combination of the fluted sheet and the facing sheet includes a lead end at a center of the coiled arrangement and a tail end at an outside of the coiled arrangement, and the curable resin is applied to the tail end;
• and
• (iii) the curable resin is applied directly to the filter media pack;
• (b) curing the curable resin to form a cured-in-place coating circumscribing the filter media pack and extending at least 80% of the length between the inlet flow face and the outlet flow face;
• and
• (c) molding a housing seal around the media pack at a location between the inlet flow face and the outlet flow face, wherein the housing seal is constructed to form a radially directed seal with an air cleaner housing when the air filter cartridge is operably installed in the air cleaner housing.

An air filter cartridge for use in an air cleaner comprising:

• (a) a filter media pack comprising a fluted sheet and a facing sheet, wherein:
• (i) the fluted sheet and the facing sheet are adhered together and provided in a coiled arrangement having the facing sheet as outwardly directed;
• (ii) the filter media pack having an inlet flow face and an outlet flow face;
• (iii) the fluted sheet and the facing sheet defining a plurality of flutes extending from the inlet flow face to the outlet flow face;
• and
• (iv) the fluted sheet and the facing sheet forming a lead end at a center of the coiled arrangement and a tail end at an outside of the coiled arrangement;
• (b) a resin jacket provided around a periphery of the filter media pack and adhered to the outwardly directed facing sheet, wherein the resin jacket extends at least 80% of a length between the filter media pack inlet flow face and the filter media pack outlet flow face;
• wherein the resin jacket is cured-in-place and seals the tail end of the fluted sheet and the facing sheet;
• and
• (c) a housing seal arrangement molded-in-place to the cured-in-place resin jacket around the periphery of the filter media pack and located between the inlet flow face and the outlet flow face, wherein the housing seal is constructed to form a radially directed seal with an air cleaner housing when the air filter cartridge is operably installed in the air cleaner housing.