Abstract:
A cast formed filter and a method for making the filter is provided. The method includes disposing a liquid filter media in a cavity of a molding tool, the molding tool having a plurality of features configured so that the filter media is formed about the plurality of features to form a plurality of inlet openings and a plurality of outlet openings in the filter media; applying at least one of pressure and heat to the filter media disposed in the molding tool to cure the liquid filter media and obtain a cast formed filter media defined by the cavity of the molding tool; and removing the cast formed filter media from the molding tool, wherein the cast formed filter media maintains a configuration having a three-dimensional periphery and the plurality of inlet openings extend from an inlet end of the cast filter media into the cast formed filter media so a first portion of the cast formed filter media is disposed between each of the plurality of inlet openings and an outlet end, and the plurality of outlet openings extend from the outlet end into the cast formed cast filter media so a second portion of the cast formed filter media is disposed between each of the plurality of outlet openings and the inlet end.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional of U.S. patent application Ser. No. 11/847,627 filed Aug. 30, 2007, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/824,128 filed Aug. 31, 2006 the contents each of which are incorporated herein by reference thereto. 
     
    
     BACKGROUND 
       [0002]    The present application relates to a cast formed filter and a method for making the same. 
         [0003]    Air induction housing systems are continually being challenged to become smaller and unique in shape without loss of system performance. In particular and referring to vehicular applications, this is due in part to the reduction in available real estate in the engine compartment. As vehicle profiles are reduced and engine systems become more complex there is very little available space for the air induction system, which is a critical component of the engine. The air induction system in an internal combustion engine of a vehicle that provides at least two important functions; providing a means for delivery of air into the combustion chambers of the engine and providing a means for filtering the air prior to its delivery to the combustion chambers. Due to its filtering function, the filter itself needs to be replaced after an extended period of use thus, accessibility to the filter is also a requirement imposed upon the air induction system as well as the housing. 
         [0004]    In some designs the air induction system is not designed until the engine design is completed thus, the designers of the air induction system are typically faced with the problem of providing a predetermined amount of airflow to the engine while also being presented with a limited or unique amount of space between the engine and the vehicle hood, front grill etc. Accordingly, the air induction housing typically has a unique configuration that is optimized for flow and space requirements, which may be contradictory to design requirements for the filter to be located within the air induction system. 
         [0005]    Furthermore, reducing the housing size and creating unique shapes limits the overall size of the filter capable of being disposed therein. Accordingly, and based upon conventional airflow technology, smaller filters typically result in less capacity thus, reduced performance. Additionally, making filters having unique configurations can require many manufacturing steps in producing the filter. 
         [0006]    Accordingly, it is desirable to provide a filter and simplified method of manufacturing the same, wherein the filter accommodates imposed size and shape limitations yet the filter provides a high capacity for filtration. 
       SUMMARY OF THE INVENTION 
       [0007]    A method of making a cast formed filter in accordance with an exemplary embodiment is provided. The method includes disposing a liquid filter media in a cavity of a molding tool, the molding tool having a plurality of features configured so that the filter media is formed about the plurality of features to form a plurality of inlet openings and a plurality of outlet openings in the filter media; applying at least one of pressure and heat to the filter media disposed in the molding tool to cure the liquid filter media and obtain a cast formed filter media defined by the cavity of the molding tool; and removing the cast formed filter media from the molding tool, wherein the cast formed filter media maintains a configuration having a three-dimensional periphery and the plurality of inlet openings extend from an inlet end of the cast filter media into the cast formed filter media so a first portion of the cast formed filter media is disposed between each of the plurality of inlet openings and an outlet end, and the plurality of outlet openings extend from the outlet end into the cast formed cast filter media so a second portion of the cast formed filter media is disposed between each of the plurality of outlet openings and the inlet end. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective and partial cross-sectional view of a portion of a cast formed filter in accordance with an exemplary embodiment of the present invention; 
           [0009]      FIG. 2  is a perspective view and partial cross-sectional of a portion of a cast formed filter in accordance with an alternative exemplary embodiment; 
           [0010]      FIG. 3  is a perspective view and partial cross-sectional of a portion of a cast formed filter in accordance with another alternative exemplary embodiment; 
           [0011]      FIG. 4  is a cross sectional view of a portion of a tool used to make a cast formed filter in accordance with an exemplary embodiment; 
           [0012]      FIG. 5  is a cross sectional view of a portion of a first tool used to make a cast formed filter in accordance with an exemplary embodiment; 
           [0013]      FIG. 6  is a cross sectional view of a portion of a second tool to be utilized with the first tool of  FIG. 5  to make the cast formed filter in accordance with an exemplary embodiment; and 
           [0014]      FIG. 7  is a cross sectional view of the first tool of  FIG. 5  being utilized with the second tool of  FIG. 6  to make the cast formed filter in accordance with an exemplary embodiment. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0015]    Reference is made to the following United States patent applications, U.S. Ser. No. 11/241,245 and U.S. Pat. No. 6,673,136 the contents of which are incorporated herein by reference thereto. 
         [0016]    In accordance with an exemplary embodiment of the present invention, a cast formed filter and a method of making the same is disclosed herein. In an exemplary embodiment, a configuration of the cast formed filter is made by forming or shaping filter media using a casting or molding process. The cast formed filter filters a fluid flowing therethrough. Non-limiting examples of the fluid to be filtered include gases and combinations thereof (e.g. air), water, fuels, oils, coolants, etc. 
         [0017]    It is contemplated that a molding or casting tool used in the manufacturing process is configured to produce a particular configuration of the cast formed filter media. Exemplary embodiments of the configuration of the cast formed filter include exterior features as well as interior features. Due to the flexibility of the molding process, the particular configuration of the cast formed filter media accommodates an application that requires a unique exterior shape and size to satisfy a restricted space limitation for the cast formed filter media and or an application that requires a non-uniform periphery. 
         [0018]    In an exemplary embodiment, an exterior periphery may be defined by a geometric shape, a non-uniform or non-geometric shape, or a combination thereof. For example and in a non-limiting exemplary embodiment, a configuration of the cast formed filter has an outer periphery that is configured to engage a complementary periphery of a housing that receives the cast formed filter media. In an exemplary embodiment, a cross sectional shape of an opening and or a shape of a length of the opening in the cast formed filter media may be defined by a geometric shape, a non-uniform or non-geometric shape, or a combination thereof. For example, in an exemplary embodiment, a periphery or an opening may have a shape that is circular, oval, hexagon, triangular, diamond, square, elliptical, non-geometric, or any combination thereof. 
         [0019]    In an exemplary embodiment, a number of openings and their configuration within the cast formed filter can increase surface filter area through the cast formed filter without restricting fluid flow, thereby providing a high capacity for filtration. In an exemplary embodiment, in accordance with a particular application, a configuration of openings in the cast formed filter media satisfies a unique fluid flow path requirement, an increase of filtration paths through the formed filter media, and or a predetermined filtration rate. Thus, a configuration of the cast formed filter can be created to provide a high capacity for filtration even for an application that has a restricted space requirement or requires a non-uniform exterior shape for the cast formed filter. 
         [0020]    In a non-limiting exemplary embodiment, a configuration of the cast formed filter includes a plurality of inlet openings extending into the cast formed filter media from an inlet end. The cast formed filter media further includes a plurality of outlet openings extending into the cast formed filter media from an outlet end. Each of the plurality of inlet openings and each of the plurality outlet openings do not extend completely through the cast formed filter media. Each of the plurality of inlet openings and each of the plurality of the outlet openings is formed within the cast formed filter media so that a portion of formed filter media separates an inlet opening from an outlet opening. In an exemplary embodiment, a configuration of at least one of the inlet openings may differ from a configuration of at least one of the outlet openings, wherein the configuration may include a cross sectional shape of the opening and or a length or shape of a length of the opening. 
         [0021]    In an exemplary embodiment, a fluid flow path extends through at least one of the plurality of inlet openings and through at least one of the plurality of outlet openings, wherein fluid flowing along the flow path is filtered by a portion of the formed filter media of the cast formed filter media. Of course, fluid can be filtered by the cast formed filter media when the fluid flows through a portion of the formed filter media without flowing through an inlet or an outlet opening. In an exemplary embodiment, media or material used to make the cast formed filter media is selected, for example, in accordance with the fluid to be filtered, a fluid flow rate through the filter, manufacturing considerations, a predetermined fluid filtration rate, an operational temperature of the fluid being filtered, and or a filter replacement interval. In a non-limiting exemplary embodiment, media used to make the cast formed filter media includes synthetic fiber, such as for example polyester fiber. 
         [0022]    Referring now to  FIGS. 1-3 , examples of exemplary embodiments of configurations of a cast formed filter will be discussed. As illustrated in  FIGS. 1-3 , a partial cross-sectional view is provided wherein an interior portion of the cast formed filter is shown in each of the figures to illustrate a configuration of inlet openings and outlet openings arranged within the cast formed filter media. Outer peripheries of the cast formed filter are not to be limited to those shown in  FIGS. 1-3 . In accordance with an exemplary embodiment of the present invention, the side walls of the cast formed filter not comprising the inlet openings or the outlet openings will consist of the filter media thus having no inlet or outlet openings therein. In some exemplary embodiments the cast formed filter media will be surrounded on the side walls not having the inlet and outlet openings by a filter housing having an inlet opening corresponding to the inlet openings and an outlet opening corresponding to the outlet openings. In one exemplary embodiment, the housing will be part of a conduit system or the housing will surround the cast formed filter media and is configured to be received within a conduit system. 
         [0023]    Referring now to  FIG. 1  and in an exemplary embodiment, a cast formed filter  10  includes a cast formed filter media  12 , an inlet end  14 , an outlet end  16 , a plurality of inlet openings  18 , and a plurality of outlet openings  20 . Each of the plurality of inlet openings extends into formed filter media  12  from inlet end  14  such that formed filter media  15  is disposed between each of the plurality of inlet openings and outlet end  16 . Each of the plurality of outlet openings extends into formed filter media  12  from outlet end  16  such that formed filter media  17  is disposed between each of the plurality of outlet openings and inlet end  14 . Formed filter media  19  is disposed between each of the plurality of inlet openings and an adjacent outlet opening. Formed filter media  15 ,  17  and  19  are portions of formed filter media  12 . Depending on a configuration of cast formed filter  10 , portions of formed filter media  15 ,  17  and  19  may blend into each other. 
         [0024]    Each of plurality of inlet openings  18  and each of plurality of outlet openings  20  has a substantially hexagon cross sectional shape. Of course, other configurations are considered to be within the scope of exemplary embodiments of the present invention. Plurality of inlet openings  18  are arranged within formed filter media  12  as spaced substantially parallel rows and spaced substantially parallel columns, as shown in  FIG. 1 . Although not fully shown in  FIG. 1 , plurality of outlet openings  20  are arranged within formed filter media  12  as spaced substantially parallel rows and spaced substantially parallel columns, wherein the rows and columns of the outlet openings are also substantially parallel with respect to the rows and columns of the inlet openings. 
         [0025]    In an exemplary embodiment, a fluid flow path extends through at least one of plurality of inlet openings  18  and through at least one of plurality of outlet openings  20 , wherein fluid is filtered by at least a portion of formed filter media  12  along the flow path. In a non-limiting example, fluid enters cast formed filter  10  through at least one of plurality of inlet openings  18  along a flow path  22  in a direction toward outlet end  16 . The fluid in the inlet opening flows through formed filter media  19  along a flow path  24  into at least one of plurality of outlet openings  20 , wherein the fluid is filtered by formed filter media  19  along flow path  24 . The fluid then flows through at least one of the outlet openings out of cast formed filter  10  along a flow path  26 . Of course in another application, the flow path could be reversed such that fluid flows into at least one of the plurality of outlet openings at the outlet end and exits the cast formed filter media by flowing through at least one of the plurality of inlet openings at the inlet end, the fluid being filtered by passing through at least a portion of the cast formed filter media along the flow path. 
         [0026]    In other applications, fluid may be filtered by formed filter media  12  by flowing along alternative flow paths. For example, fluid is filtered by formed filter media  17  when the fluid enters at least one plurality of outlet openings  20  by first passing through formed filter media  17 . In another application, fluid is filtered by formed filter media  15  when the fluid enters at least one plurality of inlet openings  18  by first passing through formed filter media  15 . Of course, fluid is filtered by formed filter media  15  if the fluid entering an inlet opening flows through formed filter media  15  at outlet end  16 , rather than flowing through another portion of formed filter media  12 . Similarly, fluid is filtered by formed filter media  17  if the fluid entering an outlet opening flows through formed filter media  17  at inlet end  14 , rather than flowing through another portion of formed filter media  12 . And in another application, fluid is filtered by a portion of formed filter media  12  when the fluid passes only through the formed filter media and does not pass through one of the inlet or outlet openings. 
         [0027]    Referring now to  FIG. 2 , a portion of a cast formed filter media  30  in accordance with another exemplary embodiment is illustrated. Cast formed filter media  30  includes formed filter media  32 , an inlet end  34 , an outlet end  36 , a plurality of inlet openings  38 , and a plurality of outlet openings  40 . Each of the plurality of inlet openings extends into formed filter media  32  from inlet end  34  such that formed filter media  35  is disposed between each of the plurality of inlet openings and outlet end  36 . Each of the plurality of outlet openings extends into formed filter media  32  from outlet end  36  such that formed filter media  37  is disposed between each of the plurality of outlet openings and inlet end  34 . Formed filter media  39  is disposed between each of the plurality of inlet openings and an adjacent outlet opening. Formed filter media  35 ,  37  and  39  are portions of formed filter media  32 . Depending on a configuration of cast formed filter media  30 , portions of formed filter media  35 ,  37  and  39  may blend into each other. 
         [0028]    Each of plurality of inlet openings  38  and each of plurality of outlet openings  40  has an approximate oval cross sectional shape. Of course, other configurations are considered to be within the scope of exemplary embodiments of the present invention. The plurality of inlet openings  38  are arranged within formed filter media  32  as spaced substantially parallel rows and spaced substantially parallel columns, as shown in  FIG. 2 . Although not fully shown in  FIG. 2 , plurality of outlet openings  40  are arranged within formed filter media  32  as spaced substantially parallel rows and spaced substantially parallel columns, wherein the rows and columns of outlet openings are also substantially parallel with respect to the rows and columns of inlet openings. The rows of the inlet openings and the outlet openings are further arranged with respect to each other so that the openings of one row are disposed between the openings of an adjacent row of openings. The columns of the inlet openings and the outlet openings are further arranged with respect to each other so that the openings of one column are disposed between the openings of an adjacent column of openings. 
         [0029]    In an exemplary embodiment, a fluid flow path extends through at least one of plurality of inlet openings  38  and through at least one of plurality of outlet openings  40 , wherein fluid is filtered by at least a portion of formed filter media  32  along the flow path. For example, fluid enters formed filter media  32  through at least one of plurality of inlet openings  38  along a flow path  42  in a direction toward outlet end  36 . The fluid in the inlet opening flows through formed filter media  39  along a flow path  44  into at least one of plurality of outlet openings  40 , wherein the fluid is filtered by formed filter media  39  along flow path  44 . The fluid then flows through at least one of plurality of outlet openings  40  out of cast formed filter media  30  along a flow path  46 . In other exemplary embodiments, fluid is filtered by cast formed filter media  30  by flowing along alternative flow paths similar to those discussed for cast formed filter media  10 . 
         [0030]    Referring now to  FIG. 3 , a portion of a cast formed filter media  50  in accordance with another exemplary embodiment is illustrated. Cast formed filter media  50  includes formed filter media  52 , an inlet end  54 , an outlet end  56 , a plurality of inlet openings  58 , and a plurality of outlet openings  60 . Each of the plurality of inlet openings extends into formed filter media  52  from inlet end  54  such that formed filter media  55  is disposed between each of the plurality of inlet openings and outlet end  56 . Each of the plurality of outlet openings extends into formed filter media  52  from outlet end  56  such that formed filter media  57  is disposed between each of the plurality of outlet openings and inlet end  54 . Formed filter media  59  is disposed between each of the plurality of inlet openings and an adjacent outlet opening. Formed filter media  55 ,  57  and  59  are portions of formed filter media  52 . Depending on a configuration of cast formed filter media  50 , portions of formed filter media  55 ,  57  and  59  may blend into each other. 
         [0031]    Each of plurality of inlet openings  58  and each of plurality of outlet openings  60  has an elongated zig-zag cross sectional shaped opening. Of course, other configurations are considered to be within the scope of exemplary embodiments of the present invention. Plurality of inlet openings  58  are arranged within formed filter media  52  as spaced substantially parallel rows, as shown in  FIG. 3 . Although not fully shown in  FIG. 3 , plurality of outlet openings  60  are arranged within formed filter media  52  as spaced substantially parallel rows, wherein the rows of outlet openings are also substantially parallel with respect to the rows of inlet openings. 
         [0032]    In an exemplary embodiment, a fluid flow path extends through at least one of plurality of inlet openings  58  and through at least one of plurality of outlet openings  60 , wherein fluid is filtered by a least a portion of formed filter media  52  along the flow path. For example, fluid enters formed filter media  52  through at least one of plurality of inlet openings  58  along a flow path  62  in a direction toward outlet end  56 . The fluid in the inlet opening flows through formed filter media  59  along a flow path  64  into at least one of plurality of outlet openings  60 , wherein the fluid is filtered by formed filter media  59  along flow path  64 . The fluid then flows through at least one of plurality of outlet openings  60  out of cast formed filter media  50  along a flow path  66 . In other exemplary embodiments, fluid is filtered by cast formed filter media  50  by flowing along alternative flow paths similar to those discussed for cast formed filter media  10 . 
         [0033]    Referring now to  FIGS. 4-7 , an exemplary embodiment of how molding or casting tools are used for making a configuration of the cast formed filter media will be briefly described. It is contemplated that the molding tools used to produce the configuration of the cast formed filter media have features to form an exterior periphery as well as interior features of the cast formed filter media. In an exemplary embodiment, the molding tools include features to form an exterior periphery that is defined by a geometric shape, a non-uniform or non-geometric shape, or a combination thereof. 
         [0034]    For example and in an exemplary embodiment, an exterior of the cast formed filter media is defined by a length and a width, wherein the width defines an outer periphery of the cast formed filter media. In another exemplary embodiment, an exterior of the cast formed filter media has a three-dimensional shape defined by a non-uniform length, a non-uniform width, and a non-uniform height, wherein the non-uniform width and the non-uniform height define an outer periphery of the cast formed filter media. Due to the flexibility of the molding process, the cast formed filter media can have a unique exterior shape and size that accommodates a restricted space limitation for the cast formed filter media and or an application that requires a non-uniform periphery. For example, a housing the cast formed filter media is inserted into. Moreover, and as discussed above the sides of the cast formed filter media not having the inlet openings and the outlet openings may be received within an outer housing that fluidly seals the side wall of the cast formed filter media not having the inlet openings and the outlet openings. 
         [0035]    In an exemplary embodiment, the molding tools also include features to form an interior configuration of the cast formed filter media. For example, the interior configuration can include cross sectional shapes of openings and shapes of lengths of the openings. In an exemplary embodiment, the tools are configured to form openings having a configuration defined by a geometric shape, a non-uniform or non-geometric shape, or a combination thereof. Thus, due to the flexibility of the molding process, a cast formed filter media can have a unique configuration of openings to accommodate an application that requires unique flows paths for the fluid to flow therethrough. Additionally, the molding tools can be configured to create a plurality of openings in the cast formed filter media, thereby increasing the surface filter area to provide a cast formed filter media having a high capacity for filtration. 
         [0036]    Referring now to  FIG. 4 , a portion of a casting or molding tool  70  contemplated for use in manufacturing a configuration of the cast formed filter media in accordance with an exemplary embodiment of the present invention is illustrated. Tool  70  includes a surface  72  that defines a cavity  74 . A periphery of surface  72  corresponds to an outer periphery of the cast formed filter media after the molding process is completed. In an exemplary embodiment, two or more tools may be combined to then form the cavity and surface within the combined tools for forming a configuration of cast formed filter media. 
         [0037]    For example and in an exemplary embodiment, one configuration of cast formed filter media made by a molding tool that includes an arrangement of inlet and outlet openings as illustrated in  FIG. 1 ,  2  or  3  and an outer periphery wherein at least a portion of the outer periphery has a circular, rectangular, square, oval, or any other a geometric shape. In another exemplary embodiment, a configuration of cast formed filter media made by a molding tool includes an arrangement of inlet and outlet openings as illustrated in  FIG. 1 ,  2  or  3  and an outer periphery wherein at least a portion of the outer periphery has a non-uniform or non-geometric shape. Of course, in an alternative exemplary embodiment, a configuration of the cast formed filter media made by a molding tool includes inlet openings and outlet openings that have a configuration different from those shown in  FIGS. 1-3  and the cast formed filter media has an exterior periphery defined by a geometric shape, a non-geometric shape, or a combination thereof. 
         [0038]    In an exemplary embodiment, the surface defined by the molding tool can be configured to produce an outer periphery of the cast formed filter media that is substantially similar to an interior surface of a housing configured to receive the cast formed filter media. For example and in an exemplary embodiment, a non-uniform configuration of the cast formed filter media is a three-dimensional shape configured to be received in a housing having a non-uniform periphery therein, wherein the non-uniform configuration is defined by a non-uniform length, a non-uniform width, and a non-uniform height. In another exemplary embodiment, a surface of the tool defines a protrusion configured to form a recess in a portion of an outer periphery of the cast formed filter media, wherein the recess is configured to engage a complementary protrusion of the housing. In another exemplary embodiment, a surface of the tool defines a recess configured to form a protrusion in a portion of an outer periphery of the cast formed filter media, wherein the protrusion is configured to engage a complementary recess of the housing. Due to the molding process, it is possible to produce a cast formed filter media that has an outer periphery configured for the geometry of the environment the cast formed filter media will be used therewith. 
         [0039]    Referring now to  FIGS. 5-7 , a non-limiting example of molding tools used to make a configuration of cast formed filter media having an arrangement of inlet openings and outlet openings substantially similar to that of cast formed filter  10  is illustrated. Only a portion of the mold tools are illustrated in  FIGS. 5-7  for discussing how a configuration of openings are formed within the cast formed filter media. Although not shown and in an exemplary embodiment, when tool  80  is assembled with tool  90  interior surfaces of tools  80 ,  90  define a cavity therein for forming an outer periphery of the cast formed filter media. In an alternative exemplary embodiment, any number of tools may be combined to define surfaces and cavities to form a configuration of the cast formed filter media. 
         [0040]    In an exemplary embodiment, tool  80  includes a base portion  82  and a plurality of pins  84  extending from base portion  82 . Pins  84  have a configuration that corresponds to the configuration of inlet openings  18  of cast formed filter  10  as illustrated in  FIG. 1 . Tool  90  includes a base portion  92  and a plurality of pins  94  extending from base portion  92 . Pins  94  have a configuration that corresponds to the configuration of outlet openings  20  of cast formed filter  10  as illustrated in  FIG. 1 . In an alternative exemplary embodiment, any pin of the tools may have a unique configuration to form a corresponding unique configuration of an inlet opening or an outlet opening that extends into the cast formed filter media. In exemplary embodiments, the configuration of the pin includes its cross sectional shape, length of the pin, and a shape of the length of the pin. For example, a length of the pin may be shaped to form an inlet opening or an outlet opening wherein at least a portion of the opening&#39;s length is substantially straight, curved, a non-uniform shape, or any combination thereof. 
         [0041]    In an exemplary embodiment, when tool  80  is assembled with tool  90  plurality of pins  84  and plurality of pins  94  substantially overlap one another in a spaced manner, as illustrated in  FIG. 7 . A quantity of filter media  102 , which is in a liquid, semi-liquid or non-solid state is then disposed or poured within the cavities of tools  80 ,  90  so that filter media  102  substantially surrounds the peripheries of each of plurality of pins  84  and  94  and substantially fills the cavities of tools  80 ,  90 . After the liquid, semi-liquid or non-solid filter media  102  has cured, or formed into a solid or semi-solid state and into the configuration defined by tools  80 ,  90 , the cast formed filter media is separated from tools  80 ,  90 , wherein the cast formed filter media has the configuration of inlet openings and outlet openings as that of cast formed filter  10  shown in  FIG. 1 . In exemplary embodiments of the cast formed filter media, the filter media is selected so the cast formed filter media filters fluid passing therethrough in accordance with predetermined filtration criteria. In an exemplary embodiment, filter media  102  includes synthetic fiber, such as for example polyester fiber. 
         [0042]    Exemplary embodiments described herein provide a cast formed filter media having unique exterior as well as interior features to accommodate specific application requirements, including restricted space and or non-uniform shape requirements, and the cast formed filter media provides a high capacity for filtration. 
         [0043]    While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the present application.