Patent ID: 8685301

Claim:
A method of making a filter element for use with a filter housing a filter housing sealing surface, the method comprising steps of: forming a fluted filter media pack having a plurality of flutes, wherein first flutes of the plurality of flutes are closed proximate an outlet face and second flutes of the plurality of flutes are closed proximate an inlet face, molding a media pack seal member, separately molding an axial seal member configured for axially sealing against the filter housing sealing surface; providing a frame having an axial seal support portion and a media pack seal support portion; wherein the step of molding a media pack seal member includes securing the frame to the fluted filter media pack with the media pack seal member; wherein the step of separatelv molding an axial seal member includes molding the axial seal member in an axial seal support portion of the frame, such that the axial seal member on the frame is in a spaced relation to the fluted filter media pack; wherein the axial seal member is molded using a first polymeric material and the media pack seal member is molded using a second polymeric material; and wherein the axial seal member and the media pack seal member are molded in a mold including an annular mold cavity, wherein the axial seal member is molded before the media pack seal member, wherein the step of molding an axial seal member includes pouring the first polymeric material in its uncured form and inserting the frame in the mold such that the axial seal support portion is placed over the annular mold cavity, wherein an axial seal molding region defined by the axial seal support portion and the annular mold cavity is formed, wherein the first polymeric material foams and cures in the axial seal molding region.