Filter assembly having a flexible housing and method of making same

The present invention relates to an improved filter device for filtering, entrapping air, and preventing foaming in fluids, such as biological matter, including whole blood or blood components. More specifically, the invention relates to a filter assembly having an injection molded filter housing and a method of making a filter housing for performing the same. The invention may be used in blood collection and processing systems for removing leukocytes from whole blood, red blood cells, plasma, and platelets prior to transfusion or long term storage. A fluid filter assembly for filtering fluids such as blood is described. The assembly includes first and second filter housing elements formed by an injection molding process. Each element is flexible and includes a peripheral flange formed thereabout and a fluid communicating port formed therein. Filter media, such as a filter membrane, is sealed between the mating flanges of two elements. The fluid filter assembly is capable of collapsing and expanding during the filtration process depending upon the composition of the fluid passed there through. A method for making the filter assembly and systems for using the filter assembly are also disclosed.