DE102015013370A1 - Filter element, in particular for a motor vehicle, and method for producing a filter element - Google Patents

Abstract

The present invention provides a filter element (1) for a motor vehicle, comprising a filter medium (2) having folds (5, 6) with a variable fold height (H), and at least one planar cover element (21) attached to the filter medium ( 2), wherein the cover element has a film (26) connected to the filter medium (2).

Description

Technical area

The present invention relates to a filter element, in particular for a motor vehicle. Furthermore, the present invention relates to a method for producing a filter element.

Filter elements are used, for example, in the air supply for internal combustion engines to clean the air supplied to the combustion of pollutants and dirt particles. In particular, such filter elements can be used in commercial vehicles, construction machines and the like.

A filter medium of such a filter element may be folded in a zigzag shape in the form of a bellows in order to increase the surface area of the filter medium. Increasing the surface area may increase the life of the filter element, as a larger filter surface can absorb more debris before the pressure loss on the filter medium caused by deposited particles becomes undesirably high, or even increased, such that the fluid no longer passes or flows through the filter medium can.

Usually, the filter element is arranged in a housing. The geometric design of the housing must be adapted to external conditions, for example space conditions in an engine compartment of the commercial vehicle. The structural design of the housing usually has an influence on the shape and size of the filter element.

In order to be able to adapt the shape of the filter element with a folded filter medium to almost any housing shapes, it has become known to provide the filter medium with folds which have a variable pleat height. Such filter media are also referred to as "Vario Pleat".

Disclosure of the invention

Against this background, the object of the present invention is to provide an improved filter element, in particular for a motor vehicle.

The filter element comprises a filter medium and at least one planar cover element. Folds of the filter element have a variable pleat height. The flat cover is attached to the filter medium. The flat cover element comprises a film connected to the filter medium. In particular, the cover serves for the lateral closure of the folds or folding pockets. Particularly preferably, at least two cover elements are provided on opposite sides of the filter element for the lateral closure of the folds.

As a result, a filter element with a cover element can be provided in a simple manner. The film can be provided with a suitable blank and attached to the filter medium. For this purpose, the film can be cut out of a corresponding raw material or made punched out. In this case, a film material is preferably used, the blend can be reused by z. B. in the production of the raw material can be added.

It is also advantageous that no injection molding tool or welding process is required for the formation of the cover. Accordingly, the filter element can be produced cost-effectively even with small numbers.

The motor vehicle is preferably a commercial vehicle. Alternatively, the filter element may also be suitable for a generator, a construction machine or any other application in which air or other fluid (gas, liquid or mixture thereof) is supplied to an internal combustion engine and purified by the filter element of pollutants and / or dirt particles. In general, the filter element can be designed as an air filter element.

The term "filter medium having pleats with a variable pleat height" here means the following: folding edges of pleats of the filter medium lie in each case in one of two surfaces. A respective surface may have a curved and / or angular course. The distance between the two surfaces varies depending on a position on a respective surface. The pleat height denotes the shortest, in particular vertical distance from a respective folding edge on the opposite surface. This pleat height varies with the filter media. That is, the fold height associated with two different fold edges is different.

By "planar cover member" is meant an element which extends over the filter element. The surface in which the cover extends, may have a curved and / or angular course. The thickness (that is, the extent of the cover in a direction perpendicular to the aforementioned surface) may be many times smaller than the width or length of the cover, for example, a tenth, a fiftieth, a hundredth or less this amount.

The filter medium is, for example, a filter fleece, a filter fabric, a filter fabric or a filter felt, in particular a needle felt. The filter medium can be produced in the meltblow process. The filter medium may include natural fibers such as cotton or synthetic fibers such as polyester, polyvinyl sulfite or polytetrafluoroethylene. The fibers may be oriented in, skewed and / or transversely to the machine direction during processing. Also, the fibers may be stretched in one spatial direction. The filter medium can be formed in one or more layers. The pleats of the filter medium typically extend across the machine direction. The folded filter medium is also referred to as pleats. The pleats can be produced by folding along sharp edges (also referred to as pleat tips or embossing edges) or by a wavy design of the filter medium. In this respect, folding edge preferably also applies here to the tip of a respective wave crest or wave trough in the case of a wave-shaped embodiment of the filter medium. A respective fold can be defined by two folding sections, which are connected to one another via a corresponding folding edge. The folding can be carried out in particular as a zigzag folding.

By "nonwoven" is meant herein an aggregate of limited length fibers, continuous filaments or cut fibers of any kind and of any origin, the fibers being interconnected in any manner; this excludes a crossing or entanglement of the fibers, as it happens during weaving, braiding or tufted generating.

The term "cellulose layer" is understood to mean a material layer which has been produced at least partially, preferably predominantly, on the basis of cellulose fibers.

In particular, for stabilizing the cover, the cover member in addition to the film on a cover layer. The cover layer at least partially forms the outside of the cover and is connected by means of the film with the filter medium, cohesively. As a cover layer preferably a cellulose layer and / or a nonwoven fabric are provided, since such material layers are characterized by a simple processability and high adaptability to the shape of the cover. In addition, due to their porosity, a cellulose layer and / or a nonwoven can be connected to the filter medium particularly well with the aid of the film or at least partially embedded in the film.

The film connects the cover layer with the filter medium in particular material and / or positive fit. The film is preferably made of a homogeneous material, thus has no fibers. In the film, the folding edges of folds of the filter medium can be formed, that is, the film encloses the fold edges partially. The film provides a fluid-tight (gas- and / or liquid-tight) connection between the filter medium and the cover layer.

According to one embodiment, the cover element is connected to fold end edges of the filter medium. The "fold end edges" are also referred to as "fold profiles". By "wrinkle front edge" is meant the frontal fold surface which extends between two adjacent fold edges of a respective fold end. The wrinkle front edge runs at an angle, in particular at an angle of 90 °, to a respective folding edge. Alternatively or additionally, the cover may be connected to fold edges of the filter medium.

For example, the cover element (the cover layer and / or the film) may extend over a part or an entire end face of the filter medium. The end face here refers to one of two opposite surfaces, in particular planes, in which lie the fold end edges of the filter medium.

According to a further embodiment, cover layer is materially connected by means of the film to the filter medium while foaming the film. In other words, the film adheres the cover layer to the filter medium. The "foaming of the film" comprises, in particular, vulcanization of the film. This results in a simple manufacturability of the filter element.

According to a further embodiment, the film is made of a rubber, in particular a nitrile butadiene rubber. Instead of nitrile butadiene rubber (NBR), another synthetic rubber could also be used.

According to a further embodiment, the cover layer is adapted to seal the filter medium with respect to a filter housing in which the filter element is receivable. Accordingly, the cover layer has a sealing function.

According to a further embodiment, an additional component is connected to the filter medium with the aid of the cover layer, in particular adhesively bonded. At the cover layer is easy to attach the additional component, such as a frame or the like. In general, the cover layer thus serves to provide a connection possibility for connecting further components to the filter medium.

According to a further embodiment, the filter element as an air filter element for a Motor vehicle trained. In particular, the filter element is designed as an air filter element for the intake tract of a commercial vehicle.

Furthermore, a series of filter elements is provided. The series comprises a first and a second filter element as described above. The respective cover element has a different blank.

By "series" herein is meant also a set of filter elements. Possible blanks include, for example, an at least partially round and / or square blank. In particular, a rectangular, trapezoidal blank or a blank according to another polygon comes into consideration. Next is a circular, oval, annular or otherwise curved blank into consideration.

Due to the manner in which the cover element is attached to the filter medium, this can easily be provided with different blanks. A respective blank preferably corresponds to the geometry of the filter medium, in particular a geometry of an end face, that is to say a side of the filter medium which surrounds the fold end edges. The blank covers the filter medium, in particular its end face, partially or completely.

In accordance with another embodiment, a method of making a filter element as described above is provided. The method includes providing a variable wrinkle height filter medium. In a further step, at least one planar cover element is attached to the filter medium. The cover element has a film connected to the filter medium and optionally a cover layer.

According to one embodiment of the method, the film is cut to size, arranged on the filter medium and subsequently connected in a fluid-tight manner to the filter medium.

The bonding of the film to the filter element can be done by foaming the film. It can be provided that initially the cover layer is arranged on the film and connected to it to form the cover. In a subsequent step, then the cutting of the cover, ie the cutting of the cover layer is carried out together with the film, so that a blank of the cover of the same geometry of the filter medium, in particular a front side corresponds. Alternatively, the cover sheet and the film may each be cut separately and then joined together to form the cover member. In a further step, this cover is then arranged on the filter medium, in particular a front side of the same. According to a further variant, the cover layer and the film are each cut separately and arranged successively to form the cover on the filter medium. The bonding of the cover layer and the film can be done by gluing in particular using an adhesive. Alternatively, bonding can be accomplished by heating and thereby at least partially vulcanizing the film on the side at which the cover sheet is brought into contact with the film.

Further possible implementations of the invention also include not explicitly mentioned combinations of features or method steps described above or below with regard to the exemplary embodiments. The skilled person will also add individual aspects as improvements or additions to the respective basic form of the invention.

Further embodiments of the invention are the subject of the dependent claims and the embodiments of the invention described below. Furthermore, the invention will be explained in more detail by means of embodiments with reference to the accompanying figures.

Brief description of the drawings

It shows:

1 in a perspective view of a filter element according to an embodiment;

2 : schematically a section from 1 ;

3 : a view III off 2 ;

4 : section of the filter element 1 in a state received in a filter housing;

5 : the filter element off 1 wherein its cover layer is connected to a further component;

6 a plan view of an end face of a filter element according to another embodiment;

7a to 7d in each case a plan view of an end face of filter elements according to different embodiments.

In the figures, like reference numerals designate like or functionally identical elements, unless indicated otherwise.

Embodiments of the invention

1 shows in a perspective view a filter element 1 in the form of an air filter element according to an embodiment. The filter element 1 includes a filter medium 2 which is in a frame 3 is held. By means of the frame 3 lets the filter element 1 fasten in a filter housing, not shown, such that the filter medium 2 in filter operation in a flow direction 4 is traversed with air to be cleaned. The air flows from a raw side RO to a clean side RE of the filter element 1 , In the process, particles, such as dust or dirt, are filtered out of the air. The purified air is then supplied to, for example, an internal combustion engine for a combustion process in this.

Such a filter element 1 can be used for example in a motor vehicle, in particular a commercial vehicle, a generator, a construction machine or other device.

Based on 2 and 3 In particular, the construction of the filter medium will be described below 2 out 1 explained in more detail.

The filter medium 2 may be made of a nonwoven or cellulosic material. In particular, the filter medium 2 a thickness of 04, up to 2 mm. The filter medium 2 may be impregnated or otherwise surface treated.

The filter medium 2 has a zigzag-shaped folding ("bellows") made, for example, from a flat sheet, so that wrinkles 5 . 6 (For example, only two of the folds have been provided with reference numerals). A respective fold 5 . 6 includes folding sections 7 . 8th , which have a folding edge 9 (also referred to as embossing edge) are interconnected. The folding sections 7 . 8th adjacent wrinkles 5 . 6 are in turn via a folding edge 10 connected with each other.

The folding edges 9 of wrinkles 5 . 6 lie in a purely-sided first (imaginary and therefore shown in dashed) area 11 and the fold edges 10 of wrinkles 5 . 6 within a raw-side, second (imaginary and therefore shown in dashed) area 12 , According to the embodiment, the area is 11 curved while the area 12 just trained. This is due to the fact that a fold height H of the folds 5 . 6 varied. The fold height H refers to the perpendicular from a folding edge 9 on the surface 12 , This results in how in 1 to see, one perpendicular to the flow direction 4 oriented upstream side 13 and an arcuate downstream side 14 , The shape of the filter medium 2 and thus the shape of the filter element 1 Due to the varying fold height H, it can easily be adapted to geometric boundary conditions, for example in the motor vehicle. Incidentally, a pleat spacing A, A ', as in FIG 3 shown between wrinkles 5 . 6 . 15 vary. This could be on the upstream side 13 varying flow properties of the filter medium 2 be achieved. The wrinkles 5 . 6 . 15 or the distances A, A 'can be stabilized by means of these in 2 shown glue beads 16 be connected to each other.

As in further 2 shown have the folding sections 7 . 8th at their front sides in each case a wrinkle front edge 17 . 18 (also referred to as fold profile) on which the folding edges 9 . 10 connects with each other. The fold front edges 17 . 18 lie in one plane, namely the front side 19 of the filter medium 2 , Opposite are the wrinkles 5 . 6 corresponding fold end edges 18 ' (only one of the fold end edges can be seen), which is an end face 20 opposite the front 19 define.

On at least one of the front sides 19 . 20 - According to the embodiment according to 1 on both - is a cover 21 appropriate. The cover element 21 can also be referred to as end plate.

The cover element 21 is flat and has only a small thickness D compared to its dimensions parallel to the front side 19 on. The cover element 21 preferably has a blank, which is the front side 19 equivalent. Accordingly, the cover member 19 a curved, the surface 11 following page 22 , an opposite, just the area 12 following page 23 as well as endfolds 5a . 5b following pages 24 . 25 on.

The cover element 21 is in 4 shown in greater detail. The cover element 21 is made up of a foil 26 and a cover layer 27 together. The cover layer 27 is with the help of the foil 26 with the front side 19 or the corresponding fold end edges 17 . 18 connected. The cover layer 27 may be formed by a nonwoven and / or by a cellulose layer.

The foil 26 For example, it may comprise a synthetic rubber, in particular nitrile butadiene rubber. For connecting to the pleated front edges 17 . 18 will the film 26 including cover layer 27 on the fold front edges 17 . 18 arranged and heated. This leads to vulcanization of the film 26 , so that a material connection with the Faltenstirnkanten 17 . 18 , in particular a bond, arises. The foil 26 can be partially in the inside of a respective fold 5 . 6 defined interior 28 vulcanising in, as in the place 29 indicated.

The cover layer 27 can for forming the cover 21 with the foil 26 in a step which involves bonding the film 26 with the filter medium 2 precedes, connected, in particular glued. Subsequently, the corresponding blank of the cover by punching or cutting the same from flat, in particular web-shaped raw material (which the film 26 and the cover layer 27 in flat, web-shaped, in particular stacked state comprises) produced.

The cover layer 27 writes as in 4 shown against a front frame section 30 (see also 1 ) of the frame 3 airtight. Instead of the frame section 30 It could also be a filter housing 31 act in which the filter element 1 is arranged.

As in 5 shown, the cover layer 27 outside (inside this is with the film 26 connected) with another component 32 , For example, a frame or other reinforcing element, connected, in particular glued.

6 now illustrates that the cover 21 not completely over the entire front side 19 (please refer 2 ), but may also have recesses, for example. The recesses 33 For example, they may be square or rounded, for example triangular, quadrangular or circular.

The 7a - 7d show a series of filter elements 1 with cover elements 21-1 . 21-2 . 21-3 and 21-4 , which each have a different cut. Each dashed (because hidden) is a filter medium 2 indicated. As can be seen, the cover elements 21 a square and / or rounded contour, also with lateral recesses 34 include.

Although the invention has been described herein with reference to preferred embodiments, it is variously modifiable.

LIST OF REFERENCE NUMBERS

1

filter element

2

filter media

3

frame

4

flow direction

5

wrinkle

5a

fold the end

5b

fold the end

6

wrinkle

7

folding section

8th

folding section

9

fold

10

fold

11

area

12

area

13

inflow

14

outflow

15

wrinkle

16

glue bead

17

Fold front edge

18

Fold front edge

18 '

Fold front edge

19

front

20

front

21

cover

22

page

23

page

24

page

25

page

26

foil

27

cover sheet

28

inner space

29

Job

30

frame section

31

filter housing

32

further component

33

recess

34

recess

A

distance

A '

distance

D

thickness

H

height

RE

clean side

RO

unfiltered side

Claims (10)

Filter element ( 1 ), in particular for a motor vehicle, with a filter medium ( 2 ), the wrinkles ( 5 . 6 ) having a variable fold height (H), and at least one planar cover element ( 21 ) which is attached to the filter medium ( 2 ) is mounted, wherein the cover element with the filter medium ( 2 ) connected film ( 26 ) having. Filter element according to claim 1, wherein the cover element ( 21 ) with pleated end edges ( 17 . 18 ) of the filter medium ( 2 ) connected is. Filter element according to claim 1 or 2, wherein the cover element ( 21 ) in addition to the film ( 26 ) a cover layer ( 27 ), wherein the cover layer ( 27 ), in particular a cellulose layer or / and a fleece, at least partially forms the outside of the cover element and with the aid of the film ( 26 ) with the filter medium ( 2 ), in particular with foaming of the film ( 26 ), is materially connected. Filter element according to one of claims 1 to 3, wherein the film ( 26 ) is made of a rubber, in particular a nitrile butadiene rubber. Filter element according to one of claims 1 to 4, wherein a cover layer ( 27 ) of the cover element ( 21 ) is adapted to the filter medium ( 2 ) with respect to a filter housing ( 31 ), in which the filter element ( 1 ) is receivable. Filter element according to one of claims 1 to 5, wherein by means of a cover layer ( 27 ) of the cover element ( 21 ) an additional component ( 32 ) with the filter medium ( 2 ), in particular glued, is. Filter element according to one of claims 1 to 6, which is designed as an air filter element for a motor vehicle. Series of filter elements ( 1 ), with at least one first and second filter element ( 1 ) according to one of claims 1 to 7, wherein the respective cover element ( 21-1 . 21-2 . 21-3 . 21-4 ) has a different cut. Method for producing a filter element ( 1 ) according to one of claims 1 to 7, wherein a filter medium ( 2 ) with wrinkles ( 5 . 6 ) variable fold height (H) and at least one flat cover element ( 21 ) on the filter medium ( 2 ), wherein the cover element ( 21 ) at least one with the filter medium ( 2 ) connected film ( 26 ) having. Method according to claim 9, wherein the film ( 26 ), on the filter element ( 2 ) and then with the filter medium ( 2 ) is fluid-tightly connected.

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