JP2020133436A - Air cleaner and its manufacturing method - Google Patents

Air cleaner and its manufacturing method Download PDF

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JP2020133436A
JP2020133436A JP2019024725A JP2019024725A JP2020133436A JP 2020133436 A JP2020133436 A JP 2020133436A JP 2019024725 A JP2019024725 A JP 2019024725A JP 2019024725 A JP2019024725 A JP 2019024725A JP 2020133436 A JP2020133436 A JP 2020133436A
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air
tubular
filter paper
air holes
hole
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浩司 夏目
Koji Natsume
浩司 夏目
文雄 小倉
Fumio Ogura
文雄 小倉
崇彰 稲森
Takaaki Inamori
崇彰 稲森
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Isuzu Motors Ltd
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Isuzu Motors Ltd
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Priority to JP2019024725A priority Critical patent/JP2020133436A/en
Priority to PCT/JP2020/004523 priority patent/WO2020166479A1/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Filtering Materials (AREA)

Abstract

To provide an air cleaner and its manufacturing method capable of improving accuracy in detecting a flow rate by reducing dispersion of detection values of a flow sensor disposed at a downstream side with respect to air flow.SOLUTION: In an air cleaner which includes a housing 2, cylindrical filter paper 3 disposed inside of the housing 2, and a cylindrical supporting material 4 disposed at an inner side or an outer side in a cylinder diameter direction, of the filter paper 3 and supporting the filter paper 3, and in which the supporting material 4 is provided with a number of air holes 5 through which air A having passed through the filter paper 3, passes in the cylinder diameter direction, the supporting material 4 has single-layered ventilation portions 6, and joining portions 7 formed with both end portions in a cylinder circumferential direction, of plate materials constituting the supporting material 4 joined in a stacked state, the ventilation portion 6 has a number of air holes 5, and the joining portion 7 has a through hole 8 penetrating through both end portions and a joining frame 15 surrounding the circumference of the through hole 8, and a passing amount of the air A is equal with respect to the ventilation portion 6 when compared on the same cylinder area.SELECTED DRAWING: Figure 1

Description

本発明は、エアクリーナ及びその製造方法に関し、より詳細には、流量の検出精度を向上させるエアクリーナ及びその製造方法に関する。 The present invention relates to an air cleaner and a method for manufacturing the same, and more particularly to an air cleaner for improving the accuracy of detecting a flow rate and a method for manufacturing the same.

エンジンのエアクリーナとして、筐体の内部に設置された筒状の濾紙と、この濾紙の筒径方向内側又は外側に設置されてこの濾紙を支持する筒状の支持材とを備えたものが提案されている（例えば、特許文献１を参照）。 As an engine air cleaner, a tubular filter paper installed inside a housing and a tubular support material installed inside or outside the filter paper in the tubular radial direction to support the filter paper have been proposed. (See, for example, Patent Document 1).

特開２００１−１３２５６２号公報Japanese Unexamined Patent Publication No. 2001-132562

ところで、特許文献１に記載のエアクリーナの支持材は、濾紙を支持すると共に濾紙を通過後の空気が通過するように、パンチングメタルやエキスパンドメタルから構成されている。具体的に、支持材は、それらの板材を丸めて筒周方向の両端部を積層して接合することで筒状を成している。 By the way, the support material for the air cleaner described in Patent Document 1 is composed of a punching metal or an expanded metal so as to support the filter paper and allow air to pass through the filter paper. Specifically, the support material has a tubular shape by rolling the plate members and laminating and joining both ends in the tubular circumferential direction.

しかし、積層して接合した部位がそれ以外の部位に対して空気の流れを阻害しており、支持材には、筒周方向の一部に、空気の流れを阻害する部位が形成されることになる。この空気の流れを阻害する部位が筒周方向の一部に形成されることにより、空気の流れに関してエアクリーナの下流側に配置された流量センサの検出値がばらつき、流量の検出精度が低下していた。特に、流量センサは吸気管の中で流路がストレートで内径の寸法ばらつきが少ない場所に設置することが精度向上に好ましいが、車両のレイアウトの制約のためエアクリーナの直後がその条件に適している場合がある。しかし、エアクリーナと流量センサとを近接させると、前述の検出値のばらつきは大きくなる。 However, the laminated and joined parts obstruct the air flow with respect to other parts, and the support material has a part that obstructs the air flow in the circumferential direction. become. Since the portion that obstructs the air flow is formed in a part in the circumferential direction, the detection value of the flow rate sensor arranged on the downstream side of the air cleaner varies with respect to the air flow, and the flow rate detection accuracy is lowered. It was. In particular, it is preferable to install the flow rate sensor in a place where the flow path is straight and there is little variation in the inner diameter of the intake pipe in order to improve accuracy, but due to restrictions on the layout of the vehicle, the condition immediately after the air cleaner is suitable. In some cases. However, when the air cleaner and the flow rate sensor are brought close to each other, the above-mentioned variation in the detected values becomes large.

本発明の目的は、空気の流れに関して下流側に配置された流量センサの検出値のばらつきを低減して、流量の検出精度を向上させることができるエアクリーナ及びその製造方法を提供することである。 An object of the present invention is to provide an air cleaner and a method for manufacturing the same, which can reduce the variation in the detection value of the flow rate sensor arranged on the downstream side with respect to the air flow and improve the flow rate detection accuracy.

上記の目的を達成する本発明のエアクリーナは、筐体と、この筐体の内部に設置された筒状の濾紙と、この濾紙の筒径方向内側又は外側に設置されてこの濾紙を支持する筒状の支持材と、を備えて、その支持材が、前記濾紙を通過した空気が筒径方向に通過する多数の空気穴が形成されてなるエアクリーナにおいて、前記支持材は、単層の通気部と、この支持材を構成する板材の筒周方向の両端部が積層した状態で接合されてなる接合部と、を有して、前記通気部は、多数の前記空気穴が形成されてなり、前記接合部は、前記両端部を貫通した貫通孔とこの貫通孔の周囲を囲繞する接合枠とを有して、同一筒面積で比較したときに前記通気部に対して空気の通過量が等しくなることを特徴とする。 The air cleaner of the present invention that achieves the above object includes a housing, a tubular filter paper installed inside the housing, and a cylinder installed inside or outside the filter paper in the radial direction to support the filter paper. In an air cleaner comprising a shape-like support material, wherein the support material is formed with a large number of air holes through which air passing through the filter paper passes in the tubular radial direction, the support material is a single-layer ventilation portion. And a joint portion formed by joining both ends of the plate material constituting the support material in the tubular circumferential direction in a laminated state, the vent portion is formed with a large number of the air holes. The joint portion has a through hole penetrating both end portions and a joint frame surrounding the through hole, and when compared with the same cylinder area, the amount of air passing through the vent portion is equal. It is characterized by becoming.

また、上記の目的を達成する本発明のエアクリーナの製造方法は、筐体の内部に筒状に形成されてなる支持材を設置し、その支持材の筒径方向内側又は外側に筒状に形成されてなる濾紙を設置したエアクリーナの製造方法において、板材に前記濾紙を通過した空気が通過可能な空気穴を多数穿ち、前記板材を丸めて筒状に形成すると共に、その板材の筒周方向の両端部を積層させるときにその両端部のうちの一端部に形成された複数の前記空気穴と、他端部に形成された複数の前記空気穴とが積層方向において一致させて貫通孔を形成し、同一筒面積で比較したときに、その積層させた部位の空気の通過量を単層の通気部と等しくした状態で接合して、前記支持材を作成することを特徴とする。 Further, in the method for manufacturing an air cleaner of the present invention that achieves the above object, a support material formed in a tubular shape is installed inside the housing, and the support material is formed in a tubular shape inside or outside in the tubular radial direction. In the method of manufacturing an air cleaner in which the filter paper is installed, a large number of air holes through which air passing through the filter paper can pass are formed in the plate material, and the plate material is rolled to form a tubular shape, and the plate material is formed in a tubular shape. When laminating both ends, the plurality of air holes formed at one end of both ends and the plurality of air holes formed at the other end are aligned in the stacking direction to form a through hole. However, when compared with the same cylinder area, the support material is produced by joining in a state where the amount of air passing through the laminated portion is equal to that of the single-layer ventilation portion.

あるいは、上記の目的を達成する本発明のエアクリーナの製造方法は、筐体の内部に筒状に形成されてなる支持材を設置し、その支持材の筒径方向内側又は外側に筒状に形成されてなる濾紙を設置したエアクリーナの製造方法において、板材の中央部に前記濾紙を通過した空気が通過可能な空気穴を多数穿って通気部を形成し、前記板材を丸めて筒状に形成すると共に、その板材の筒周方向の両端部を積層させて接合して接合部を形成し、前記接合部に、同一筒面積で比較したときに、前記接合部の空気の通過量を前記通気部の空気の通過量と等しくする貫通孔を形成して、前記支持材を作成することを特徴とする。 Alternatively, in the method for manufacturing an air cleaner of the present invention that achieves the above object, a support material formed in a tubular shape is installed inside the housing, and the support material is formed in a tubular shape inside or outside in the tubular radial direction. In the method of manufacturing an air cleaner on which the filter paper is installed, a large number of air holes through which air passing through the filter paper can pass are formed in the central portion of the plate material to form a ventilation portion, and the plate material is rolled into a tubular shape. At the same time, both ends of the plate material in the cylinder circumferential direction are laminated and joined to form a joint portion, and when compared with the joint portion in the same cylinder area, the amount of air passing through the joint portion is measured by the ventilation portion. It is characterized in that the support material is formed by forming a through hole equal to the amount of air passing through.

本発明によれば、多数の空気穴が形成されてなる単層の通気部と、積層して接合された貫通孔を有する接合部を形成して、同一筒面積で比較したときに複層の接合部の空気の通過量を単層の通気部に対して等しくした。それ故、支持材を通過した後の空気の流れを整流することができる。これにより、空気の流れに関してエアクリーナの下流側に配置された流量センサの検出値のばらつきを低減するには有利になり、流量センサによる流量の検出精度を向上させることができる。 According to the present invention, when a single-layer ventilation portion in which a large number of air holes are formed and a joint portion having through holes joined by stacking are formed and compared in the same cylinder area, the plurality of layers The amount of air passing through the joint was made equal to that of the single layer vent. Therefore, the flow of air after passing through the support can be rectified. This is advantageous for reducing the variation in the detection value of the flow rate sensor arranged on the downstream side of the air cleaner with respect to the air flow, and the flow rate detection accuracy by the flow rate sensor can be improved.

本発明の第１実施形態のエアクリーナの構成を例示する図である。It is a figure which illustrates the structure of the air cleaner of 1st Embodiment of this invention. 支持材を構成するパンチングメタルを例示する図である。It is a figure which illustrates the punching metal which constitutes a support material. 溶接用治具を例示する図である。It is a figure which illustrates the welding jig. 第２実施形態の支持材を構成するエキスパンドメタルを例示する図である。It is a figure which illustrates the expanded metal which comprises the support material of 2nd Embodiment. 図４のエキスパンドメタルを筒状にした構成を例示する図である。It is a figure which illustrates the structure which made the expanded metal of FIG. 4 into a tubular shape. 第３実施形態の支持材の接合部周辺を筒径方向からみた構成を例示する図である。It is a figure which illustrates the structure which looked at the periphery of the joint part of the support material of 3rd Embodiment from the cylinder radial direction. 支持材を構成するパンチングメタルを筒状にして貫通孔を形成する前の状態を例示する図である。It is a figure which illustrates the state before forming a through hole by making a punching metal which constitutes a support material into a tubular shape.

以下、本発明のエアクリーナ及びその製造方法について図に示した実施形態に基づいて説明する。なお、本実施形態では、Ｚ方向を筒状に形成された支持材４の筒軸方向、α方向を筒周方向とすると共に、Ｚ方向を筒状に形成する前の板状の支持材４における短手方向、α方向を長手方向とする。また、本実施形態では、後述する濾紙３、支持材４、９を円筒形状としているが、例えばこれらの部材を角筒形状等の他の形状としても支持材４または支持材９に接合部があれば本発明を適用することができる。 Hereinafter, the air cleaner of the present invention and a method for manufacturing the same will be described based on the embodiments shown in the drawings. In the present embodiment, the Z direction is the tubular axial direction of the support member 4 formed into a tubular shape, the α direction is the tubular circumferential direction, and the Z direction is the plate-shaped support member 4 before being formed into a tubular shape. The lateral direction and the α direction are the longitudinal directions. Further, in the present embodiment, the filter paper 3, the support members 4 and 9, which will be described later, have a cylindrical shape, but for example, even if these members have other shapes such as a square cylinder shape, the joint portion is formed on the support member 4 or the support member 9. If so, the present invention can be applied.

図１に示すように、本発明の第１実施形態のエアクリーナ１は、車両用のエンジンに吸入される空気Ａの不純物を取り除くものである。エアクリーナ１は、筐体２と、濾紙３と、支持材４、９とを備えている。 As shown in FIG. 1, the air cleaner 1 of the first embodiment of the present invention removes impurities of air A sucked into a vehicle engine. The air cleaner 1 includes a housing 2, a filter paper 3, and support members 4 and 9.

筐体２は、その内部に濾紙３及び支持材４、９を収納して、濾紙３及び支持材４、９を筐体２の外部から作用する衝撃力等から保護するケースである。筐体２は、上端が閉口し、下端が開口して吸気通路１３に連通した筒状を成している。筐体２には、側面（筒面）に大気から筐体２内部に空気（吸気）を流入させる空気流入口１１と、下端に筐体２内部に流入された空気を中心部（空洞）１２を介してエンジン側の吸気通路１３に流出させる空気流出口が設けられる。 The housing 2 is a case in which the filter paper 3 and the support members 4 and 9 are housed therein, and the filter paper 3 and the support materials 4 and 9 are protected from an impact force acting from the outside of the housing 2. The housing 2 has a tubular shape with the upper end closed and the lower end open to communicate with the intake passage 13. The housing 2 has an air inlet 11 that allows air (intake) to flow into the housing 2 from the atmosphere on the side surface (cylindrical surface), and a central portion (cavity) 12 that has air that has flowed into the housing 2 at the lower end. An air outlet is provided to allow the air to flow out to the intake passage 13 on the engine side.

吸気通路１３にはエアクリーナ１から吸気通路１３に流出する空気Ａの量を検出するＭＡＦセンサ（流量センサ）１４が設けられる。ＭＡＦセンサ１４は、吸気管（吸気通路）１３の中で流路がストレートで内径の寸法ばらつきが少ない場所に設置することが精度向上に好ましいが、車両のレイアウトの制約のためエアクリーナ１の直後がその条件に適している場合がある。しかし、エアクリーナ１とＭＡＦセンサ１４を近接させると、前述の検出値のばらつきは大きくなる。 The intake passage 13 is provided with a MAF sensor (flow rate sensor) 14 that detects the amount of air A flowing out from the air cleaner 1 to the intake passage 13. It is preferable to install the MAF sensor 14 in a place in the intake pipe (intake passage) 13 where the flow path is straight and there is little variation in the inner diameter, but due to restrictions on the layout of the vehicle, immediately after the air cleaner 1 It may be suitable for that condition. However, when the air cleaner 1 and the MAF sensor 14 are brought close to each other, the above-mentioned variation in the detected values becomes large.

濾紙３は、筐体２の内部に設置されて、空気流入口１１から流入される空気Ａに含まれる塵等を除去する筒状の濾過装置で、Ｚ方向から見てプリーツ加工により筒径方向外側に突出した部分と筒径方向内側に窪んだ部分とが交互に配置されたひだが形成されている。支持材（インナーライナー）４は、濾紙３の筒径方向内側に設置される筒状の装置である。支持材（アウターライナー）９は、濾紙３の筒径方向外側に設置される筒状の装置である。支持材４、９により濾紙３は支持される。濾紙３と支持材４、９を発泡ウレタン等で一体化したものはエレメント１０と称される。図２に例示するように、支持材４、９はパンチングメタルで構成され、濾紙３を通過した空気Ａが筒径方向に通過する多数の空気穴５が形成されている。 The filter paper 3 is a tubular filtration device installed inside the housing 2 to remove dust and the like contained in the air A flowing in from the air inlet 11, and is pleated in the tubular radial direction when viewed from the Z direction. The folds are formed in which the portions protruding outward and the portions recessed inward in the radial direction of the cylinder are alternately arranged. The support material (inner liner) 4 is a tubular device installed inside the filter paper 3 in the radial direction. The support material (outer liner) 9 is a tubular device installed on the outer side of the filter paper 3 in the tubular radial direction. The filter paper 3 is supported by the support members 4 and 9. A filter paper 3 and support materials 4 and 9 integrated with urethane foam or the like is referred to as an element 10. As illustrated in FIG. 2, the support members 4 and 9 are made of punching metal, and a large number of air holes 5 through which the air A passing through the filter paper 3 passes in the tubular radial direction are formed.

本発明のエアクリーナ１では、支持材４は、単層の通気部６と、この支持材４を構成する板材のα方向の両端部が積層した状態で接合されてなる接合部７とを有している。通気部６は、支持材４を構成する板材に形成されていた多数の空気穴５を有する部位である。接合部７は、両端部を貫通した複数の空気穴で構成される貫通孔８とこの貫通孔８の周囲を囲繞する接合枠１５とを有して、同一筒面積で比較したときに通気部６に対して空気Ａの通過量が等しくなる構成である。言い換えれば、支持材４は空気Ａの通過量が異なる部位が存在せず、α方向の全域に渡って空気Ａの通過量が略等しくなる。 In the air cleaner 1 of the present invention, the support member 4 has a single-layer ventilation portion 6 and a joint portion 7 formed by bonding both ends of the plate members constituting the support member 4 in the α direction in a laminated state. ing. The ventilation portion 6 is a portion having a large number of air holes 5 formed in the plate material constituting the support member 4. The joint portion 7 has a through hole 8 composed of a plurality of air holes penetrating both ends and a joint frame 15 surrounding the periphery of the through hole 8, and is a ventilation portion when compared in the same cylinder area. The configuration is such that the amount of air A passing through is equal to that of 6. In other words, the support member 4 does not have a portion where the amount of air A passing through differs, and the amount of air A passing through is substantially equal over the entire area in the α direction.

接合部７は、両端部のそれぞれに通気部６に形成された空気穴５と同一の空気穴８が同一の割合で形成されて、一端部に形成された複数の空気穴８と、他端部に形成された複数の空気穴８とが積層方向において一致して貫通孔を形成してなる構成である。 In the joint portion 7, the same air holes 8 as the air holes 5 formed in the ventilation portion 6 are formed at the same ratio at both end portions, and a plurality of air holes 8 formed at one end portion and the other end thereof. The structure is such that a plurality of air holes 8 formed in the portions coincide with each other in the stacking direction to form through holes.

接合部７における隣接する空気穴８の間の筒周方向の距離と、接合部７の空気穴８とこの空気穴８に隣接する通気部６の空気穴５の間の筒周方向の距離は、通気部６の各空気穴５の間の筒周方向の距離とほぼ同距離となるように形成される。接合部７の各空気穴８の間の筒軸方向の距離は、通気部６の各空気穴５の間の筒軸方向の距離とほぼ同距離となる様に形成される。すなわち、支持材４の筒周方向及び筒軸方向で多数のほぼ同じ空気穴が均等に形成される。 The distance in the tube circumference direction between the adjacent air holes 8 at the joint portion 7 and the distance in the cylinder circumference direction between the air hole 8 of the joint portion 7 and the air hole 5 of the ventilation portion 6 adjacent to the air hole 8 are , It is formed so as to be substantially the same distance as the distance in the circumferential direction between the air holes 5 of the ventilation portion 6. The distance in the tubular axis direction between the air holes 8 of the joint portion 7 is formed so as to be substantially the same as the distance in the tubular axial direction between the air holes 5 of the ventilation portion 6. That is, a large number of substantially the same air holes are uniformly formed in the tubular circumferential direction and the tubular axial direction of the support member 4.

図２に例示するように、支持材４はパンチングメタルを丸めて筒状に形成して構成される。パンチングメタルは、長手方向がα方向に、短手方向がＺ方向に向いてなる金属板材に空気穴５、８として多数の穿孔が形成されたものである。具体的に、パンチングメタルは、α方向の両端部に互いに積層した状態で接合される接合部７と、α方向の中央部に通気部６とが配置されている。また、パンチングメタルは、両端部の接合部７のそれぞれに第一目印１６と第二目印１７とが形成されている。 As illustrated in FIG. 2, the support member 4 is formed by rolling a punching metal into a tubular shape. The punching metal is a metal plate in which the longitudinal direction is in the α direction and the lateral direction is in the Z direction, and a large number of holes are formed as air holes 5 and 8. Specifically, in the punching metal, a joint portion 7 which is joined to both ends in the α direction in a laminated state and a ventilation portion 6 are arranged in the central portion in the α direction. Further, in the punching metal, a first mark 16 and a second mark 17 are formed at each of the joint portions 7 at both ends.

通気部６は、多数の空気穴５がＺ方向に等間隔に配置された多数の穴列がα方向に等間隔に配置されて構成された部位である。通気部６において、α方向に隣り合う穴列で空気穴５がＺ方向にずれていてもよい。 The ventilation portion 6 is a portion formed by arranging a large number of air holes 5 at equal intervals in the Z direction and a large number of holes arranged at equal intervals in the α direction. In the ventilation portion 6, the air holes 5 may be displaced in the Z direction in a row of holes adjacent to each other in the α direction.

接合部７は、パンチングメタルを丸めて筒状に形成したときに積層した状態で接合される部位であり、通気部６と同様に多数の空気穴８がＺ方向に等間隔に配置された多数の穴列がα方向に等間隔に配置されて構成された部位である。接合部７におけるα方向の一端とその一端に隣接する穴列との間の幅は、通気部６におけるα方向に隣り合う穴列の間の幅よりも短い。このように構成することで、両端部の接合部７を互いに積層したときに、筒径方向に見て、通気部６の穴列と接合部７の筒径方向に重なった穴列の間にその一端が配置されることになり、空気穴８が塞がれることを回避するには有利になる。 The joint portion 7 is a portion to be joined in a laminated state when the punching metal is rolled into a tubular shape, and a large number of air holes 8 are arranged at equal intervals in the Z direction as in the ventilation portion 6. This is a part formed by arranging a row of holes at equal intervals in the α direction. The width between one end of the joint portion 7 in the α direction and the row of holes adjacent to the one end is shorter than the width between the rows of holes adjacent to each other in the α direction at the ventilation portion 6. With this configuration, when the joints 7 at both ends are laminated to each other, between the hole rows of the ventilation portion 6 and the hole rows overlapping in the cylinder diameter direction of the joint portion 7 when viewed in the cylinder radial direction. One end of the air hole 8 will be arranged, which is advantageous in avoiding the air hole 8 being blocked.

通気部６及び接合部７は、多数の空気穴５と、少なくとも４つの空気穴５により周囲を囲繞された領域１８とが形成されている。接合部７におけるこの領域１８は、スポット溶接により両端部の接合部７どうしを接合したときに生じる接合点が配置される領域である。スポット溶接は、接合部７のその領域１８を電極棒で加圧しつつ電流を流し、その接触面に発生する抵抗熱により接合部７に溶解凝固を起こさせて溶接するものである。 The ventilation portion 6 and the joint portion 7 are formed with a large number of air holes 5 and a region 18 surrounded by at least four air holes 5. This region 18 in the joint portion 7 is a region in which a joint point generated when the joint portions 7 at both ends are joined by spot welding is arranged. In spot welding, an electric current is passed while pressurizing the region 18 of the joint portion 7 with an electrode rod, and the joint portion 7 is melted and solidified by the resistance heat generated on the contact surface thereof for welding.

この領域１８の面積は、スポット溶接により形成された点状の溶接点１９の面積よりも広くすることが望ましい。つまり、パンチングメタルのα方向に隣り合う空気穴５、８どうしの間の幅と、Ｚ方向に隣り合う空気穴５、８どうしの間の幅はそれぞれ、溶接点１９の幅よりも広くすることが望ましい。 It is desirable that the area of this region 18 is larger than the area of the dot-shaped welding points 19 formed by spot welding. That is, the width between the air holes 5 and 8 adjacent to each other in the α direction of the punching metal and the width between the air holes 5 and 8 adjacent to each other in the Z direction should be wider than the width of the welding point 19, respectively. Is desirable.

第一目印１６は、パンチングメタルのα方向の一端部の接合部７のＺ方向の下端面に形成されている。第二目印１７は、パンチングメタルのα方向の他端部の接合部７のＺ方向の下端面に形成されている。第一目印１６及び第二目印１７は、接合部７のＺ方向の端面に形成されていればよく、上端面に形成されていてもよい。なお、接合部７のＺ方向の上端面及び下端面の両方に形成されることがより好ましい。 The first mark 16 is formed on the lower end surface in the Z direction of the joint portion 7 at one end in the α direction of the punching metal. The second mark 17 is formed on the lower end surface in the Z direction of the joint portion 7 at the other end of the punching metal in the α direction. The first mark 16 and the second mark 17 may be formed on the end surface of the joint portion 7 in the Z direction, and may be formed on the upper end surface. It is more preferable that the joint portion 7 is formed on both the upper end surface and the lower end surface in the Z direction.

第一目印１６及び第二目印１７は、接合部７が互いに積層したときの空気穴５の位置を一致させる目印としての機能を有する。具体的に、接合部７が互いに積層した状態で、Ｚ方向から見て第一目印１６と第二目印１７とが積層方向に一致したときに、一方の接合部７に形成された複数の空気穴８と、他方の接合部７に形成された複数の空気穴８とが積層方向において一致する。 The first mark 16 and the second mark 17 have a function as marks for matching the positions of the air holes 5 when the joint portions 7 are laminated on each other. Specifically, in a state where the joint portions 7 are laminated to each other, when the first mark 16 and the second mark 17 coincide with each other in the stacking direction when viewed from the Z direction, a plurality of air formed in one joint portion 7 is formed. The holes 8 and the plurality of air holes 8 formed in the other joint portion 7 coincide with each other in the stacking direction.

パンチングメタルを丸めて筒状に形成されて構成された支持材４は、α方向の全域において単位面積当たりの空気Ａの通過量が等しい。 The support member 4 formed by rolling the punching metal into a tubular shape has the same amount of air passing per unit area over the entire area in the α direction.

エアクリーナ１の製造方法について説明する。この製造方法は、濾紙３の作成方法、支持材４の作成方法、エアクリーナ１の組み付け方法の３つの方法に大別される。濾紙３の作成方法は、以下の第１〜３工程を順に行う方法である。第１工程では、濾紙３をプリーツ加工してひだを形成する。第２工程では、第１工程でプリーツ加工した濾紙３をひだに直交する方向に切断して複数枚の濾紙３を形成する。第３工程では、第２工程で切断して形成された濾紙３を丸めてその両端部を接着して、筒状に形成する。 A method of manufacturing the air cleaner 1 will be described. This manufacturing method is roughly classified into three methods: a method for producing the filter paper 3, a method for producing the support material 4, and a method for assembling the air cleaner 1. The method for producing the filter paper 3 is a method in which the following steps 1 to 3 are sequentially performed. In the first step, the filter paper 3 is pleated to form folds. In the second step, the filter paper 3 pleated in the first step is cut in a direction orthogonal to the folds to form a plurality of filter papers 3. In the third step, the filter paper 3 formed by cutting in the second step is rolled and both ends thereof are adhered to form a tubular shape.

次に、支持材４の作成方法について説明する。まず、打ち抜き加工機の搬送レール上に板材を置き、打ち抜き加工用のパンチを搬送レールの上部に設置した加工部まで板材を搬送する。そして、加工部に到達した板材にパンチで多数の穿孔を穿つ（打ち抜く）ことで、空気穴５、８を形成してパンチングメタルは作成される。 Next, a method of producing the support material 4 will be described. First, the plate material is placed on the transfer rail of the punching machine, and the plate material is conveyed to the processing portion where the punch for punching is installed on the upper part of the transfer rail. Then, by punching (punching) a large number of holes in the plate material that has reached the processed portion, air holes 5 and 8 are formed and the punching metal is created.

本発明では、さらに、打ち抜き加工機の穴ピッチを調整して、パンチングメタルのα方向及びＺ方向に空気穴５、８を均等に形成しつつ、パンチングメタルの全域に空気穴５、８を形成する。次いで、パンチングメタルのα方向の両端部に第一目印１６及び第二目印１７を形成する。次いで、パンチングメタルを丸めて両端部の接合部７を積層したときに、第一目印１６及び第二目印１７をＺ方向に見て積層方向に一致させて接合する。 In the present invention, the hole pitch of the punching machine is further adjusted to evenly form the air holes 5 and 8 in the α direction and the Z direction of the punching metal, and the air holes 5 and 8 are formed in the entire area of the punching metal. To do. Next, the first mark 16 and the second mark 17 are formed at both ends of the punching metal in the α direction. Next, when the punching metal is rolled and the joint portions 7 at both ends are laminated, the first mark 16 and the second mark 17 are joined so as to match the stacking direction when viewed in the Z direction.

この丸めたパンチングメタルの積層された両端部をスポット溶接等により接合して筒状に形成することで、同一筒面積で比較したときに、その積層させた部位（接合部）７の空気Ａの通過量を単層の通気部６の空気Ａの通過量と等しくした支持材４の作成が完了する。目印を設けずに治具等により空気穴８が重なるように調整しても良い。 By joining both ends of the laminated punching metal of the rounded metal by spot welding or the like to form a tubular shape, when compared with the same tubular area, the air A of the laminated portion (joint portion) 7 The production of the support material 4 in which the passing amount is equal to the passing amount of the air A of the single-layer ventilation portion 6 is completed. The air holes 8 may be adjusted so as to overlap with each other by a jig or the like without providing a mark.

なお、支持材９についても支持材４と同様の方法で作成してもよいが、空気穴８を設ける必要性がないため空気穴８は形成しなくてもよい。また、支持材９自体を作成しなくてもよい。 The support member 9 may be created in the same manner as the support member 4, but the air holes 8 may not be formed because it is not necessary to provide the air holes 8. Moreover, it is not necessary to prepare the support material 9 itself.

次に、筒状の濾紙３、支持材４、９を作成後、エアクリーナ１の組み付けを行う。この組み付け方法は以下の第１〜６工程を順に行う方法である。第１工程では、支持材９の筒径方向内側に筒状の濾紙３を取り付ける。第２工程では、第１工程で取り付けた筒状の濾紙３の筒径方向内側に支持材４を取り付ける。第３工程では、筒状の濾紙３、支持材４、９が一体化するよう出口側を通路を設けた形状で発泡ウレタン等で固定する。第４工程では、濾紙３、支持材４、９が一体化するように図１Ｚ方向を発泡ウレタン等で固定しエレメント１０は完成する。この第３、４工程の発泡ウレタン等は濾紙３の両端部のエア漏れを防止し、エレメント１０と筐体２間のエア漏れを防止し、エレメント１０が筐体２内で固定される形状に形成される。第５工程では、濾紙３と支持材４、９の間の隙間にシリコンやホットメルトを塗布して、濾紙３が支持材４、９により確実に固定されるようにしても良い。第６工程でエレメント１０が筐体２内に設置される。以上で、エアクリーナ１の組み付けが完了して、エアクリーナ１は完成する。 Next, after creating the tubular filter paper 3 and the support members 4 and 9, the air cleaner 1 is assembled. This assembly method is a method in which the following steps 1 to 6 are performed in order. In the first step, the tubular filter paper 3 is attached to the inside of the support member 9 in the tubular radial direction. In the second step, the support member 4 is attached to the inside of the tubular filter paper 3 attached in the first step in the tubular radial direction. In the third step, the outlet side is fixed with urethane foam or the like in a shape provided with a passage so that the tubular filter paper 3 and the support members 4 and 9 are integrated. In the fourth step, the element 10 is completed by fixing the filter paper 3 and the support members 4 and 9 with urethane foam or the like in FIG. 1Z so as to be integrated. The urethane foam and the like in the third and fourth steps prevent air leakage at both ends of the filter paper 3, prevent air leakage between the element 10 and the housing 2, and form the element 10 to be fixed in the housing 2. It is formed. In the fifth step, silicon or hot melt may be applied to the gap between the filter paper 3 and the support members 4 and 9 to ensure that the filter paper 3 is securely fixed by the support members 4 and 9. In the sixth step, the element 10 is installed in the housing 2. With the above, the assembly of the air cleaner 1 is completed, and the air cleaner 1 is completed.

なお、濾紙３を作成する際のプリーツ加工は実施してもしなくてもよいが、実施する場合は支持材４の筒周方向に濾紙３のひだが均等に配置されるようにすると好ましい。また、エアクリーナ１を組み付ける際のホットメルト等の塗布は実施してもしなくてもよいが、実施する場合は支持材４、９の空気穴５、８を塞がないようにホットメルト等を塗布することが望ましい。ホットメルトなどの接着部材は、空気穴５、８を塞ぐおそれがある。そこで、ホットメルトなどの接着部材を通気部６や接合部７の空気穴５、８が形成されていない領域１８に塗布することで、支持材４の全域における通気抵抗の増加を抑制することができる。 The pleating process for producing the filter paper 3 may or may not be performed, but when it is performed, it is preferable that the folds of the filter paper 3 are evenly arranged in the tubular circumferential direction of the support member 4. Further, hot melt or the like may or may not be applied when assembling the air cleaner 1, but when it is applied, hot melt or the like is applied so as not to block the air holes 5 and 8 of the support materials 4 and 9. It is desirable to do. An adhesive member such as a hot melt may block the air holes 5 and 8. Therefore, by applying an adhesive member such as hot melt to the region 18 where the air holes 5 and 8 of the ventilation portion 6 and the joint portion 7 are not formed, it is possible to suppress an increase in the ventilation resistance in the entire area of the support member 4. it can.

エアクリーナ１の空気流入口１１より空気Ａが流入し、この流入した空気Ａは支持材９の空気穴、濾紙３、支持材４の空気穴５を経由して、支持材４より筒径方向内側の中心部１２に流出する。本発明では、支持材４のα方向及びＺ方向で多数のほぼ同じ空気穴が均等に形成されるので、中心部１２内の接合部７付近でのみ空気Ａが乱流化することなく、エアクリーナ１を吸気通路１３側からみたときの中心部１２内の空気Ａは整流される。この整流された空気Ａは空気流出口より吸気通路１３側へ流出する。 Air A flows in from the air inlet 11 of the air cleaner 1, and the inflowing air A passes through the air holes of the support member 9, the filter paper 3, and the air holes 5 of the support member 4, and is inside the support member 4 in the tubular radial direction. It flows out to the center 12 of the. In the present invention, since a large number of substantially the same air holes are uniformly formed in the α direction and the Z direction of the support member 4, the air cleaner does not turbulently flow the air A only in the vicinity of the joint portion 7 in the central portion 12. The air A in the central portion 12 when 1 is viewed from the intake passage 13 side is rectified. The rectified air A flows out from the air outlet to the intake passage 13 side.

以上より、本発明のエアクリーナ１によれば、多数の空気穴５が形成されてなる単層の通気部６と、積層して接合された貫通孔８を有する接合部７を形成して、同一筒面積で比較したときに複層の接合部７の空気Ａの通過量を単層の通気部６に対して等しくした。それ故、支持材４を通過した後の空気Ａの流れを整流することができる。これにより、空気Ａの流れに関してエアクリーナ１の下流側に配置された流量センサ１４の検出値のばらつきを低減するには有利になり、流量センサ１４による流量の検出精度を向上させることができる。 From the above, according to the air cleaner 1 of the present invention, the single-layer ventilation portion 6 in which a large number of air holes 5 are formed and the joint portion 7 having the through holes 8 laminated and joined are formed and are the same. When compared in terms of cylinder area, the amount of air passing through the multi-layered joint 7 was made equal to that of the single-layer air vent 6. Therefore, the flow of air A after passing through the support member 4 can be rectified. This is advantageous for reducing the variation in the detection value of the flow rate sensor 14 arranged on the downstream side of the air cleaner 1 with respect to the flow of the air A, and the flow rate detection accuracy of the flow rate sensor 14 can be improved.

また、接合部７は、両端部のそれぞれに通気部６に形成された空気穴５と同一の空気穴８が同一の割合で形成されて、一端部に形成された複数の空気穴と、他端部に形成された複数の空気穴とが積層方向において一致して貫通孔８を形成してなる構成とすることで、複層の接合部７の空気Ａの通過量を単層の通気部６に対して確実に等しくすることができる。 Further, in the joint portion 7, a plurality of air holes 8 formed in the ventilation portion 6 at the same ratio as the air holes 5 formed in the ventilation portion 6 are formed at both ends thereof, and a plurality of air holes formed at one end portion and the like. By forming a through hole 8 in which a plurality of air holes formed at the end coincide with each other in the stacking direction, the amount of air A passing through the joint portion 7 of the multi-layers can be controlled by the single-layer ventilation portion. It can be made surely equal to 6.

また、接合部７の両端部のそれぞれに第一目印１６と第二目印１７とを形成することで、一端部に形成された複数の空気穴８と他端部に形成された複数の空気穴８とが積層方向において一致するように支持材４の両端部を積層することが容易になるので、支持材４の作成に係る作業効率を向上させることができる。 Further, by forming the first mark 16 and the second mark 17 at both ends of the joint portion 7, a plurality of air holes 8 formed at one end and a plurality of air holes formed at the other end are formed. Since both ends of the support member 4 can be easily laminated so that 8 and 8 coincide with each other in the lamination direction, the work efficiency related to the production of the support member 4 can be improved.

第一目印１６及び第二目印１７を接合部７のＺ方向の同一方向端面に形成することで、パンチングメタルを丸めてＺ方向に見たときに目視可能になり、より目印としての機能性が増す。 By forming the first mark 16 and the second mark 17 on the end faces of the joint portion 7 in the same direction in the Z direction, the punching metal can be rolled and made visible when viewed in the Z direction, and the functionality as a mark is further improved. Increase.

また、支持材４を構成する板材を丸めて筒状に形成すると共に、その板材の筒周方向の両端部を積層させるときにその両端部のうちの一端部に形成された複数の空気穴８と、他端部に形成された複数の空気穴８とが積層方向において一致させて、同一筒面積で比較したときに、その積層させた部位（接合部）７の空気Ａの通過量を単層の通気部６の空気Ａの通過量と等しくした状態で接合することで、本発明のエアクリーナ１の一部品である支持材４を比較的簡単に作成することができる。その結果、本発明のエアクリーナ１の製造効率を向上させることができる。 Further, a plurality of air holes 8 formed at one end of both ends when the plate members constituting the support member 4 are rolled to form a tubular shape and both ends of the plate material in the tubular circumferential direction are laminated. And the plurality of air holes 8 formed at the other end are matched in the stacking direction, and when compared with the same cylinder area, the amount of air A passing through the laminated portion (joint portion) 7 is simply increased. By joining the layers in a state equal to the amount of air passing through the ventilation portion 6, the support member 4 which is a part of the air cleaner 1 of the present invention can be relatively easily produced. As a result, the manufacturing efficiency of the air cleaner 1 of the present invention can be improved.

図３に例示するように、パンチングメタルの空気穴８の位置を重ね合わせて接合部７を形成する際に、溶接用治具２０を用いることが望ましい。溶接用治具２０は、空気穴８に挿通可能な複数の凸部２１が支持材４を構成するパンチングメタルにおける隣り合う空気穴８どうしの間の長さと同等に離間配置されて構成される。パンチングメタルの空気穴８の位置を接合部７の積層方向に重ね合わせるときに、溶接用治具２０の複数の凸部２１を複数の重ね合わせた空気穴８に挿入して位置合わせするようにすると、重ね合わせた空気穴８がずれることなく溶接することが可能となる。このように、溶接用治具２０を用いることで、空気穴８を重ね合わせた接合部７を容易に形成することできる。 As illustrated in FIG. 3, it is desirable to use the welding jig 20 when the positions of the air holes 8 of the punching metal are overlapped to form the joint portion 7. The welding jig 20 is configured such that a plurality of convex portions 21 that can be inserted into the air holes 8 are arranged at intervals equal to the length between adjacent air holes 8 in the punching metal forming the support member 4. When the positions of the air holes 8 of the punching metal are overlapped in the stacking direction of the joints 7, the plurality of convex portions 21 of the welding jig 20 are inserted into the plurality of overlapped air holes 8 so as to be aligned. Then, the overlapped air holes 8 can be welded without being displaced. In this way, by using the welding jig 20, it is possible to easily form the joint portion 7 in which the air holes 8 are overlapped.

図４に例示するように、第２実施形態のエアクリーナ１は、第１実施形態のエアクリーナ１の支持材４をパンチングメタルではなくエキスパンドメタルで構成する点で異なり、その他の点では同じ構成である。 As illustrated in FIG. 4, the air cleaner 1 of the second embodiment is different in that the support material 4 of the air cleaner 1 of the first embodiment is made of expanded metal instead of punching metal, and has the same structure in other respects. ..

エキスパンドメタルは、長手方向がα方向に、短手方向がＺ方向に向いてなる金属板材に空気穴５として千鳥状の切れ込みを押し広げて構成された菱形や亀甲形を成す多数の孔が形成されたメッシュ状のものである。 In expanded metal, a large number of rhombic or hexagonal holes formed by expanding staggered notches as air holes 5 are formed in a metal plate whose longitudinal direction is in the α direction and in the lateral direction is in the Z direction. It is a mesh-like material.

エキスパンドメタルは、第１実施形態と同様に、通気部６及び接合部７に、多数の空気穴５、８と、少なくとも４つの空気穴５、８により周囲を囲繞された領域１８とが形成されている。つまり、エキスパンドメタルにおいては、メッシュを構成する金属部位（菱形や亀甲型を成す孔の周囲を囲繞する金属部位）が第１実施形態における領域１８と同等の領域となる。つまり、エキスパンドメタルは、スポット溶接により形成された点状の溶接点１９よりも大きい幅の金属部位に囲繞された菱形や亀甲形を成す多数の孔が形成されてメッシュ状のものである。 In the expanded metal, as in the first embodiment, a large number of air holes 5 and 8 and a region 18 surrounded by at least four air holes 5 and 8 are formed in the ventilation portion 6 and the joint portion 7. ing. That is, in the expanded metal, the metal portion forming the mesh (the metal portion surrounding the circumference of the hole forming the rhombus or the hexagonal shape) is the same region as the region 18 in the first embodiment. That is, the expanded metal is a mesh-like structure in which a large number of rhombic or hexagonal holes surrounded by a metal portion having a width larger than the point-shaped welding point 19 formed by spot welding are formed.

この実施形態の支持材４の作成方法について説明する。まず、メッシュ製造機を用いて金属板材の幅方向上側と下側に千鳥配列で切り込みを入れる。そして、この切り込みを入れた板材を幅方向に引き延ばすことで多数の菱形や亀甲形を成す孔を有するメッシュ状のエキスパンドメタルを作成する。 A method of producing the support material 4 of this embodiment will be described. First, a mesh making machine is used to make staggered cuts on the upper and lower sides of the metal plate in the width direction. Then, by stretching the plate material with the cut in the width direction, a mesh-shaped expanded metal having a large number of rhombic or hexagonal holes is created.

図５に例示するように、次いで、第１実施形態と同様に作成したエキスパンドメタルを丸めてα方向の両端部の接合部７を積層してスポット溶接などにより接合して筒状に形成する。なお、図５では、簡略化のため、メッシュ状の孔の図示を省略している。 As illustrated in FIG. 5, next, the expanded metal prepared in the same manner as in the first embodiment is rolled, and the joint portions 7 at both ends in the α direction are laminated and joined by spot welding or the like to form a tubular shape. Note that in FIG. 5, for the sake of simplicity, the mesh-shaped holes are not shown.

つまり、支持材４の作成時で金属板材であるエキスパンドメタルを丸めてそのα方向の両端部のうちの一端部と他端部が積層されたときに、一端部に形成された空気穴８と他端部に形成された空気穴８とが積層方向において一致するように、エキスパンドメタルを丸める。この丸めたエキスパンドメタルの積層された両端部をスポット溶接（図５の符号１９はスポット溶接箇所を示す）等により接合して筒状に形成することで、同一筒面積で比較したときに、その積層させた部位（接合部）７の空気Ａの通過量を単層の通気部６の空気Ａの通過量と等しくした支持材４の作成が完了する。 That is, when the expanded metal, which is a metal plate material, is rolled at the time of producing the support material 4 and one end and the other end of both ends in the α direction are laminated, the air hole 8 formed at one end is formed. The expanded metal is rounded so that the air holes 8 formed at the other end coincide with each other in the stacking direction. When both ends of the laminated expanded metal are joined by spot welding (reference numeral 19 in FIG. 5 indicates a spot welded portion) to form a tubular shape, the tubular areas are compared. The production of the support material 4 is completed in which the passage amount of air A of the laminated portion (joint portion) 7 is equal to the passage amount of air A of the single-layer ventilation portion 6.

図６に例示するように、第３実施形態のエアクリーナ１は、支持材４の接合部７に単一の貫通孔８を形成する点で、第１実施形態のエアクリーナ１と異なり、その他の点では同じ構成である。この貫通孔８の面積は、通気部６に形成された空気穴５の面積よりも大きくする。貫通孔８の空気Ａの通過量は、同一筒面積で比較したときに、単層の通気部６の空気Ａの通過量と等しい。なお、貫通孔８の面積が空気穴５の面積よりも大きければよく、接合部７に複数の貫通孔８を形成して、接合部７と単層の通気部６との通過量を等しくしてもよい。 As illustrated in FIG. 6, the air cleaner 1 of the third embodiment is different from the air cleaner 1 of the first embodiment in that a single through hole 8 is formed in the joint portion 7 of the support member 4, and other points. Then it has the same configuration. The area of the through hole 8 is made larger than the area of the air hole 5 formed in the ventilation portion 6. The passage amount of air A in the through hole 8 is equal to the passage amount of air A in the single-layer ventilation portion 6 when compared in the same cylinder area. It is sufficient that the area of the through hole 8 is larger than the area of the air hole 5, and a plurality of through holes 8 are formed in the joint portion 7 so that the amount of passage between the joint portion 7 and the single-layer ventilation portion 6 is made equal. You may.

この実施形態の支持材４の作成方法について説明する。第３実施形態の支持材４の作成方法は、第１実施形態の支持材４の作成方法とは以下の点で異なる。すなわち、第３実施形態では、打ち抜き加工機の穴ピッチを調整して、板材の中央部にのみ空気穴５を多数穿って通気部６を形成し、この通気部６を形成したパンチングメタルを丸めて筒状に形成すると共に、そのパンチングメタルのα方向の両端部を積層させてスポット溶接等により接合して接合部７を形成した後、この接合部７に単一の貫通孔８を形成して、支持材４を作成する。この貫通孔８は、同一筒面積で比較したときに、接合部７の空気Ａの通過量を通気部６の空気Ａの通過量と等しくするように形成する。接合部の溶接点１９は貫通孔８が形成される箇所以外の接合部７の領域に形成する。 A method of producing the support material 4 of this embodiment will be described. The method for producing the support material 4 of the third embodiment is different from the method for producing the support material 4 of the first embodiment in the following points. That is, in the third embodiment, the hole pitch of the punching machine is adjusted, a large number of air holes 5 are drilled only in the central portion of the plate material to form the ventilation portion 6, and the punching metal forming the ventilation portion 6 is rounded. In addition to forming a tubular shape, both ends of the punching metal in the α direction are laminated and joined by spot welding or the like to form a joint portion 7, and then a single through hole 8 is formed in the joint portion 7. Then, the support material 4 is created. The through hole 8 is formed so that the passage amount of air A of the joint portion 7 is equal to the passage amount of air A of the ventilation portion 6 when compared with the same cylinder area. The welding point 19 of the joint portion is formed in the region of the joint portion 7 other than the portion where the through hole 8 is formed.

図７に例示するように、この実施形態の支持材４を構成するパンチングメタルは、隣り合う空気穴５、８Ａ、８Ｂ間が等ピッチｄで、かつ、空気穴５、８Ａ、８Ｂの直径Ｄがこのピッチｄよりも小さくなるものが好ましく、空気穴５、８Ａ、８Ｂの直径Ｄがこのピッチｄの半分以下となるものがより好ましい。例えば、このパンチングメタルは、隣り合う三つの空気穴５、８Ａ、８Ｂが辺の長さが等ピッチｄの正三角形状に配置されている。なお、隣り合う空気穴５、８Ａ、８Ｂどうしの間が等ピッチｄであればよく、空気穴５、８Ａ、８Ｂの配置は特に限定されない。例えば、隣り合う四つの空気穴５、８Ａ、８Ｂが辺の長さが等ピッチｄの正方形状に配置されてもよい。 As illustrated in FIG. 7, the punching metal constituting the support member 4 of this embodiment has an equal pitch d between adjacent air holes 5, 8A and 8B, and the diameters D of the air holes 5, 8A and 8B. Is smaller than this pitch d, and more preferably the diameter D of the air holes 5, 8A and 8B is half or less of this pitch d. For example, in this punching metal, three adjacent air holes 5, 8A, and 8B are arranged in a regular triangle shape having side lengths of equal pitch d. It is sufficient that the adjacent air holes 5, 8A, 8B have an equal pitch d, and the arrangement of the air holes 5, 8A, 8B is not particularly limited. For example, four adjacent air holes 5, 8A, and 8B may be arranged in a square shape having side lengths of equal pitch d.

空気穴５、８Ａ、８Ｂの直径Ｄがピッチｄよりも小さいパンチングメタルは、筒周方向の両端部を積層して筒状にする際に、両端部が積層されて形成された接合部７において、一端部に形成された空気穴８Ａと他端部に形成された空気穴８Ｂとが積層方向に重なっていない状態である。つまり、一端部に形成された空気穴８Ａどうしの間に他端部に形成された空気穴８Ｂが配置される。換言すると、一端部の隣り合う四つの空気穴８Ａにより形成される菱形の領域の内部に、他端部の空気穴８Ｂが一つ配置される。 The punching metal having the diameter D of the air holes 5, 8A, 8B smaller than the pitch d is formed in the joint portion 7 formed by laminating both ends when the both ends in the circumferential direction are laminated to form a cylinder. The air hole 8A formed at one end and the air hole 8B formed at the other end do not overlap in the stacking direction. That is, the air holes 8B formed at the other end are arranged between the air holes 8A formed at one end. In other words, one air hole 8B at the other end is arranged inside a diamond-shaped region formed by four adjacent air holes 8A at one end.

つまり、空気穴５の直径Ｄがピッチｄよりも小さいパンチングメタルにおいては、接合部７で一端部の空気穴８Ａと他端部の空気穴８Ｂとをずらして配置するだけで、空気穴８Ａ、８Ｂどうしを重ね合わせることなく支持材４を形成した後に、貫通孔８を形成する。このように、支持材４を形成してから、接合部７と通気部６との空気の通過量が等しくなるように接合部７に貫通孔８を形成することで、複数の空気穴８Ａ、８Ｂどうしを重ね合わせるという手間を省くことが可能になり、支持材４を製造する際の作業効率を向上させることができる。 That is, in the punching metal in which the diameter D of the air holes 5 is smaller than the pitch d, the air holes 8A at the one end and the air holes 8B at the other end are simply arranged by shifting the air holes 8A. After forming the support member 4 without overlapping the 8Bs, the through hole 8 is formed. In this way, after the support member 4 is formed, the through holes 8 are formed in the joint portion 7 so that the amount of air passing through the joint portion 7 and the ventilation portion 6 becomes equal, so that the plurality of air holes 8A, It is possible to save the trouble of superimposing the 8Bs on top of each other, and it is possible to improve the work efficiency when manufacturing the support member 4.

既述した実施形態では、エレメント３の内側に配置される支持材４について説明したが、エレメント３の外側に配置される支持材９に貫通孔を有する接合部を形成してもよい。また、支持材４、９の両方に形成してもよい。 In the above-described embodiment, the support member 4 arranged inside the element 3 has been described, but a joint portion having a through hole may be formed in the support member 9 arranged outside the element 3. Further, it may be formed on both the support members 4 and 9.

また、支持材４としては、上記のように金属板材から構成されるパンチングメタルやエキスパンドメタルを用いる代わりに樹脂部材から構成されるものを用いてもよい。 Further, as the support material 4, instead of using the punching metal or the expanded metal composed of the metal plate material as described above, a material composed of a resin member may be used.

１ エアクリーナ
２ 筐体
３ 濾紙
４ 支持材（インナーライナー）
５ 空気穴
６ 通気部
７ 接合部
８ 空気穴
９ 支持材（アウターライナー）
１０ エレメント 1 Air cleaner 2 Housing 3 Filter paper 4 Support material (inner liner)
5 Air hole 6 Ventilation part 7 Joint part 8 Air hole 9 Support material (outer liner)
10 elements

Claims (6)

筐体と、この筐体の内部に設置された筒状の濾紙と、この濾紙の筒径方向内側又は外側に設置されてこの濾紙を支持する筒状の支持材と、を備えて、その支持材が、前記濾紙を通過した空気が筒径方向に通過する多数の空気穴が形成されてなるエアクリーナにおいて、
前記支持材は、単層の通気部と、この支持材を構成する板材の筒周方向の両端部が積層した状態で接合されてなる接合部と、を有して、前記通気部は、多数の前記空気穴が形成されてなり、前記接合部は、前記両端部を貫通した貫通孔とこの貫通孔の周囲を囲繞する接合枠とを有して、同一筒面積で比較したときに前記通気部に対して空気の通過量が等しくなることを特徴とするエアクリーナ。 A housing, a tubular filter paper installed inside the housing, and a tubular support material installed inside or outside the filter paper in the tubular radial direction to support the filter paper, and the support thereof. In an air cleaner in which a large number of air holes are formed in which the material passes through the filter paper in the radial direction of the cylinder.
The support material has a single-layer ventilation portion and a joint portion formed by bonding both ends of the plate material constituting the support material in the tubular circumferential direction in a laminated state, and the support material has a large number of ventilation portions. The air hole is formed, and the joint portion has a through hole penetrating both end portions and a joint frame surrounding the periphery of the through hole, and the ventilation is compared when compared in the same cylinder area. An air cleaner characterized in that the amount of air passing through the parts is equal. 前記接合部は、前記両端部のそれぞれに前記通気部に形成された前記空気穴と同一の空気穴が同一の割合で形成されて、一端部に形成された複数の前記空気穴と、他端部に形成された複数の前記空気穴とが積層方向において一致して前記貫通孔を形成してなる請求項１に記載のエアクリーナ。 In the joint portion, a plurality of the air holes formed at one end portion and the other end thereof are formed by forming the same air holes as the air holes formed in the ventilation portion at the same ratio at each of the both end portions. The air cleaner according to claim 1, wherein a plurality of the air holes formed in the portion coincide with each other in the stacking direction to form the through holes. 前記貫通孔の面積は、前記通気部に形成された前記空気穴の面積よりも大きい請求項１に記載のエアクリーナ。 The air cleaner according to claim 1, wherein the area of the through hole is larger than the area of the air hole formed in the ventilation portion. 前記接合部は、一端部の筒軸方向の端面に形成された第一目印と、他端部の筒軸方向の端面に形成された第二目印とを有し、前記両端部が積層した状態で、筒軸方向から見て前記第一目印と前記第二目印とが積層方向に一致したときに、前記貫通孔が形成される請求項１〜３のいずれか１項に記載のエアクリーナ。 The joint portion has a first mark formed on the end face of one end in the tubular axis direction and a second mark formed on the end face of the other end in the tubular axis direction, and the both ends are laminated. The air cleaner according to any one of claims 1 to 3, wherein the through hole is formed when the first mark and the second mark coincide with each other in the stacking direction when viewed from the tubular axis direction. 筐体の内部に筒状に形成されてなる支持材を設置し、その支持材の筒径方向内側又は外側に筒状に形成されてなる濾紙を設置したエアクリーナの製造方法において、
板材に前記濾紙を通過した空気が通過可能な空気穴を多数穿ち、
前記板材を丸めて筒状に形成すると共に、その板材の筒周方向の両端部を積層させるときにその両端部のうちの一端部に形成された複数の前記空気穴と、他端部に形成された複数の前記空気穴とが積層方向において一致させて貫通孔を形成し、同一筒面積で比較したときに、その積層させた部位の空気の通過量を単層の通気部と等しくした状態で接合して、前記支持材を作成することを特徴とするエアクリーナの製造方法。 In a method for manufacturing an air cleaner in which a support material formed in a tubular shape is installed inside a housing, and a filter paper formed in a tubular shape is installed inside or outside the support material in the tubular radial direction.
The plate material is provided with a large number of air holes through which the air that has passed through the filter paper can pass.
The plate material is rolled into a tubular shape, and when both ends of the plate material in the tubular circumferential direction are laminated, a plurality of the air holes formed at one end of both ends and the other end are formed. A state in which a plurality of the above-mentioned air holes are aligned in the stacking direction to form a through hole, and when compared with the same cylinder area, the amount of air passing through the laminated portion is equal to that of the single-layer ventilation portion. A method for manufacturing an air cleaner, which comprises joining with and to produce the support material. 筐体の内部に筒状に形成されてなる支持材を設置し、その支持材の筒径方向内側又は外側に筒状に形成されてなる濾紙を設置したエアクリーナの製造方法において、
板材の中央部に前記濾紙を通過した空気が通過可能な空気穴を多数穿って通気部を形成し、
前記板材を丸めて筒状に形成すると共に、その板材の筒周方向の両端部を積層させて接合して接合部を形成し、
前記接合部に、同一筒面積で比較したときに、前記接合部の空気の通過量を前記通気部の空気の通過量と等しくする貫通孔を形成して、前記支持材を作成することを特徴とするエアクリーナの製造方法。 In a method for manufacturing an air cleaner in which a support material formed in a tubular shape is installed inside a housing, and a filter paper formed in a tubular shape is installed inside or outside the support material in the tubular radial direction.
A large number of air holes through which air that has passed through the filter paper can pass are formed in the central portion of the plate material to form a ventilation portion.
The plate material is rolled to form a tubular shape, and both ends of the plate material in the tubular circumferential direction are laminated and joined to form a joint portion.
It is characterized in that a through hole is formed in the joint portion so that the air passage amount of the joint portion is equal to the air passage amount of the ventilation portion when compared with the same cylinder area to create the support material. The manufacturing method of the air cleaner.
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