JP2923496B1 - Molding method of cylindrical air filter for automobile - Google Patents

Abstract

An object of the present invention is to provide a cylindrical air filter for an automobile, which maintains rigidity in a height direction and maintains air tightness between an outer peripheral surface and an inner peripheral surface of a filter medium. The invention relates to filter material P folded in a bellows, each peripheral edge of the four sides of the filter body bulk A ₀ which is formed into a substantially rectangular shape, joining plate 2 and the gas-tight seal plate 3 with a flexible Along the folding direction Q of the filter medium P.
Or the filter body A ₁ which is formed by fixing a plurality of intermediate ribs 4 of the filter material P axis C provided in parallel with the ridge line 1 of corrugation formed by being folded
_It is formed into a cylindrical shape by rounding around ₁ and joining the joining plates 2 at both ends.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention mainly in introducing air into the carburetor of the engine in an automobile, formed automotive cylindrical air filter for removing dust in the air
It relates to the shape method .

[0002]

2. Description of the Related Art As shown in FIG. 14, air sucked from the atmosphere together with gasoline is introduced into a carburetor (not shown) of an engine E in an automobile. The amount of this air is 5,000 to 10,000 per liter of gasoline.
It is a huge amount of liter. Therefore, it is necessary to remove dust floating in the air in advance to prevent the cylinders and the like of the engine E from being damaged. Usually, a dry air filter is used to remove the dust. This air filter is available in various shapes depending on the displacement of the vehicle, installation location, etc. Recently, it has been said that the overall shape can be made compact with a large filtration area. For that reason, the cylindrical air filter F 'is often used.

FIG. 15 shows a conventional cylindrical air filter F '.
Is shown. Filter media 5 constituting this cylindrical air filter F '
Reference numeral 1 denotes a cylindrical shape, and a large number of pleats project radially from an axis C 'thereof in the radial direction. The material of the filter medium 51 is a nonwoven fabric, paper, glass fiber, or the like.
The upper end surface and the lower end surface of the filter medium 51 are fixed to ring-shaped upper and lower lids 52a and 52b made of metal. In addition, filter media 5
An outer peripheral surface and an inner peripheral surface of each of the first and second reinforcing meshes are covered with outer and inner reinforcing meshes 53a and 53b made of wire mesh. For this reason, the rigidity of the cylindrical air filter F 'in the height direction is maintained. As shown in FIG. 14, the cylindrical air filter F ′ is
It will be decorated in. The air introduced from the air supply cylinder 54a provided on the outer wall of the filter case 54
When passing through the inner peripheral surface from the outer peripheral surface, dust in the air is filtered and removed. Then, only clean air is introduced into the engine E.

[0004] A method of forming a conventional cylindrical air filter F 'will be described with reference to FIGS.
The filter medium 51 is folded in a bellows shape to form a filter main body. Then, the filter main body is a filter medium 5.
1 is formed into a cylindrical shape by being rounded around an axis C ′ provided along the ridge lines 51a of the many folds in FIG. 1 and joined at both ends. However, the filter medium 5
In the case where 1 is made of a soft material such as a non-woven fabric, the filter body A ′ formed by the above-described method lacks rigidity in the height direction. And each inner reinforcing mesh 53
a, 53b are attached. Therefore, many man-hours are required. The upper and lower lids 52a, 5
To maintain the airtightness of the part 2b, a large amount of adhesive is injected into the part. It takes a long time to solidify the adhesive, and the working efficiency is poor.

[0005] In order to secure the rigidity of the cylindrical air filter F 'in the height direction, a rib 55 may be fixed to the outer peripheral edge of the filter medium 51 in some cases. A case where the rib 55 is fixed by a mold will be described. As shown in FIG. 16, a bellows-shaped filter medium 51 is wound around the outer peripheral surface of an inner mold 57 from which a large number of projections 56 project radially with respect to the axis C ′, and both ends are joined. Is done. Then, outer molds 58 corresponding to a large number of folds of the filter medium 51 are fitted from outside thereof. The outer mold 58 is provided with a rib 5
After being fixed, it is divided into many parts so that it can be easily removed. In addition, the outer mold 58 is provided with an injection hole (not shown) for injecting the molten resin. In the fold of the filter medium 51 wound around the inner mold 57,
The outer mold 58 is mounted, and the molten resin is injected. After the molten resin is solidified, many outer dies 58 are removed and the inner dies 57 are removed.

The configuration of the above-mentioned molds (the inner mold 57 and the outer mold 58) is extremely complicated, and the molding method is extremely troublesome. For this reason, there is a problem that the manufacturing cost of the mold becomes extremely high.

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to provide a cylindrical air filter that can be easily formed in view of the above-mentioned problems.

[0008]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides an automotive cylindrical type which is exchangeably incorporated in a filter case to remove dust in air introduced into a carburetor of an engine. The air filter molding method
The filter body is obtained by fixing one or more ribs having flexibility along the folding direction of the filter medium to the filter body original body in which the filter medium is folded in a bellows shape and formed into a substantially square shape. Is formed into a cylindrical shape by rounding the filter body around an axis provided in parallel with the ridge line of the filter medium, and then joining both ends of the filter medium in the folding direction. And

A filter body is formed by folding a filter material in a bellows shape and attaching one or a plurality of ribs to a substantially square shaped filter body original along the folding direction of the filter material. . Since the rib is made of a soft material and has flexibility, the filter body can be deformed into almost any shape. The filter body is formed into a cylindrical shape by being rounded around an axis provided in parallel with the ridge line of the filter medium and joined at both ends in the folding direction of the filter medium. Since one or a plurality of ribs are fixed to the outer peripheral surface of the many folds in the cylindrical air filter thus formed, the rigidity in the height direction is maintained as it is.

In the case where flexible frame members alone are fixed to each of the four peripheral edges of the filter main body in a frame shape while being separated from each other at each corner of the filter main body, When the filter body is formed into a cylindrical shape, ribs are fixed to upper and lower ends thereof. Therefore, when the cylindrical air filter is housed in the filter case, air tightness is maintained at the upper and lower ends.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail by way of examples. Figure 1 is a perspective view of a cylindrical air filter F ₁ of the first embodiment of the present invention, FIG 2 is a perspective view of a filter body A ₁ constituting a cylindrical air filter F ₁ of the first embodiment, FIG. 3 is also plan view, FIG. 4 is X ₁ -X ₁ line sectional view of FIG. 3, FIG. 5 is also X ₂ -X ₂ line cross-sectional view, and FIG. 6 is a plan of a state in which round the filter body a ₁ about the axis C ₁ FIG. 7 and FIG. 7 are perspective views of FIG.

[0012] With reference to FIGS. 5 to describe a cylindrical air filter F ₁ of the first embodiment. First, a description will be given of a molding method of the cylindrical air filter F _1. As shown in FIGS. 2 to 4, the filter medium P is folded in a bellows shape to form a substantially rectangular filter main body A ₀ provided with a large number of folds. The material of the filter medium P is a nonwoven fabric, paper, glass fiber, or the like. An injection molding machine, at both ends of the folding direction Q of the filter material P in the filter body conformation A _0, junction plate 2 is fixed, the filter body A ₁ is formed. The joining plate 2 is made of a soft resin having flexibility, and has a function of reinforcing the rigidity in the width direction (the direction orthogonal to the folding direction Q of the filter medium P) at both ends of the filter medium P. . Furthermore,
On both sides in the width direction of the filter medium P in the filter body A _1, is the gas-tight seal plate 3 is fixed. This airtight plate 3
Is made of a soft resin having flexibility similarly to the joining plate 2, and its height is slightly higher than the height of the ridgeline 1 of each fold. The airtight holding plate 3, as well to hold the length along the folding direction Q of the filter body bulk A ₀ constant in the height direction of the air filter F ₁ which is formed into a cylindrical shape on the air at the lower end It has the function of maintaining airtightness.

Two intermediate ribs 4 are fixed to one surface of the fold of the filter body A ₁ along the folding direction Q of the filter medium P at a constant distance from each airtight holding plate 3. I have. The two intermediate ribs 4 are made of a soft resin having flexibility similarly to the joining plate 2 and the airtight holding plate 3 described above. The length of each intermediate rib 4 is slightly shorter than the airtight holding plate 3. Since the joining plate 2 and each intermediate rib 4 are fixed along the folding direction Q of the filter medium P, the folding pitch of the filter medium P in the filter body A1 (the interval between the ridge lines ₁ of a large number of folds) is constant. Will be retained. Both ends of each of the intermediate ribs 4 in the folding direction Q of the filter medium P are fixed while being separated from the joining plate 2. Thus, each joining plate 2 and each airtight holding plate 3
And each intermediate rib 4 are both together are provided with a flexible, because it is fixed in a state of being separated, respectively, the filter body A ₁ is deformable in substantially any shape.

As shown in FIGS. 6 and 7, the filter body A ₁ is rounded about an axis C ₁ provided in parallel with the ridge line 1 of each fold. The axis C ₁ is provided in the filter body A ₁ on the opposite side of the intermediate rib 4 has fixed side. At this time, the airtight holding plate 3 located on both sides (upper and lower ends) in the width direction of the filter medium P and the filter body A
Two intermediate ribs 4 fixed along _one folding direction Q are simultaneously rounded in respective horizontal planes. This state is shown by a two-dot chain line in FIG. The axis of this intermediate state, shown at C _2. Then, the joining plates 2 fixed to both ends of the filter medium P in the folding direction Q are overlapped with each other, and both are joined. At the same time, the end faces of the upper and lower airtight holding plates 3 are joined together. This state is shown by a dashed line in FIG. Each joining plate 2 and each airtight holding plate 3 are joined by means such as vibration welding, ultrasonic welding, an adhesive, or a separate fastener member (not shown). By doing this, as shown in FIG. 1, the filter body A ₁
Is formed into a cylindrical shape, a large number of corrugation which is projected radially from the axis C ₁ is formed on its outer peripheral surface. Each joining plate 2
The airtightness of the air in this portion is maintained by joining the upper and lower airtight holding plates 3 together and joining them together. Each airtight holding plate 3 secured to both sides of the width direction of the filter material P by being rounded around the axis C ₁ in each of the horizontal plane, each rib 5a of the upper and lower in the cylindrical air filter F _1, 5b Is formed.

The cylindrical air filter F ₁ thus formed is provided with two intermediate ribs 4 fixed along the circumferential direction on the outer peripheral edge thereof at predetermined intervals in the height direction. I have. Therefore, the folding pitch of each fold is kept constant, the folds do not adhere to each other, and the filtration efficiency does not decrease. The joint of the cylindrical air filter F ₁ is joined by a joint plate 2. Therefore, the rigidity in the height direction of the filter F ₁ is reinforced, air-tightness of the air is retained in the joint. Further, in the central portion of the cylindrical type air filter F _1, by two intermediate ribs 4 are fixed, each rib 5a of the upper and lower in the cylindrical-type air filter F _1, 5b
The distance between the intermediate rib 4 is very short, the filter F ₁ is prevented from buckling and. As a result, the rigidity in the height direction of the cylindrical type air filter F ₁ is increased, it does not occur buckling even filter medium P is soft material. The upper and lower ribs 5a and 5b (the airtight holding plate 3) and the intermediate rib 4 are
Notches (not shown) at their outer peripheral edge and inner peripheral edge
By being provided, it can be easily rounded.

[0016] The description of the operation of the cylindrical air filter F _1. As shown in FIGS. 8 to 10, this cylindrical air filter F ₁ is housed in a filter case 6. A pedestal portion 7 is provided on the bottom surface of the filter case 6. A guide portion 7a protruding upward is provided on the outer peripheral edge of the pedestal portion 7, and the pedestal portion 7 has a short cylindrical shape. This pedestal 7, the lower rib 5b of the cylindrical air filter F ₁ is placed fits with little clearance. Therefore, the axis of the pedestal 7 is substantially the same as the axis C ₁ of the cylindrical air filter F ₁ . that time,
Since the lower ribs 5b are guided by the guide portion 7a, the cylindrical air filter F ₁ is inhibited to move in the horizontal direction. An air supply cylinder 8 is provided on an outer peripheral surface of the filter case 6 along a tangential direction of the filter case 6 in a plan view. The axis (C ₁ ) of the pedestal portion 7 is provided at a position shifted from the axis C ₃ of the filter case 6. For this reason, the air introduced through the air supply cylinder 8 flows into the cylindrical air filter F _1.
And the large dust in the air is blown outward in advance.

[0017] filter case 6 as described above, the cover 9 is mounted in a state in which the cylindrical air filter F ₁ is furnished. On the lower surface of the lid 9, a ring-shaped pressing portion 9a is provided. The axis of the pressing portion 9a is
Are arranged on the same straight line as the axis (C ₁ ). Immediately above the axis (C ₁ ) on the upper surface of the lid 9,
An air outflow cylinder 11 is provided. When the cover 9 is mounted on the filter case 6, the pressing portion 9a of the cover 9
But it presses the upper rib 5a of the cylindrical air filter F ₁ which is furnished to the filter case 6. Then, the lower ribs 5b of the cylindrical air filter F ₁ is pressed against the pedestal 7. As a result, it held airtightness of air at each end of the upper and lower cylindrical air filter F _1, never air leaks in the part. Further, on the outer circumferential surface of the filter material P in the cylindrical air filter F _1, since the two intermediate ribs 4 is fixed, also the filter F ₁ is pressed,
It does not buckle.

Dust in the air introduced into the filter case 6 from the air supply cylinder 8 is removed by the cylindrical air filter F _1.
While circulating around the portion between the outer peripheral surface of the filter case 6 and the inner wall surface of the filter case 6, it collides with a large number of folds. Then, dust in the air is filtered by a number of corrugation, only clean air is passed through a portion of the inner peripheral surface of the cylindrical air filter F _1. Only this clean air is introduced from the air outlet tube 11 into the carburetor of the engine E (see FIG. 14).

Next, a cylindrical air filter F2 according to a _second embodiment will be described with reference to FIG. Cylindrical air filter F ₂ of this embodiment, and below each rib 5a, 5b
Are fixed, and the intermediate rib 4 is not fixed. In this embodiment, as in the cylindrical air filter F ₁ of the first embodiment, bonding the filter body A ₂ are rounded about the axis C _1, which is fixed at both ends of the folding direction Q of the filter medium P The plates 2 and the end faces of the airtight holding plate 3 fixed to both sides in the width direction of the filter medium P are overlapped and joined. Filter media P of this embodiment, it because itself comprises a rigid, height direction rigidity of the cylindrical air filter F ₂ is ensured as is. Therefore, the intermediate rib 4 is unnecessary. Each joining plate 2 and each airtight holding plate 3
Are joined by means such as vibration welding, ultrasonic welding, and an adhesive, so that the airtightness of the air in the relevant portion is maintained.

Next, with reference to FIG. 12, described cylindrical air filter F ₃ of the third embodiment. Cylindrical air filter F ₃ in this embodiment, and below each rib 5a, 5b
Are not fixed, and only two intermediate ribs 4 are fixed. As in the case of the cylindrical air filter F _{1 of} the first embodiment, the filter body A ₃ is rounded about the axis C ₁ , and the joining plates 2 fixed to both ends of the filter medium P in the folding direction Q are overlapped. And joined. The joining plates 2 are joined by means such as vibration welding, so that the airtightness of the air in the corresponding portions is maintained. Further, on the lower end of the filter body A _3, writes the cap 12 respectively fits. The cap 12 includes a cap main body 12a formed of a ring-shaped flat plate, and a filter support portion 12b attached to one surface of the cap 12 coaxially with the cap main body 12a. Filter support portion 12b has a cylindrical shape, it is fitted with little clearance to the inner peripheral surface of the filter body A _3. Also, the cap body 12
the outer diameter of a is slightly larger than the outer diameter of the large number of corrugation of the filter body A _3. Filter support unit 12b of the cap 12 is mounted on the lower end portion of the filter body A _3. Then, the upper and lower ends of the filter body A _3,
An adhesive is poured into a contact portion of the cap 12 with the cap body 12a, and the two are joined. Filter body A ₃
The upper and lower end portions are joined to the cap 12 in close contact with each other, so that the airtightness of the air in the portion is maintained. In this embodiment, since each filter support unit 12b in the upper and lower cap 12, together with the fitted on the inner peripheral surface of the filter body A _3, intermediate rib 4 of two to filter body A ₃ is fixed, Even if the filter medium P is a soft material such as a nonwoven fabric, the rigidity in the height direction is maintained.

Next, with reference to FIG. 13, described cylindrical air filter F ₄ of the fourth embodiment. In the cylindrical air filter F ₄ of this embodiment, the above-mentioned caps 12 are fitted into upper and lower ends of a filter body A ₄ formed by folding a filter medium P in a bellows shape. intermediate rib 13 of the separate to a ₄ is a case which is fixed mounted. The separate intermediate rib 13 will be described. This intermediate rib 13 is made of resin. And its axial direction, vent holes 13a corresponding to the number of corrugation of the filter body A ₄ are provided.
1 or a plurality of intermediate ribs 13 is fitted along the direction of the axis C ₁ of the filter body A _4, it is secured by means such as adhesive. By doing so, the rigidity in the height direction of the filter body A ₄ is maintained. In this embodiment, even in the filter body A ₄ made of soft material, without attaching the mesh for reinforcing as in the prior art (see FIG. 15), the rigidity in the height direction can be held.

As described above, in the method for forming a cylindrical air filter according to the present invention, the filter body formed by almost the same means as the conventional one is rounded and formed into a cylindrical shape only by joining both ends thereof. Therefore, it can be molded very easily. Moreover, since the ribs are fixed to at least one of the upper and lower ends or the center of the filter body, the rigidity of the cylindrical air filter in the height direction is maintained.

The filter body A of the fourth embodiment described above.
₄ an upper end (see FIG. 13), the pucker toward the axis C _1, by widening away the lower portion from the axis C _1, it may be a bevel gear shape. In this case, since the air filter has a conical shape, the air filter can be mounted on a narrow portion that cannot be mounted with a cylindrical air filter.

The cylindrical air filter for an automobile according to the present invention can be used for purposes other than removing dust from air in an automobile. For example, it may be used for removing sand in air in an automobile, or for filtering impurities such as sewage, juice, oil, and the like in liquids other than automobiles. It can also be used to remove pollen and the like. Further, by mixing activated carbon into a filter medium constituting the cylindrical air filter, it can be used for removing bad smell and the like.

[0025]

According to the present invention of the automobile cylindrical air filter of the present invention
The forming method is a forming method of a cylindrical air filter for an automobile which is exchangeably incorporated into a filter case to remove dust in air introduced into a carburetor of an engine, wherein the filter medium is folded in a bellows shape. A filter body is formed by fixing one or more ribs having flexibility along a folding direction of the filter medium to a filter body original formed in a substantially square shape, thereby forming a filter body. After being rounded around an axis provided in parallel with the ridge line of the filter medium, the filter medium is formed into a cylindrical shape by joining both ends in the folding direction of the filter medium. Therefore, the cylindrical air filter in which the outer peripheral surface of the fold of the filter medium is reinforced by the ribs can be formed extremely easily.
The molding method of the filter body is almost the same as the conventional molding method, and no new equipment is required.

[Brief description of the drawings]

FIG. 1 shows a cylindrical air filter F _{1 according to a} first embodiment of the present invention.
It is a perspective view of.

2 is a perspective view of a filter body A ₁ constituting a cylindrical air filter F ₁ of the first embodiment.

FIG. 3 is a plan view of the same.

FIG. 4 is a sectional view taken along line X ₁ -X ₁ of FIG. 3;

FIG. 5 is a sectional view taken along the line X ₂ -X _{2 in the} same manner.

FIG. 6 is a plan view showing a state where the filter main body A ₁ is rounded around an axis C ₁ .

FIG. 7 is a perspective view of FIG. 6;

FIG. 8 shows a cylindrical air filter F _{1 according to} the first embodiment of the present invention.
FIG. 6 is a side view of a state in which the filter case 6 is provided inside.

FIG. 9 is a sectional view taken along line YY of FIG. 8;

FIG. 10 is a sectional view taken along line ZZ of FIG. 9;

FIG. 11 is a perspective view of a cylindrical air filter F2 of a _second embodiment.

[12] a filter body A ₂ constituting the cylindrical air filter F ₃ of the third embodiment is a perspective view of a separated state between the caps 12 of the upper and lower.

FIG. 13 is a perspective view showing a state where a filter main body A ₄ constituting a cylindrical air filter F ₄ of a fourth embodiment is separated from upper and lower caps 12 and a separate intermediate rib 13.

FIG. 14 is a schematic perspective view showing a state in which air from which dust has been removed by a cylindrical air filter F ′ is introduced into a carburetor of an engine E;

FIG. 15 is a perspective view of a conventional cylindrical air filter F ′ with a part cut away.

FIG. 16 is a schematic view of a conventional method of forming a cylindrical air filter F ′ using a mold.

[Explanation of symbols]

A ₀ : Filter main body A _{1 to} A ₄ : Filter main body C ₁ : Shaft center E: Engine F _{1 to} F ₄ : Cylindrical air filter P: Filter medium Q: Folding direction 1: Ridge 2: Joint plate (frame material) Single unit 3: Airtight holding plate (Frame material alone) 4, 13: Intermediate rib 5a: Upper rib 5b: Lower rib 6: Filter case

Claims (2)

(57) [Claims] 1. A method of forming a cylindrical air filter for an automobile, which is replaceably incorporated in a filter case to remove dust in air introduced into a carburetor of an engine, wherein the filter medium is folded in a bellows shape. The filter body is formed by fixing one or more ribs having flexibility along the folding direction of the filter medium to the filter body original body formed in a substantially square shape. A cylindrical air filter for an automobile, which is formed into a cylindrical shape by rounding around an axis provided in parallel with the ridge line of the filter medium and then joining both ends of the filter medium in a folding direction. Molding method. 2. A frame member having flexibility is fixed to each of the four peripheral edges of the filter body in a frame shape in a state of being separated from each other at each corner of the filter body. The method for forming a cylindrical air filter for an automobile according to claim 1 , wherein: