JP3499320B2 - Air filter - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air filter installed in an air passage of an internal combustion engine or the like for collecting dusts mixed in the air.

[0002]

2. Description of the Related Art As a conventional air filter of this type, for example, a peripheral portion of a filter body having a large number of pleats is embedded in a frame made of a hard synthetic resin, and an outer peripheral portion of the frame is made of a rubber gasket. Air filters coated by are used. Further, as a conventional technique, for example, Japanese Patent Laid-Open No.
62-268862, Japanese Patent Laid-Open No. 6-57293, Japanese Utility Model Publication 61
-43532 and the like, in these publications, the entire filter is composed of a fiber layer, and an air filter in which the outer peripheral edge is compressed by heat to form a flange, a first filtration base material composed of a fiber layer, and many Disclosed are an air filter in which a second filtration base material having individual pleats is superposed, an air filter in which a band-shaped filter material and filter materials on both end faces are separately formed, and the filter materials are joined by heat-sealing fibers. ing.

[0003]

SUMMARY OF THE INVENTION The present invention is an airfill.
To improve the dust collection efficiency and filtration characteristics of the
In addition, it is necessary to stabilize the mounting condition of the air filter.
It is the subject.

[0004]

According to a first aspect of the present invention, there is provided a filter body having a plurality of ridges arranged in a fold-like bent state, and a state surrounding a part of the filter body. in the installed possess a rectangular frame-like flange, and the said濾体flange formed by the base material of the same quality of the fiber aggregate, its
The filter body and the flange are joined by injection synthetic resin, and a pair of wall bodies installed along the arrangement direction of the pleats and joined to the flanges are joined to both side edges of the folds, respectively . It is an air filter with a configuration
The fiber density of the filter gradually changes in the thickness direction.
However, the fiber density on the air outlet side of the filter body is
Characterized by being configured to have a higher density than
And

According to the present invention, the air inlet side, that is, the dust
The side where the air containing the air exists (hereinafter referred to as the dusty side.
The dust in the air that has entered the filter body from the
Side, that is, the side where clean air after filtration exists (below
The order of size before reaching the bottom (called the clean side)
To be collected by. That is, the relatively large dust is the air of the filter body.
Fine particles collected at the entrance side and its vicinity and passed through there
Dust is collected on the air outlet side and its vicinity. did
Therefore, dust of different sizes is distributed in the thickness direction of the filter body.
The effective filtration area of the filter body can be
Expands in the thickness direction to concentrate the collection load on the air inlet side of the filter body
It is possible to solve the problem that occurs. Therefore, the filter
Stroke collection efficiency and filtration characteristics can be improved.

According to the invention of claim 2, it is bent in a fold shape.
Filter body on which multiple ridges are formed
And a rectangular frame installed so as to surround a part of this filter body
A flange, and the filter body and the flange are the same.
Formed by a base material of high quality fiber aggregate,
While joining the flange with injection synthetic resin,
The flange is installed along the arrangement direction of the folds
A pair of walls connected to each side wall of each fold.
An air filter configured to be joined to each other, wherein
Is compressed by being heated and pressed.
Hardened hard part and compressible deformable around the hard part
And a soft portion arranged. Book
According to the invention, the flange has good strength characteristics and morphological stability.
To stabilize the mounting condition of the air filter.
Wear.

According to the invention of claim 3, it is bent in a fold shape.
Filter body on which multiple ridges are formed
And a rectangular frame installed so as to surround a part of this filter body
A flange, and the filter body and the flange are the same.
Formed by a base material of high quality fiber aggregate,
While joining the flange with injection synthetic resin,
The flange is installed along the arrangement direction of the folds
A pair of walls connected to each side wall of each fold.
An air filter configured to be joined to each other, wherein
The wall and the wall form a cut in a square plate-shaped fiber assembly.
Bend and bend a pair of plate pieces with the cut edge as the cutting edge.
It is characterized by being integrally molded by rubbing. Starting
According to Ming, both walls are used as the base material for the fiber aggregate of the same quality as the filter body.
It is created by adding a filtering function to both walls.
The collection load on the body can be reduced.

According to the air filter of claim 4, both sides are
Between the walls of the mountain are installed along the direction of the array of Mount Hida
The reinforcing plate is formed by injection molding, and the reinforcing plate is
Is joined to each fold. The present invention
According to the report, the filter body is effectively reinforced by the reinforcing plate and the negative pressure is applied.
The rigidity of the filter section against the
Strength characteristics can be enhanced.

According to the invention of claim 5, the softening of the flange
The thickness of the quality part depends on the filter case where the flange is clamped.
When the clamp portion of the cover and the clamp portion of the cap are fitted together
Is set to a thickness greater than the width of the clearance formed in
It is characterized by being According to the invention, both flanges are
Strengthens and secures the fixed state when fixed by the clamp.
It can be standardized, and with the flange and both clamping parts
The sealing performance between the two can be improved.

According to the invention of claim 6, the hardness of the flange is
In the quality part, the engagement formed on one of the two
An engaging portion that engages with the stopper is formed.
It According to the present invention, the flange can be accurately
Can be firmly fixed by positioning
It is possible to eliminate positional deviation with time.

According to the invention of claim 7, the flange is hardened.
When the hard part is formed, it is fused to the hard part.
It is characterized in that a sealing material is joined. The present invention
According to the seal material that is fixed to the hard part of the flange,
The sealing performance is strengthened and
It is possible to eliminate dust leaks from them.

According to the invention of claim 8, the hardness of the flange is
Bend the flange at the boundary between the soft and soft parts.
It is characterized in that a hinge part that holds it is formed.
To do. According to the present invention, no flange is provided at the position of the hinge portion.
You can easily bend it, and when you bend the flange
It is possible to prevent wood damage and strength deterioration. Also, hard and soft
Part and the part on top of each other
Since it can be stopped, the gap between both clamping parts can be
A strong seal can be obtained.

[0013]

According to the present invention, the dust collection efficiency of the filter body
In addition to improving the filtration characteristics, the air filter
The mounting condition of the filter can be stabilized.

[0014]

[0015]

[0016]

[0017]

[0018]

[0019]

[0020]

[0021]

[0022]

[0023]

[0024]

[0025]

[0026]

[0027]

[0028]

[0029]

[0030]

[0031]

An embodiment of the present invention will be described below with reference to the drawings. In an air filter A installed in the middle of an air flow path formed in an internal combustion engine or the like, a filter body 1 having a plurality of folds 1a arranged in a horizontal row in a fold-like bent state A flange 2 which is formed in the shape of a rectangular frame and is installed so as to surround one end of the filter body 1 is joined.

The filter body 1 and the flange 2 are made of non-woven fabric, filter paper,
The filter body 1 and the frame body 2 are each formed of a fibrous base material of the same quality such as felt, and in this example, the filter body 1 and the frame body 2 are made of a fibrous base material whose fiber density gradually changes in the thickness direction.

The filter body 1 is installed such that the fiber density thereof gradually increases from the clean side a of the filter body 1 to the dusty side b, and the fiber density of the layer of the clean side a of the filter body 1 is set to the filter body 1. The density is higher than that of the dusty side b layer.

The dust that has entered into the filter body 1 from the dusty side b of the filter body 1 is collected in order of size before passing through the layers of the filter body 1 and reaching the clean side a. Dust is dusty side b of filter body 1
Of the dusty side b and the fine dust passing through the layers of the dusty side b are collected in the layers of the clean side a of the filter body 1.

The flange 2 is formed by endlessly punching a plate-shaped fiber assembly as shown in FIG. 3 or a band made by slicing the plate-shaped fiber assembly as shown in FIG. It is formed by a base material 23 or the like in which both end surfaces 24a of the band 24 are joined by bending 24 into a rectangular frame shape.

Both folds at both ends of the folds 1a of the filter body 1
The outer edge 1c of 1a and both frame pieces 2a on the short side of the flange 2 are integrally joined by a synthetic resin injected during injection molding in the injection molding process, and the filter body 1 and the flange 2 are joined together. , The synthetic resin injected at the time of injection molding is molded into a plate shape rising from the flange 2 and installed along the arrangement direction of the folds 1a of the filter body 1, and both side edges of each fold 1a of the filter body 1
1b and the inner surface of the frame piece 2b on the long side of the flange 2 are joined by a pair of wall bodies 3 respectively joined, and the filter body 1 has each fold 1a sandwiched between both wall bodies 3. Both walls 3 in the state
Is joined to.

When the filter body 1 and the flange 2 are joined and joined by the both wall bodies 3, the individually prepared filter body 1 and the flange 2 are melted in a state where they are inserted into the mold of the injection molding machine and melted PP or the like. Both outer edges 1c of the filter body 1 and both frame pieces 2a of the flange 2 are joined with each other by injection synthetic resin, and at the same time, both wall bodies 3 are formed by molding both wall bodies 3 with the injection synthetic resin. A method of joining the filter body 1 and the flange 2 by joining 3 to each side edge 1b of each fold 1a of the filter body 1 and both frame pieces 2b of the flange 2 is applied.

The center portion of each ridge 1a of the filter body 1 is molded into a plate shape by the synthetic resin injected at the time of injection molding of both wall bodies 3, and the fold ridges 1a are arranged in the middle portion between both wall bodies 3 in the arrangement direction. And are joined to the reinforcing plates 4 that reinforce the filter body 1, respectively.

The air filter A is composed of a holding portion 17 formed on the peripheral portion of a box-shaped filter case 16 and a filter case.
The flange 2 was bent and sandwiched between the box-shaped cap 18 and the sandwiching portion 19 formed on the peripheral portion of the box-shaped cap 18, and the filter body 1 was inserted into the filter case 16 and the cap 18. In this state, the filter case 16 and the cap 18 are fixed.

The flange 2 has an endless hard portion 6 formed by heating and pressurizing a part of the base material of the fiber assembly over the entire circumference, and is compressed and hardened, and is arranged around the hard portion 6. Endless soft parts 7 having the same thickness as that of the filter body 1 without being heated and pressed and formed so as to be compressively deformable are formed adjacent to each other inside and outside.

The hard portion 6 is sandwiched between the inner sandwiching piece 17a of the sandwiching portion 17 and the inner sandwiching portion 19a of the sandwiching portion 19, and the soft portion 7 is the outer sandwiching piece 17b of the sandwiching portion 17. And the outer clamping piece 19b of the clamping part 19 are clamped.

A filter case is provided on the hard portion 6 of the flange 2.
An engaging groove 8 that engages with a locking protrusion 20 that is provided on the pinching portion 17 of 16 and an engaging protrusion 9 that engages with an engaging groove 21 that is recessed on the pinching portion 19 of the cap 18. Are formed over the entire circumference of the flange 2.

Of the both sides of the hard portion 6 of the flange 2, the tape-like sealing material 10 fused to the hard portion 6 when the hard portion 6 is formed is formed on the extension surface of the clean side a of the filter body 1 of the flange 2. It is joined all around.

The thickness d1 of the soft portion 7 of the flange 2 is such that when the pinching part 17 of the filter case 16 and the pinching part 19 of the cap 18 are fitted together, the pinching part 17b of the pinching part 19 and the pinching part 17b of the pinching part 19 are pinched. The width of the clearance formed between the portion 19 and the outer clamp piece 19b is set to be larger than the width d2 such that d1> d2, and the soft portion 7 is set when both the clamp portions 17 and 19 are fitted to each other. Both outer clamping pieces 17a, 19
It is sandwiched between a and compressed.

At the boundary between the hard portion 6 and the soft portion 7 of the flange 2, a hinge portion 11 is formed which serves as a rotation fulcrum when the soft portion 7 is rotated and folded back, and allows the flange 2 to be bent. When the soft portion 7 is folded back around the hinge portion 11 as a fulcrum, the flange 2 is inserted into the inner holding pieces 17a and 19a of the two holding portions 17 and 19 while the soft portion 7 and the hard portion 6 are overlapped with each other.
Sandwiched between.

Next, the operation and effect of the embodiment having the above-mentioned structure will be described. In this example, a filter body 1 formed with a plurality of folds 1a arranged in a fold-like shape, and a rectangular frame-shaped flange 2 installed so as to surround a part of the filter body 1. An air filter A having a filter body 1
And the flange 2 are formed of a base material of the same quality fiber aggregate, and the filter body 1 and the flange 2 are formed by injection molding and installed along the arrangement direction of the folds 1a,
The side ridges 1a of each fold 1a and the inner side surfaces of both frame pieces 2b of the flange 2 are joined by a pair of wall bodies 3 respectively joined by injection molding, and the folds 1a between both wall bodies 3 are formed.
The reinforcing plate 4 installed along the arrangement direction of is joined to each fold 1a, and the filter body 1 is made of a fiber assembly in which the fiber density of the layer on one side is higher than that of the layer on the other side. The filter body 1 is formed and placed so that the fiber density of the layer of the clean side a thereof is higher than that of the layer of the dusty side b, and the flange 2 is heated and pressed to harden and Compressed hard part 6 and compressible deformable hard part 6
And the soft part 7 disposed around the outer circumference of the filter part 16 and the thickness d1 of the soft part 7 are fitted to the pinch part 17 of the filter case 16 and the pinch part 19 of the cap 18 on which the flange 2 is pinched. Set the thickness to be more than the width d2 of the clearance that is formed when
The hard portion 6 is formed with an engagement projection 9 that engages with the locking groove 21 formed in the pinching portion 17, and the hard portion 6 has a seal fused to the hard portion 6 when the hard portion 6 is formed. A material 10 is joined and a hinge portion 11 that allows the flange 2 to be bent is formed at a boundary portion between the hard portion 6 and the soft portion 7.

Therefore, the filter body 1 and the flange 2 can be firmly joined by the both wall bodies 3 to strengthen the structural strength of the air filter A, and the filter body 1 and the flange 2 can be strengthened.
The step of connecting and can be simplified.

Particularly, the rigidity of the filter body 1 against negative pressure can be secured by the both wall bodies 3 and the negative pressure resistance characteristic of the filter body 1 can be stabilized.

Further, since the filter body 1 and the flange 2 are made of the same material as the base material of the fiber assembly, the material cost and the manufacturing cost of the air filter A can be reduced, and the filter body 1 and the flange 2 can be reduced. The bonding state of can be stabilized.

Further, since the conventional air filter does not require a frame made of synthetic resin, and a protective member such as a gasket for protecting the outer peripheral portion of the frame is not required, the amount of synthetic resin used and the air filter A are not required. It is possible to reduce the number of parts and reduce the material cost of the air filter.

Further, the filter body 1 can be effectively reinforced by the reinforcing plate 4 to further enhance the rigidity of the filter portion against negative pressure, and further improve the structural strength characteristics of the air filter A.

Furthermore, dusts of different sizes can be distributed and collected in the thickness direction of the filter body 1, and the effective filtration area of the filter body 1 can be expanded in the thickness direction of the filter body 1 to obtain the filter body. The problem that the collection load is concentrated on the dusty side layer of No. 1 can be solved, and the dust collection efficiency and the filtration characteristics of the filter body 1 can be improved.

Further, the hard portion 6 improves the strength characteristics and the shape stability of the flange 2 to stabilize the mounting state of the air filter A.

Furthermore, the fixing state when the flange 2 is fixed by the both pinching portions 17 and 19 can be strengthened and stabilized, and the sealing performance between the flange 2 and the both pinching portions 17 and 19 can be improved. Can be improved.

Further, the flange 2 is provided with the engaging groove 8 and the locking projection 2
0, and the engaging projections 9 and the locking grooves 21 cause both pinching portions 1
It can be accurately positioned and firmly fixed to 7 and 19, and the positional displacement of the flange 2 with time can be eliminated.

Further, the sealing material 10 improves the sealing performance of the flange 2 itself so that the clamping portions 17 and 19 and the flange 2 can be improved.
It is possible to eliminate dust leakage from between.

Further, it is possible to bend the flange 2 with the hinge portion 11 as a fold, and to prevent damage and reduction in strength when the flange 2 is folded, and at the same time the soft portion 7 and the hard portion 6 are superposed. Since the flange 2 can be clamped between the two clamping portions 17 and 19, both clamping portions 1
The gap between 7 and 19 can be firmly sealed by the flange 2.

Next, a second embodiment of the present invention shown in FIGS. 8 and 9 will be described. In this example, the base 30 of the rectangular plate-shaped fiber assembly shown in FIG. A pair of cuts 31 formed along the vicinity of both end edges and a cut 31 formed in parallel with the long side in the middle portion of the long side end edges, and each cut 31 is referred to as a cut edge. As shown in FIG. 8 (B), a flange 2 and a pair of wall bodies 3 integrally connected to the flange 2 are formed by bending and bending up a pair of plate pieces to be used. As shown, cut off the cut portion 34 by cutting the base material 30 of the fiber assembly by a cut 33 surrounding the cut portion 34 so that the cut portion 34 which becomes an unnecessary portion is cut out,
A pair of plate pieces whose cut edges are cut edges 33 are bent and bent to form the flange 2 and the both wall bodies 3.

The outer edges 1c of the filter body 1 and the frame pieces 2a on the shorter side of the flange 2, the side edges 1b of the folds 1a of the filter body 1 and the wall bodies 3 are formed by an injection molding process. While being joined by the injected synthetic resin, the central portion of each fold 1a is joined to the reinforcing plate 4 formed in the injection molding process.

According to the second embodiment, since both wall bodies 3 are made of a base material of a fiber aggregate having the same quality as that of the filter body 1, the filter body 1 receives the both wall bodies 3 with a filtering function. The collection load can be reduced.

[Brief description of drawings]

FIG. 1 is a perspective view of an air filter showing an embodiment of the present invention.

FIG. 2 is a perspective view of a filter body.

FIG. 3 is a perspective view of a flange base material.

FIG. 4 is a perspective view showing another example of the flange base material.

5 is an enlarged cross-sectional view taken along line XX of FIG.

FIG. 6 is a vertical sectional view of a flange.

FIG. 7 is a cross-sectional view of a main part for explaining an attachment mode of an air filter.

FIG. 8 shows a second embodiment of the present invention and is a perspective view for explaining the manufacturing process of the flange and the wall body.

FIG. 9 is a perspective view illustrating another example of the manufacturing process of the flange and the wall body.

[Explanation of symbols]

1 Filter body 1a Mount Hida 2 flange 3 walls 4 Reinforcement plate 6 hard part 7 Soft part 8 engaging groove 9 Engagement protrusion 10 Seal material 11 Hinge part 16 filter case 17 Clip part 18 cap 19 Clip part a clean side b dusty side

Continuation of the front page (56) Reference JP-A-8-24546 (JP, A) JP-A-63-287522 (JP, A) JP-A-6-226024 (JP, A) JP-A-6-218208 (JP , A) JP 4-180808 (JP, A) JP 5-208110 (JP, A) JP 60-12113 (JP, A) Actual flat 1-101615 (JP, U) Actual flat 6-81606 (JP, U) Actual opening Sho 56-129814 (JP, U) Actual opening 4-106606 (JP, U) Actual opening 5-63625 (JP, U) Actual opening 6-7817 (JP, U) Actual Kaihei 5-37317 (JP, U) Actual Kaihei 6-15712 (JP, U) Special Tables 5-500628 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) ) F02M 35/024 511 B01D 46/52

Claims (8)

(57) [Claims] 1. A filter body having a plurality of folds arranged in a fold-like bent state, and a rectangular frame-shaped flange installed so as to surround a part of the filter body. Existence
Then, the filter body and the flange are formed from a base material of the same quality fiber aggregate , and the filter body and the flange are joined by injection synthetic resin, and the filter body and the flange are installed along the arrangement direction of the folds. An air filter having a structure in which a pair of wall bodies joined to the flange are joined to both side edges of each of the folds , wherein the filter body has a fiber density that gradually changes in the thickness direction.
The fiber density of the air outlet side of the filter body is lower than that of the air inlet side.
Is also configured to have a high density
Air filter. 2. A filter body formed with a plurality of folds arranged in a fold-like bent state, and a rectangular frame-shaped flange installed so as to surround a part of the filter body. Existence
Then, the filter body and the flange are formed from a base material of the same quality fiber aggregate , and the filter body and the flange are joined by injection synthetic resin, and the filter body and the flange are installed along the arrangement direction of the folds. a <br/> air filter arrangement for joining each pair of wall coupled to the flange on both side edges of each pleat peaks, the flange, by being molded heat and pressure to
Air filter, characterized in that it comprises a compression and cured rigid portion, and a soft portion arranged around the compression deformable said hard portion. 3. A filter body formed with a plurality of folds arranged in a fold-like bent state, and a rectangular frame-shaped flange installed so as to surround a part of the filter body. Existence
Then, the filter body and the flange are formed from a base material of the same quality fiber aggregate , and the filter body and the flange are joined by injection synthetic resin, and the filter body and the flange are installed along the arrangement direction of the folds. An air filter having a structure in which a pair of wall bodies coupled to the flange are joined to both side edges of the folds, respectively , wherein the flange and the wall body are rectangular plate-shaped fiber aggregates. To
A pair of plates forming a cut and using the cut as a cutting edge
By bending up one piece, it is molded integrally
Air filter to do. 4. The method according to claim 1, claim 2 or claim 3.
It is an air filter described in a staggered manner, and is installed between the wall bodies on both sides along the direction of the array of folds.
The reinforced plate is formed by injection molding.
An air filter characterized by a strong plate joined to each ridge . 5. A air filter described in claim 2, the thickness of the soft portion of the flange has fitted the Kyotome portion of Kyotome portion and cap of the filter case in which the flange is locked clamping air filter, characterized that you have been set to the width or thickness of the clearance formed when. 6. A air filter described in claim 2 or claim 5, the rigid portion of the flange, engages with a locking portion formed on Kyotome portion of one of the Ryokyotome portion An air filter characterized in that an engaging portion is formed . 7. The air filter according to claim 2, 5 or 6, wherein the hard portion of the flange is fused to the hard portion when the hard portion is formed. air filter sealing material, characterized in Tei Rukoto joined. 8. A air filter described in claim 2 or claims 5 to 7, the boundary between the hard portion and the soft portion of the flange, the furan <br/> di air filter according to claim <br/> the hinge unit which enables holding bending is formed.