JPS6041517A - Manufacture of air cleaner element - Google Patents

Abstract

PURPOSE:To obtain a titled element having excellent resistance to heat, chemicals, and impact as compared with the conventional element by closing a wavy sheet-shaped filter medium hermetically with slit dice while leaving the circumferential end part, and forcing a thermoplastic resin into the clearance formed by the slit dice at the circumferential end part to form an external frame combined with the filter medium. CONSTITUTION:The paper is made by using linter, pulp, etc. as an essential raw material, impregnated with a fixing agent for preventing the fraying, and bent into a wavy form to make a filter medium 16. The filter medium 16 is then put between both metallic molds 18 and 19 for shaping, and an external frame 15 and a retainer 15a combined with the filter medium 16 are molded into a body by injecting PP, etc. into the clearance formed in both metallic molds 18 and 19 through an injection passage 19a at a low injection pressure of about 5kg/cm<2>. In this case, the end surface of the filter medium 16 is preferably bent in the direction opposite to the flow of injection, or toward the metallic mold 18 to facilitate the flow of the resin in the metallic molds 18 and 19.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an air cleaner element, and more particularly to a method of manufacturing a box-type air cleaner element used for internal combustion engines.

Conventionally, this type of air cleaner element has been made by bonding a filter material to an outer frame made of steel plate with adhesive and integrating it, or a sheet-like filter material bent into a corrugated shape as shown in Figure 1. 1 and a peripheral material 2 made of steel plate etc. that reinforces its shape.
It is generally known that the frame is integrated with an outer frame 8 made of synthetic resin that also serves as an adhesive.As for this kind of synthetic resin, polyvinyl chloride-based resin and polyurethane-based resin are used and layered. .

Conventionally, when manufacturing an air cleaner element i that uses the entire outer frame 8 made of synthetic resin, first, a sol-like synthetic resin is poured into a predetermined mold to form the outer frame 8.
Before this outer frame 8 solidifies, the filter material 1 and the outer peripheral material 2 are
Further, in some cases, a method may be adopted in which the outer circumferential material 2 is omitted and only the filter material 1 is cast therein to be integrated.

However, with this method, the selection range is narrow because there are only a limited number of sol-form synthetic resins, and the methods for solidifying this type of synthetic resin include natural leaving, heat curing, and (b) a two-part chemical reaction. All of these commonly used resins solidify without applying external pressure, so the bonding strength of the resin is extremely weak. Therefore, even if an extremely weak external force is applied, the joint may separate or easily deform.

In addition, many of this type of sol-like synthetic resins are sensitive to heat and chemicals, and they also have the disadvantage of being limited in their range of use.

The present invention was made in view of the current situation, and it is possible to arbitrarily select and use various synthetic resins that have excellent heat resistance, chemical resistance, impact resistance, etc. according to the purpose.
It is an object of the present invention to provide a method for manufacturing an air cleaner element that allows a good air cleaner to be obtained.

As a means for achieving the above object, the present invention places a sheet-like filter material folded into a corrugated shape into a split mold, and seals the filter material with the split mold while leaving the peripheral edge of the filter material. This is an example of the implementation of the present invention, characterized in that a thermoplastic synthetic resin material is pressure-injected into the void formed at the edge of the material layer to form an outer frame integrated with the temporary material. This will be explained with reference to the drawings.

FIG. 2 shows an automobile air cleaner constructed by incorporating an air cleaner element IO according to the present invention.
The air cleaner element 10 has an air population 11a?
A backing 13 is interposed between the lower case 11 and the Ajipa case 12, which has an air outlet 12aQ connected to the carburetor shown in the figure, and are integrally connected and fixed by a screw member 14. In order to maintain engine performance, this air cleaner element 1O is taken out from both cases 11, 12 and cleaned periodically.

The air cleaner element IO is shown in FIGS. 8 to 6.
As shown in the figure, there is a short cylindrical outer frame 15 that is integrally formed on the outer periphery of the flange-shaped holding part 15avi interposed between both cases 11 and 12, and the entire periphery of the outer frame 15 is provided inside the outer frame 15. Frame 15
It is composed of nine filtration materials 16, which are integrally arranged in a state of being embedded within the filter.

As shown in FIGS. 4 to 6, the filter material 16 is made by impregnating a sheet of paper, including links and valves, etc. as main raw materials with phenol resin or the like as a sticking agent to prevent fraying. The filtration material 16 is formed and bent into a waveform with an amplitude of approximately k 4 w, and the peripheral edge of the filter material 16 is embedded inside the outer frame 15 to form an integral structure, as shown in FIGS. 4 and 6. It becomes b.

As shown in Figures 8 to 5, this outer frame 15 is formed by injection molding of a thermoplastic synthetic resin with excellent heat resistance, chemical resistance, and impact resistance, such as polyethylene or polypropylene. , the through hole 1 of the screw member 14 is provided in the center of the outer circumferential surface as shown in FIGS. 8 to 5.
A holding portion 15a having 7 parts is integrally molded.

As a mold for the injection molding, for example, as shown in FIG. 7, a split mold consisting of a mold 18 and a mold 19 having a passage 19ai for resin injection is used, and a filtration filter inserted under pressure therebetween is used. The material 16 is molded together with both molds 18 and 19t, so that both sides of the material 16 are tightly closed by both molds 18 and 19, leaving the peripheral edges. The outer frame 1 communicates with the injection passage 19a.
5 and the holding portion 15at - a gap having a matching shape is formed. Then, in this gap, a thermoplastic resin such as polypropylene is filled with a total injection pressure of 5 p/di.
By injecting with a moderate pressure, the outer frame 15 and the holding part 15a, which are integral with the %-overfill material 16, are injection molded.

Next, a method for manufacturing the air cleaner element 10 will be explained.

First, paper is made into a sheet using links, pulp, etc. as main raw materials, and is impregnated with, for example, phenol resin as a sticking agent to prevent sagging, to form a temporary paper.
A temporary material 16t- is formed by bending it into a waveform with an amplitude of approximately +.

Next, this filter material 16t is put into both molds 18 and 19 and molded, and an injection pressure of 5Kp/C1 is applied to the gap formed in both molds 18 and 19 through the injection passage 19a'i.
For example, polypropylene or the like is injected at a low pressure of about 1°C.

Then, the outer frame 15 and the holding part 15 integrated with the filter medium 16
a is integrally molded.

At this time, care must be taken because if the injection pressure is too high, the resin will protrude from the gap in the filter material 16 and cover the surface of the filter material 16, reducing the entire filter area.

As shown in FIG. 7, the end face of the shredded filter material 16 is bent in the direction opposite to the injection direction to facilitate the flow of the resin in the molds 18 and 19. In addition, the through hole 17 provided in the holding part 15a is preferably
The boss may be formed at 8.19 at the same time as injection molding, or may be bored in the next step.

Since the outer frame 15 is formed by injection molding, the most suitable synthetic resin for the air cleaner of the internal combustion engine is selected from among the synthetic resins with excellent heat resistance, chemical resistance, and impact resistance. can be selected. Therefore, it is possible to obtain an element that will not be easily damaged during the fateful cleaning work as an element of the air cleaner.
Furthermore, it is possible to use an element with less deterioration even for alcohol fuel, which has recently been in the spotlight as a fuel source for internal combustion engines.

Furthermore, since a thermoplastic resin is used as the synthetic resin for injection molding, it is extremely easy to mold the outer frame 15 and the holding part 15a and to integrate it with the filter material 16, and it can also be used constantly as an air cleaner for internal combustion engines. It is hardened in a relatively low temperature range such as the operating temperature, and can sufficiently maintain its hardness and strength.

In the above embodiment, the holding part 15a is provided at the center of the outer surface of the outer frame 15, but as shown in FIG. It may be provided in the section.

Further, the present invention can be applied not only to air cleaner elements for internal combustion engines but also to various types of air cleaner elements.

As explained above, the present invention involves placing a sheet-like filter material folded into a corrugated shape into a split mold, sealing the filter material with the split mold leaving the periphery of the filtration material, and A thermoplastic synthetic resin material is pressure-injected into the void formed in the filter to form the entire outer frame that is integrated with the filtration material, so select the synthetic resin that best suits your purpose from among various synthetic resins. can do. Therefore, it is possible to easily obtain Nirementora which has superior heat resistance, chemical resistance, impact resistance, etc. compared to conventional products.

In addition, the outer frame is formed by so-called injection molding, so
Integrity with filter media? It can be made sufficient.

[Brief Description of the Drawings] Fig. 1 is a sectional view showing the entire conventional example, Fig. 2 is a sectional view showing an example in which the air cleaner element according to the present invention is used as an air cleaner for an internal combustion engine, and Fig. 3 shows details of the air cleaner element. 4 is an enlarged sectional view of the same, FIG. 5 is a sectional view taken along the line v-v of FIG. 4, FIG. 6 is a perspective view of the filter material, and FIG. 7 is a method of forming the outer frame. The explanatory drawing, FIG. 8, is a sectional view of a main part showing an air cleaner element in which the position of the holding part is changed. 10... Air cleaner element, 15... Outer frame,
15a... Holding part, 16...-Surface material, 18.19.
... Mold, 19a... Injection passage. Applicant's agent Kiyoshi Inomata Figure i Figure 3 Kaya Figure 7 Figure 5 n Figure 2 2 ■ Figure 4 Figure 6 Figure 6 Figure 6

Claims (1)

[Claims] 1) A sheet-like filter material bent into a corrugated shape is placed in a split mold, and the entire peripheral edge of the filter material is sealed with the split mold. A method for manufacturing an air cleaner element, characterized by injecting a thermoplastic synthetic resin material under full pressure into a gap formed in the air cleaner element to form an outer frame integrated with a filter material. 2) The method for manufacturing an air cleaner element according to claim 1, characterized in that a holding portion for setting the entire element inside the air cleaner case is integrally formed on the outer frame.