WO2018008327A1 - Water flocculator, fuel filter device, and method for manufacturing water flocculator - Google Patents

Abstract

A fuel filter device (2) has a water flocculator (32). The water flocculator has a frame (51) and a fiber layer (61). The fiber layer is a cylindrical roll of a belt-shaped material. The belt-shaped material is wound at least twice around. The belt-shaped material forms a thick fiber layer. The fiber layer is secured to the frame by a plurality of bonding parts. The plurality of bonding parts secure both a highest fluid layer and a lowest fluid layer of the belt-shaped material to the frame. A case (6) can be separated into a cap (21) and a cup (22) in order to replace a filter (31). The water flocculator is linked to the cup by engaging parts (22a, 51a).

Description

Water aggregator, fuel filter device, and water agglomerator manufacturing method Cross-reference of related applications

This application is based on Japanese Patent Application No. 2016-133710 filed on July 5, 2016 and Japanese Patent Application No. 2016-133711 filed on July 5, 2016, which are described herein. Incorporate content.

The disclosure in this specification relates to a water aggregator that aggregates water contained in fuel, a fuel filter device, and a method for manufacturing the water agglomerator.

Patent Documents 1-5 disclose a fuel filter device. These fuel filter devices include a filter for removing solid foreign matters by filtering the fuel, and a water separator for aggregating and separating water contained in the fuel. At least a part of the ability to separate water from the fuel can be evaluated by the ability to aggregate water to grow into large water droplets, that is, the ability to aggregate water. Large water droplets have the advantage of being easily separated by known separation techniques such as gravity separation, collision separation, and separation by a water repellent layer. In Patent Documents 1-5, an attempt is made to use a water aggregator that agglomerates water by a water agglomeration layer. The contents of the prior art documents listed as the prior art are incorporated by reference as an explanation of the technical elements in this specification.

JP 2010-223028 A US Patent Application Publication No. 2014/0102969 U.S. Pat. No. 8,360,251 US Patent No. 7,874,704 US Patent Application Publication No. 2014/0284268

In order to exhibit high water aggregation performance, a thick aggregation layer may be required. However, thick agglomerated layers have several different challenges.

In one aspect, a thick agglomerated layer is difficult to reliably fix. In the fuel flow, it is necessary to maintain the thickness and the large surface area while suppressing the crushing and decomposition of the thick agglomerated layer.

In another aspect, a thick single agglomerated layer is difficult to manufacture. A thick single agglomerated layer is difficult to process in the manufacturing process and handle in the manufacturing process. For this reason, a thick single agglomerated layer requires special consideration in the manufacturing process.

Further, there are some problems when a fuel filter device includes a filter for removing solid foreign matters and a water aggregator for aggregating water.

In one aspect, it is desirable that the filter be replaceable because it will cause functional degradation or failure. In addition, the water aggregator may also be required to be replaceable because it causes functional degradation or failure. Furthermore, the filter replacement time and the water aggregator replacement time may be different. Therefore, it is desirable that the filter can be separated and replaced from the water aggregator.

In another aspect, users or workers may place importance on environmental impact or economy. In this case, it is required to provide a replacement method with a small environmental load or an economically advantageous replacement method. For example, a structure that makes it easy to understand that only the filter can be replaced is required.

In the above-mentioned viewpoints or other viewpoints not mentioned, further improvements are required for the water aggregator and the fuel filter device.

One disclosed object is to provide a water aggregator having a thick agglomerated layer, a fuel filter device, and a method for producing the water agglomerator.

Another object of the disclosure is to provide a water aggregator having a thick agglomerated layer, a fuel filter device, and a method for producing the water agglomerator that are easy to manufacture.

Still another object of the present invention is to provide a water aggregator, a fuel filter device, and a method for producing a water agglomerator that can fix a thick agglomerated layer with a small number of parts.

Also, one disclosed object is to provide a water aggregator that can be used in a life cycle different from that of a filter.

Another object of the disclosure is to provide a fuel filter device that can facilitate replacement of only the filter.

The water aggregator disclosed herein is a frame that allows the flow of fuel in the radial direction, a cylindrical fiber layer that is attached to the frame and aggregates water in the fuel, and has two or more layers in the radial direction A fiber layer including a roll body of a strip-shaped material disposed so as to overlap two or more rounds, and a plurality of joint portions for fixing the fiber layer to the frame. In the disclosed water aggregator, a fiber layer is provided by a roll body of a band-shaped material. The material is arranged in two or more rounds so as to overlap two or more layers in the radial direction. A thick fiber layer is obtained using a strip-shaped material. In addition, since a strip-shaped material is used, manufacturing advantages can be obtained from the viewpoint of ease of handling and low waste.

A water aggregator disclosed herein is a frame that allows a fuel flow in a radial direction, a cylindrical fiber layer that is attached to the frame and aggregates water in the fuel, and is at least partially in the radial direction. And a plurality of joints for fixing the fiber layer to the frame, the plurality of joints being at least one intervening layer from the frame. And a through-joining portion that joins the material forming the last layer arranged at a distance to the frame through the intervening layer. The disclosed water aggregator includes a cylindrical fiber layer. The fiber layer is fixed to the frame by a plurality of joints. The plurality of joints provide secure fixation. The plurality of joints have through joints. The through-bonding portion joins the material constituting the last layer arranged at least one intervening layer from the frame through the intervening layer to the frame. The through joint secures the last layer to the frame while maintaining a thick fiber layer. Therefore, damage to the fiber layer due to the fuel flow is suppressed.

The fuel filter device disclosed herein includes the water aggregator, a filter that removes solid foreign matters from the fuel, a fuel passage that defines a fuel passage, and a case that accommodates the water agglomerator and the filter.

The water aggregator manufacturing method disclosed herein includes a frame that allows fuel flow in a radial direction and a cylindrical fiber layer that agglomerates water in the fuel. On the inside or outside of the frame, a winding process for forming a roll body of the material by winding a belt-shaped material that agglomerates water in the fuel so as to at least partially overlap two or more layers, and a fiber layer on the frame The winding step has a step of placing the last layer at least one intervening layer from the frame, and the joining step joins the material forming the last layer to the frame through the intervening layer. The process of carrying out. In the disclosed method for producing a water aggregator, a belt-shaped material is wound so as to at least partially overlap two or more layers. As a result, the last layer is arranged at least one intervening layer away from the frame. In the joining process, the material forming the last layer is joined to the frame through the intervening layer. According to this method, the fiber layer can be manufactured by a winding process. Moreover, the fiber layer is securely fixed to the frame by the joining process.

Also, the water aggregator disclosed herein agglomerates water in the fuel. The water aggregator is accommodated together with a filter for removing solid foreign matters from the fuel in a case forming a fuel passage. The water aggregator includes a case coupling portion formed so as to be able to maintain a coupled state with the case even when the filter is removed from the case. According to the disclosed water aggregator, even when the filter is removed from the case, the connection state between the water aggregator and the case is maintained by the case coupling portion. Even if the filter is removed, the water agglomerator remains. As a result, the simultaneous exchange with the filter is suppressed. The water aggregator can be used in a different life cycle than the filter.

The fuel filter device disclosed herein includes a water aggregator, a case, and a filter. Even if a filter is removed from a case, a fuel filter apparatus maintains the connection state of a water aggregator and a case by a case connection part by a case connection part. The fuel filter device can indicate that only the filter can be replaced.

The plurality of modes disclosed in this specification adopt different technical means to achieve each purpose. The reference numerals in parentheses described in the claims and this section exemplify the correspondence with the embodiments described later, and are not intended to limit the technical scope. The objects, features, and advantages disclosed in this specification will become more apparent with reference to the following detailed description and accompanying drawings.

It is a block diagram of the fuel supply device concerning a 1st embodiment. It is sectional drawing of a fuel filter apparatus. It is a longitudinal cross-sectional view of the water aggregator of a fuel filter apparatus. It is a cross-sectional view of the water aggregator of the fuel filter device. It is sectional drawing which shows a 1st fixing | fixed part. It is sectional drawing which shows a 1st fixing | fixed part. It is sectional drawing which shows a 1st fixing | fixed part. It is sectional drawing which shows a 2nd fixing | fixed part. It is sectional drawing which shows a 2nd fixing | fixed part. It is sectional drawing which shows the modification of a 2nd fixing | fixed part. It is sectional drawing of the fuel filter apparatus which concerns on 2nd Embodiment. It is an exploded view of the fuel filter apparatus which concerns on 2nd Embodiment. It is an exploded view of the fuel filter apparatus which concerns on 3rd Embodiment. It is an exploded view of the fuel filter apparatus which concerns on 4th Embodiment. It is a cross-sectional view of the water aggregator according to the fifth embodiment.

A plurality of embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding parts and / or associated parts may be assigned the same reference signs or reference signs that differ by more than a hundred. For the corresponding parts and / or associated parts, the description of other embodiments can be referred to.

First Embodiment <Fuel Supply Device>
FIG. 1 shows a cross section of a fuel filter device 2 in a fuel supply device 1 mounted on a vehicle. In the figure, the fuel flow direction is indicated by a thick arrow. The fuel supply device 1 supplies fuel from a fuel tank (TNK) 3 to an internal combustion engine (ENG) 4 as a fuel consuming device. An example of the internal combustion engine 4 is a diesel engine using light oil as fuel. The type of the internal combustion engine 4 is not limited. For example, an internal combustion engine that uses various hydrocarbon fuels such as gasoline and biodiesel can be applied. The internal combustion engine 4 is used as a power source for the machine. For example, the internal combustion engine 4 provides a power source for driving the vehicle. The internal combustion engine 4 is provided with a high-pressure pump that is also a part of the fuel supply device 1 and a fuel injection valve.

The fuel supply device 1 has a low-pressure pump that pumps up the fuel in the fuel tank 3. The low pressure pump is provided between the fuel filter device 2 and the fuel tank 3 or between the fuel filter device 2 and the internal combustion engine 4. In the illustrated example, the low-pressure pump is accommodated in the fuel tank 3. The fuel pressurized by the low pressure pump is supplied to the fuel filter device 2. The fuel filter device 2 filters the fuel. The fuel filtered by the fuel filter device 2 is supplied to the internal combustion engine 4 via a high-pressure pump and a fuel injection valve.

<Fuel filter device>
The fuel filter device 2 includes a case 6 and a filter unit 7. Case 6 accommodates filter unit 7. The case 6 has a fuel inlet 11 and a fuel outlet 12. The case 6 has a cap 21 and a cup 22. The cap 21 provides a holding bracket for fixing the fuel filter device 2. The holding bracket is used to fix the fuel filter device 2 to the vehicle. The cap 21 and the cup 22 can be separated to replace the filter unit 7. When the cup 22 is removed from the cap 21, the filter unit 7 is exposed and can be replaced. The case 6 is made of metal or resin. The cap 21 is made of metal, for example, aluminum alloy. The cup 22 is made of resin.

FIG. 2 shows a cross section of the fuel filter device 2. The case 6 has an inlet passage 13 extending from the inlet 11. The inlet passage 13 provides a part of the dirty side DS through which unfiltered fuel flows. The case 6 has an outlet passage 14 extending from the outlet 12. The outlet passage 14 provides a portion of the clean side CS through which filtered fuel flows. The case 6 provides a fuel flow path that connects the inlet 11 and the outlet 12. The cap 21 and the cup 22 define a cavity as a fuel passage therein. The cap 21 and the cup 22 define a chamber including the dirty side DS and the clean side CS. An entrance passage 13 communicates with the dirty side DS. An exit passage 14 communicates with the clean side CS.

The case 6 is also a member that provides a container for housing the filter unit 7. Case 6 can be opened to remove the filter unit. The cap 21 and the cup 22 are configured to be detachable. The cap 21 provides a first case portion that is fixedly disposed. The cup 22 provides a detachable second case portion.

A connecting mechanism 23 is provided between the cap 21 and the cup 22 so as to detachably connect them. The coupling mechanism 23 is provided by a screw mechanism including a female screw provided on the cap 21 and a male screw provided on the cup 22. The coupling mechanism 23 can include a seal member that provides a seal between the cap 21 and the cup 22.

A drain hole 24 and a drain plug 25 are provided at the bottom of the cup 22. The drain hole 24 and the drain plug 25 provide a discharge mechanism for discharging moisture and foreign matter accumulated at the bottom of the cup 22.

A water level sensor 26 is provided at the bottom of the cup 22. The water level sensor 26 outputs a detection signal when the water level accumulated in the cup 22 reaches a predetermined level. The water level sensor 26 includes a float 27 and a support column 28. The support column 28 is arranged so as to extend upward from the bottom of the cup 22. The float 27 can float along the support column 28. The float 27 floats corresponding to the water level. For example, a magnet switch is accommodated in the support column 28. A permanent magnet is accommodated in the float 27. Thereby, when the float 27 reaches a predetermined height, the magnet switch outputs a detection signal.

The filter unit 7 is detachably attached to the case 6. The filter unit 7 is replaceable. The filter unit 7 is attached to the open end of the cup 22. The cup 22 with the filter unit 7 attached is inserted into the cap 21, and the cap 21 and the cup 22 are connected by the connecting mechanism 23, so that the filter unit 7 is positioned at a normal position. At the regular position, the filter unit 7 partitions the dirty side DS and the clean side CS.

The filter unit 7 has a basic element that provides a basic function of the fuel filter device 2 and an additional element that provides an additional function. The basic element is a filter 31 that removes solid foreign matters by filtering fuel. The additional element is a water separator that separates moisture in the fuel. The water separator includes an agglomeration stage that captures moisture in the fuel, forms water droplets, and grows water droplets large, and a separation phase that separates the water droplets from the fuel. The agglomeration stage is provided by a water agglomerator 32 having a fiber layer that traps moisture. The separation stage is provided by a settling separation chamber that settles the water droplets. The settling separation chamber is defined in the case 6. The water separator is disposed in the dirty side DS.

The filter 31 has a frame 41. The frame 41 is a member that partitions the dirty side DS and the clean side CS when disposed between the cap 21 and the cup 22. Furthermore, the frame 41 is also a member that defines a filtration passage that allows fuel to flow from the dirty side DS to the clean side CS.

The frame 41 is also a member for supporting the element 42. The element 42 is formed of a filter medium for removing foreign matters from the fuel. The filter medium forming the element 42 is a fiber product that can be called paper. The filter medium removes foreign matters by flowing fuel in the thickness direction. The element 42 is disposed across the filtration passage. The element 42 filters the fuel flowing through the filter passage. The element 42 is formed in a substantially cylindrical shape. The element 42 includes a number of cylinders formed by a filter medium. Many cylinders are bundled in a cylindrical shape. Many cylinders filter fuel by flowing fuel along the axial direction of the cylinder. The element 42 is an axial flow type filter. In the illustrated example, fuel flows from the lower end to the upper end of the element 42.

The frame 41 includes a cover portion 43, a connection portion 44, and a center pipe 45. The cover portion 43 is connected to the element 42 so as to cover the outflow end of the element 42. The radially outer edge of the cover portion 43 is in sealing contact with the case provided by the cap 21 and the cup 22.

The connecting portion 44 is connected to the wall surface of the case 6 in a sealed state. The connection portion 44 is provided with a lip seal as a seal member. The connecting portion 44 is positioned between the opening end of the inlet passage 13 and the opening end of the outlet passage 14 in the case 6. The connection portion 44 is also a member that partitions the dirty side DS and the clean side CS.

The center pipe 45 is a cylindrical member that extends through the center of the element 42 along the axial direction. The center pipe 45 defines an inlet passage extending in the axial direction from the radially inner side of the connection portion 44 in the center pipe 45. The center pipe 45 is a passage member that forms a fuel passage for passing the fuel before being filtered by the element 42. The center pipe 45 has a connecting pipe 46 connected to the water aggregator 32. The connecting pipe 46 is also referred to as a first connecting portion that is detachably connected to the water aggregator 32 so as to supply fuel to the water aggregator 32. The connecting pipe 46 is provided on the outer surface of the projecting portion of the center pipe 45 projecting from the element 42. Further, the center pipe 45 has an opening 47 at its tip. The center pipe 45 is also an opening partition member that partitions an opening 47 as a fuel passage in the case. The opening 47 opens in the center of the case where the cap 21 and the cup 22 are partitioned.

The filter unit 7 is held between a cap 21 and a cup 22. The cover portion 43 is held between the connection portion 44 and the cap 21 and between the outer edge of the cover portion 43 and the cup 22.

The water aggregator 32 is formed as a member having a cylindrical appearance. The water aggregator 32 includes a frame 51 and a fiber layer 61. The frame 51 has a plurality of openings in the radial direction so as to allow the fuel flow in the radial direction. The frame 51 supports the fiber layer 61. The frame 51 can also be called a cage-type holder or bobbin. The frame 51 has an upper end plate 52 and a lower end plate 53. The end plates 52 and 53 are connected by snap fit, adhesion, or welding. The frame 51 is made of resin. This resin is thermoplastic.

The case 6 and the water aggregator 32 have a connection mechanism that connects the case 6 and the water aggregator 32. The coupling mechanism includes an engaging portion 22 a provided on the cup 22 and an engaging portion 51 a provided on the frame 51. The engaging portions 22a and 51a provide a snap-fit mechanism that can be engaged and disengaged using elastic deformation of a resin material. The engaging mechanism connects the case 6 and the water aggregator 32 so that the water agglomerator 32 remains in the cup 22 when the filter unit 7 is taken out from the case 6. The connection strength provided by the connection mechanism provided by the engaging portions 22 a and 51 a is stronger than the connection strength provided by the connection pipe 46.

When the filter 31 is pulled upward from the cup 22, the engaging portions 22 a and 51 a maintain the connection state between the cup 22 and the water aggregator 32, but the connection pipe 46 is connected to the filter 31 and the water aggregator 32. To separate. This configuration encourages reuse of the water aggregator 32 and facilitates replacement of only the filter 31. The water aggregator 32 is less likely to clog than the filter 31. The water aggregator 32 withstands longer-term use than the filter 31. This configuration makes it possible to reduce costs caused by replacement.

The fiber layer is cylindrical. The fiber layer 61 is held on the frame 51. The fiber layer 61 is attached to the frame 51. The fiber layer 61 is also called an agglomerated layer. The fiber layer 61 provides a water aggregation member that aggregates moisture in the fuel. The fiber layer 61 captures and aggregates minute water droplets dispersed in the fuel. The fiber layer 61 captures moisture and grows the size of water droplets. The fiber layer 61 releases the water droplets which have been aggregated and greatly grown into the fuel again, and settles in the cup 22. The fiber layer 61 is formed of fibers having physical properties suitable for capturing water droplets and chemical properties.

The fiber layer 61 provides a larger gap than the filter medium of the filter 31. The filter 31 has a relatively small hole in order to remove the required minimum foreign matter. On the other hand, the fiber layer 61 cannot remove the required minimum foreign matter. The fiber layer 61 has relatively large holes. Further, the fiber layer 61 has a thickness that is far greater than the thickness of the filter 31 in the flow direction of the filter medium. Further, the fiber layer 61 is softer than the filter medium of the filter 31 due to its relatively high porosity and thickness.

For the fiber layer 61, Patent Documents 1 to 5 can be referred to. The contents of Patent Document 1 to Patent Document 5 are incorporated herein by reference. For example, the fiber layer 61 is a hydrophilic fiber such as rayon.

<Water aggregator>
3 and 4 are cross-sectional views showing the water aggregator 32. FIG. 3 shows a cross section taken along line III-III in FIG. FIG. 4 shows a cross section taken along line IV-IV in FIG. The frame 51 has a shape similar to a bobbin for winding a long object. The frame 51 has both end plates 52 and 53. The end plates 52 and 53 are disposed so as to face each other. The frame 51 has a core 54 disposed between the end plates 52 and 53. The core 54 is also a winding core for the fiber layer 61. The core 54 has many gaps to allow fuel flow through the fiber layer 61. The core 54 provides a plurality of passages extending in the radial direction.

The end plate 52 is also called an upper member. The end plate 52 is an annular plate. The end plate 52 has a cylindrical portion 52a. The cylindrical portion 52 a is provided at the center of the end plate 52. The cylindrical portion 52 a is connected to the center pipe 45 by receiving the center pipe 45. The cylindrical portion 52 a defines an inlet for receiving fuel from the center pipe 45. The water aggregator 32 can be separated from the filter unit 7 through the cylindrical portion 52a. Therefore, only the filter 31 or the water aggregator 32 can be replaced. The cylindrical portion 52 a is also a part of the core 54.

The end plate 52 provides an annular flat surface 52b. The flat surface 52b is located on the radially outer side of the cylindrical portion 52a. The flat surface 52 b provides a contact seal that prevents leakage from between the end face of the fiber layer 61 and the end plate 52 by contacting the end face of the fiber layer 61. Between the plane 52b and the fiber layer 61, an adhesive portion such as an adhesive or a recured layer is not provided.

The end plate 53 is also called a lower member. The end plate 52 and the end plate 53 are connected to form the illustrated frame 51. The end plate 53 has a conical portion 53a at the center. The conical portion 53a provides a downwardly inclined surface that extends downward while spreading outward in the radial direction. The downward sloping surface contributes to creating a downward flow. The downward flow promotes water droplet settling.

The end plate 53 has an annular flat surface 53b facing the flat surface 52b. The flat surface 53b is located on the radially outer side of the conical portion 53a. The two planes 52b and 53b are opposed to each other with respect to the vertical direction. The two flat surfaces 52b and 53b face each other in the width direction of the fiber layer 61. The flat surface 53 b provides a contact seal that prevents leakage from between the end face of the fiber layer 61 and the end plate 53 by contacting the end face of the fiber layer 61. Between the plane 53b and the fiber layer 61, an adhesive portion such as an adhesive or a recured layer is not provided.

The flat surfaces 52 b and 53 b are opposed to both end surfaces of the fiber layer 61. In other words, the fiber layer 61 has both end faces that are in contact with the flat surfaces 52b and 53b.

The end plate 53 has a downward wall 53c extending downward at the outer edge. The downward wall 53c promotes the growth of water droplets and promotes the release of the water droplets into the fuel.

Furthermore, the end plate 53 has a plurality of ribs 55. The rib 55 is plate-shaped. The plurality of ribs 55 are arranged radially. The plurality of ribs 55 are arranged away from each other in the circumferential direction. A plurality of passages extending in the radial direction are defined between the plurality of ribs 55. The plurality of ribs 55 are provided by eight ribs including a winding start rib 55a and a winding end rib 55b. The plurality of ribs 55 are also part of the core 54.

The end plate 53 has a plurality of support portions 56. The plurality of support portions 56 are arranged in a distributed manner on the radially outer edges of the plurality of ribs 55. The support portion 56 is a protrusion that protrudes outward in the radial direction. The plurality of support portions 56 are arranged away from each other in the axial direction. The plurality of support portions 56 are arranged away from each other in the circumferential direction. The radially outer surface of the support portion 56 is a curved surface. The radially outer side surface of the support portion 56 is in contact with the inner surface of the fiber layer 61. The plurality of support portions 56 provide contact surfaces that receive and support the fiber layer 61.

A fiber layer 61 is disposed on the outer side in the radial direction of the frame 51. The fiber layer 61 is cylindrical. The fiber layer 61 has a slightly multi-faced cylindrical shape corresponding to the plurality of ribs 55. The fiber layer 61 has an inner peripheral surface, an outer peripheral surface, and both end surfaces. The inner peripheral surface provides a fuel inlet surface. The outer peripheral surface provides a fuel exit surface. Both end surfaces are pressed against the end plates 52 and 53. Both end surfaces provide a sealing surface.

The fiber layer 61 has a plurality of layers along the flow direction. The multiple layers are in direct contact with each other. Each layer is formed by the same fiber. The fiber layer 61 is formed of a strip-shaped material 62. The strip-shaped material 62 can be obtained by cutting a long base material into a predetermined length or by cutting from a square base material. Therefore, waste of material is suppressed as compared with a case where a disk is cut out from the base material. The material 62 is a nonwoven fabric. The material 62 can be called cotton-like. The material 62 has a much lower fiber density than the material of the filter 31. The material 62 has a softness that can be wound around the frame 51.

The fiber layer 61 is disposed on the core 54. The fiber layer 61 is disposed on the radially outer side of the core 54. The material 62 has a shape that can be called a spiral shape or a spiral shape. The fiber layer 61 includes a cylindrical roll body of a strip-shaped material 62. The fiber layer 61 can be provided only by a roll body. The fiber layer 61 is provided by a laminated body of a series of strip-shaped materials 62. The fiber layer 61 may include an additional layer in addition to the roll body of the material 62.

The material 62 is laminated on the core 54. The material 62 is disposed so as to at least partially overlap two or more layers in the radial direction. The material 62 is arranged in two or more rounds so as to overlap two or more layers in the radial direction. The material 62 is arranged in three or more rounds so as to form three layers. The material 62 laminated in two or more layers makes it possible to form a thick fiber layer 61 along the fuel passing direction.

The material 62 is arranged along a virtual peripheral surface provided by the core 54. The material 62 circulates around the core 54 over two or more rounds. The material 62 may circulate the core 54 over three or more rounds. Two adjacent layers stacked in the fiber layer 61 are in direct contact. This configuration makes it possible to form a thick fiber layer 61.

The material 62 has an end portion 63 and an end portion 64. The inner end 63 is a winding start end. The outer end 64 is the end of winding. The end 63 and the end 64 are disposed between two ribs 55a and 55b adjacent in the circumferential direction. The material 62 has a shift portion from the inner layer to the outer layer between the two ribs 55a and 55b. The shift portion is a portion where the material 62 bends in a step shape. A plurality of shift portions are concentrated between the two ribs 55a and 55b. This arrangement enables the outer peripheral surface of the fiber layer 61 to be close to a circle.

The frame 51 and the fiber layer 61 are joined at a plurality of joints 71. The joining portion 71 has a dot shape on the inner surface or the outer surface of the fiber layer 61. In other words, when the fiber layer 61 is viewed from the outside in the radial direction, the joint portion 71 has a dot shape. The joint portion 71 is a re-cured portion obtained by melting the material of the frame 51, infiltrating the fiber layer 61, and curing the material again. In the joint portion 71, the frame 51 and the fiber layer 61 are joined so as not to be separated.

The plurality of joints 71 are arranged in a distributed manner on the cylindrical peripheral surface of the fiber layer 61. The plurality of joints 71 are uniformly dispersed. The plurality of joints 71 are dispersed in the axial direction and the circumferential direction.

3, the plurality of joints 71 include a plurality of joints 71 provided apart from each other in the axial direction. In the drawing, four joints 71 arranged along the axial direction are shown. As illustrated in FIG. 4, the plurality of joints 71 include a plurality of joints 71 provided apart from each other in the circumferential direction. In the drawing, eight joints 71 arranged along the circumferential direction are shown. The plurality of joints 71 are arranged at equal intervals in the axial direction and the circumferential direction. In the illustrated example, the plurality of joints 71 are arranged in a 4 × 8 = 32 polka dot pattern (Polkadots Pattern).

The plurality of joints 71 join the innermost layer (the innermost material 62) and the frame 51 together. The joint portion 71 joins at least one layer and the frame 51. The plurality of joints 71 are disposed at the tips of the plurality of ribs 55.

As illustrated in FIG. 4, the plurality of joint portions 71 include a joint portion 71 a and a joint portion 71 b. The joining portion 71 a joins the material 62 that forms the first layer in the radial direction from the frame 51 to the frame 51. The joint portion 71a is also referred to as an adjacent joint portion. The joining portion 71 a joins the material 62 to the frame 51 in the vicinity of one end portion 63. The joining portion 71 a joins the innermost layer and the frame 51. The joint 71 a fixes the layer located at the most upstream side of the fuel flow to the frame 51. A plurality of joint portions 71a are provided on the first layer.

The joining portion 71b joins the material 62 constituting the last layer disposed at least one intervening layer from the frame 51 to the frame 51 through the intervening layer. The joint portion 71b is also referred to as a through joint portion. The joining portion 71 b joins the material 62 to the frame 51 in the vicinity of the other end portion 64. The joining portion 71 b joins the outermost layer and the frame 51. The joining portion 71 b joins the outermost layer and the frame 51. The joint 71 b fixes the layer located on the most downstream side of the fuel flow to the frame 51. The joining portion 71 b is provided only in the vicinity of the end portion 64 at the end of winding of the material 62.

The joint portion 71b may join a plurality of layers and the frame 51 together. For example, the joining part 71b may join all the layers and the frame 51 in some cases. The joint portion 71 b fixes a plurality of layers to the frame 51. The joint portion 71 b fixes the entire fiber layer 61 to the frame 51 in the thickness direction of the fiber layer 61. In other words, the joint portion 71 b sews the fiber layer 61 to the frame 51. The joint portion 71 b joins three layers of the material 62 to the frame 51.

The joint portion 71a is provided on the rib 55a at the start of winding. The joining part 71a is the first joining position. The joint portion 71b is provided on the winding end rib 55b. The joining part 71b is the last joining position after the winding which forms an overlapping part.

The plurality of joints 71 fix the material 62 to the frame 51 in the circumferential direction, the axial direction, and the radial direction. The extending piece between the end portion 63 and the joint portion 71a maintains the shape illustrated by its own rigidity. The extending piece between the end portion 64 and the joint portion 71b maintains the shape illustrated by its own rigidity. These extended pieces maintain a shape that contacts adjacent layers as shown, even when the fuel flows, that is, under normal use conditions.

The plurality of joints 71 dispersed along the inner or outer peripheral surface of the fiber layer 61 contributes to secure fixing. Moreover, the joining part 71 which is a recuring part provides reliable fixation. The plurality of joints 71a suppresses the crushing of the fiber layer 61 from the upstream side of the fuel flow. The joint portion 71b suppresses the separation of the fiber layer 61 toward the downstream side of the fuel flow. The fiber layer 61 provides a seal only by contacting the flat surfaces 52b and 53b at the end face. For this reason, a stable seal can be obtained without depending on the thickness of the adhesive. As a result, reliable fixing of the fiber layer 61 and sealing performance are realized. This structure enables cost reduction.

As shown in FIG. 2, the engaging portions 22a and 51a provide case connecting portions. The case coupling portion is formed so that the water aggregator 32 can maintain the coupling state with the case 6 even when the filter 31 is removed from the case 6. The replacement operation includes a step of loosening the coupling mechanism 23 and a step of removing the cup 22 from the cap 21. The operation of separating the cap 21 and the cup 22 in the connection mechanism 23 is a rotation operation. The connection state between the water aggregator 32 and the cup 22 by the case connecting portion can be released by an operation different from the rotation operation. The case connecting portion is released by an axial operation of pulling out the water aggregator 32 in the axial direction or an axial operation of pulling out slightly obliquely while elastically deforming the resin material. Therefore, the connection state in the case connection portion is not released by the operation for the connection mechanism 23.

Furthermore, the replacement operation includes a step of pulling out the filter 31 from the cup 22, a step of pulling out the water aggregator 32 from the cup 22, and a step of replacing and reassembling them. When the filter 31 is pulled out in the axial direction, the case coupling portion maintains the engaged state, and maintains the coupled state between the water aggregator 32 and the cup 22. Therefore, even if the filter 31 is removed from the cup 22, the water aggregator 32 remains in the cup 22. Thereby, replacement of only the filter 31 is promoted. In addition, the inside of the cup 22 is dirty side DS, and the upstream and downstream of the fiber layer 61 are also dirty side DS. Therefore, even if a new filter 31 is inserted after the connecting pipe 46 is pulled out, entry of foreign matter into the clean side CS is suppressed.

The connecting pipe 46 and the cylindrical part 52a are connecting parts that mechanically connect the filter 31 and the water aggregator 32. Further, the connecting pipe 46 and the cylindrical portion 52 a are also fluid connecting portions that provide fluid connection of the fuel passages so that fuel flows through the fiber layer 61. The case connection part is formed so as to be able to maintain the connection state with the case 6 even in a state where the connection in the fluid connection part is released.

<Manufacturing method>
The method for manufacturing the fuel filter device 2 includes a step of forming the case 6, a step of disposing the filter unit 7 in the case 6, and a step of closing the case 6. The manufacturing method of the filter unit 7 includes a step of assembling the filter 31, a step of assembling the water aggregator 32, and a step of connecting the filter 31 and the water aggregator 32.

The method for replacing the filter unit 7 includes a step of opening the case 6, a step of taking out the old filter unit 7, a step of arranging a new filter unit 7, and a step of closing the case 6. When only the filter 31 is replaced, the step of disassembling the old filter unit 7 into the filter 31 and the water aggregator 32, and the step of connecting the old water aggregator 32 to the new filter 31 and manufacturing the new filter unit 7 Is added. The decomposition process may include a step of separating the filter 31 and the water aggregator 32 while maintaining the connection state between the water aggregator 32 and the cup 22. The disassembling process can be performed simultaneously in the process of opening the case 6 in the case 6. The step of connecting can be performed in the case 6 while maintaining the connection state of the water aggregator 32 and the cup 22. The connecting step can be executed simultaneously in the step of closing the case 6.

The method for manufacturing the water aggregator 32 includes a forming step of forming the frame 51, a mounting step of mounting the fiber layer 61 on the frame 51, and a fixing step of fixing the fiber layer 61 to the frame 51. The forming step can include a step of forming the frame 51 with a resin material. The mounting process can be provided by a winding process of winding the material 62 along the frame 51. The mounting process may be provided by a process of mounting the frame 51 in the fiber layer 61 around which the material 62 is wound. In this embodiment, the mounting process is provided by a winding process.

The mounting step includes a step of forming a seal between the fiber layer 61 and the frame 51 so that the fuel passes through the fiber layer 61. The seal is formed by pressing the end face of the cylindrical fiber layer 61 against the flat surfaces 52b and 53b. The seal is formed by pressing the longitudinal end surface of the material 62 against the flat surfaces 52b and 53b in the winding process. In the winding process, the material 62 is wound around the frame 51 while pressing the end face in the longitudinal direction against the flat surfaces 52b and 53b.

The winding process is a process of winding the material 62 on the frame 51. The winding process starts with starting winding on the rib 55a. The material 62 is wound from the end 63. The winding process ends when the end 64 is positioned at the specified position shown in the figure.

The winding process is a process of winding the material 62 so as to at least partially overlap two or more layers. The winding process includes a first stage in which the material 62 is wound around the frame 51 only once. Thereby, the first round of the material 62 is formed. The winding process includes a second stage in which the material 62 is additionally wound around the frame 51 only once. Thereby, the second round of the material 62 is formed. The winding process includes a third stage in which the material 62 is additionally wound only once around the frame 51. Thereby, the third circumference of the material 62 is formed. As a result, the fiber layer 61 is formed.

The winding process includes an initial stage of positioning the material 62 at the tip of the rib 55a. In the initial stage, the end portion 63 is positioned between the first rib 55a and the last rib 55b. In the initial stage, the material 62 is further positioned on the tip of the rib 55a. In the initial stage, the material 62 is disposed beyond the rib 55a. In the initial stage, the material 62 may be disposed up to the second rib 55. After the initial stage, the above-described first stage, second stage, and third stage are executed.

The winding step has a step of arranging the last layer with at least one intervening layer separated from the frame 51. This process is provided by the third stage. The intervening layer is provided by the first layer and the second layer.

In the fixing step, the fiber layer 61 is fixed to the frame 51 by forming a plurality of joints 71. The fixing process is executed intermittently in the winding process. The fixing process includes a plurality of stages for forming each of the plurality of joints 71. The fixing process may include an initial stage for forming the first joint 71a after the material 62 is positioned on the rib 55a. The fixing process may include an intermediate stage for forming the joint portion 71a after the material 62 is positioned on the second and subsequent ribs 55.

The intermediate stage may be executed so that the plurality of joints 71a are formed in order after the material 62 is positioned on the plurality of ribs 55. The intermediate stage may be executed such that after the material 62 is positioned on one rib 55, a single stage for forming one joint 71 is repeated on the plurality of ribs 55. Further, the intermediate stage may be executed by being divided into a plurality of partial stages. In one partial stage, after the material 62 is disposed on a group of a plurality of ribs 55, for example, three ribs 55, a plurality of joint portions 71 a are formed on the plurality of ribs 55. In the remaining partial stage, after the material 62 is disposed on the remaining group of ribs 55, for example, three ribs 55, a plurality of joint portions 71 a are formed on the ribs 55.

FIG. 5 shows the first rib 55a. A support portion 56 is formed at the tip of the rib 55a. Prior to melting, the support 56 is slightly larger. The rib 55 a is given a volume capable of supplying a molten resin that fixes a single layer of the material 62.

FIG. 6 shows a state in which the material 62 is positioned at the tip of the rib 55a. In the winding process, the material 62 is positioned on the rib 55a.

The fixing step includes a step of melting a part of the rib 55a. The fixing process includes a process of pressing the material 62. A part of the rib 55a is melted by pressing the hot member 57. The material 62 is pressed and compressed by the member 57. A part of the rib 55a can be melted by high energy supplied from the outside, for example, by laser irradiation, ultrasonic irradiation, electromagnetic wave irradiation, hot air supply, or the like. A portion of the rib 55a is deformed from the shape illustrated in FIG. 6 during the melting phase. This stage is a supply stage in which a fluid material is supplied between the frame 51 and the material 62. The material is given fluidity so as to penetrate into the material 62.

The fixing step includes a step of positioning the fibers of the material 62 in the molten resin material. At this stage, the molten resin material spreads while penetrating into the fiber layer. Some fibers enter the molten resin material. This stage is a stage in which a fluid material and the raw material 62 are mixed.

The fixing step includes a step of recuring the once melted resin material. This step is a step of reducing the fluidity of the fluid material. The fluidity of the material decreases to a low level that fixes the material 62 to the frame 51.

FIG. 7 shows an example of the joint 71. The joint 71 is a lump of resin that has been recured. The joint portion 71 incorporates the fibers of the material 62 into the resin lump. The shape of the joint portion 71 is different from the rib 55a. The shape of the rib 55 a is changed to an indeterminate lump of the joint portion 71. The surface of the joint portion 71 is given an irregular surface with flow. The shape of the joint portion 71 can also be referred to as a rod shape or a column shape that extends radially outward from the tip of the support portion 56. Furthermore, the material 62 may be deformed so as to be slightly dented by contraction when the joint portion 71 is re-cured or by a pressing force applied from the outside in order to melt the rib 55a. For example, the thickness of the material 62 may slightly decrease around the joint 71.

As described above, the innermost layer of the material 62 is disposed on the frame 51 by the first stage of the winding process. A plurality of joints 71a are formed by the fixing step. This fixing step provides an adjacent joining step in which only the first layer in the radial direction is joined to the frame 51. As a result, the innermost layer of the material 62, that is, the uppermost stream layer is firmly fixed to the frame 51. Further, the winding process proceeds with a first stage, a second stage, and a third stage. Each time the winding process progresses, the material 62 is stacked on the last rib 55b.

FIG. 8 shows the last rib 55b. A support portion 56 is formed at the tip of the rib 55b. The rib 55b is given a volume capable of supplying a molten resin for fixing three layers of the material 62. The frame 51 corresponds to the number of layers of the material 62 fastened thereto or the thickness of the fiber layer fastened thereto. When the third layer blank 62 is positioned on the winding end rib 55b, the last partial stage of the fixing process is performed. In the last partial stage, the last rib 55b is melted and re-cured.

FIG. 9 shows an example of the joint 71b on the winding end rib 55b. By the fixing step, the rib 55b is melted so as to be joined to at least the outermost layer of the material 62 constituting a plurality of layers. The rib 55b is melted so as to be bonded to the plurality of layers. The rib 55b is melted so as to be bonded to all the layers. The joining portion 71b fixes the fiber layer 61 composed of a plurality of layers. It can be said that the joint portion 71b sews the fiber layer 61. The three-layer material 62 is greatly compressed by the member 57 to form a recess 66. This step provides a through-joining step in which the last layer in the radial direction is joined to the frame 51 through the intervening layer.

A plurality of support portions 56 are provided on one rib 55 along the axial direction. For example, a plurality of support portions 56 are provided along the axial direction on the first rib 55a. For example, a plurality of support portions 56b are provided along the axial direction on the last rib 55b. Therefore, a plurality of joints 71a are formed on the rib 55a along the axial direction. A plurality of final joints 71b are formed on the rib 55b. The plurality of final joining portions 71 b fix the end portion 64 at the end of winding of the material 62 to the frame 51. Since the end portion 64 is located on the most downstream side, the joint portion 71 b fixes the entire fiber layer 61 in the thickness direction on the frame 51.

FIG. 10 shows a modified example of the joint 71b. When the joint portion 71b is formed from the rib 55b, a thick three-layer material 62 is laminated around the rib 55b. The joining portion 71b may not completely penetrate the three layers of the material 62.

<Operation>
Returning to FIG. 2, the fuel flow is illustrated by arrows in the figure. The fuel supplied from the inlet 11 passes through the water aggregator 32, passes through the filter 31, and exits from the outlet 12. The water droplets that have flowed out of the water aggregator 32 settle by their own weight and sink into the cup 22. On the other hand, the fuel flows upward in the cup 22 and flows into the filter 31. The fuel that has passed through the filter 31 reaches the outlet 12.

Water droplets that have sunk in the cup 22 accumulate at the bottom of the cup 22. In the figure, a water droplet WD and a water surface WL which is a boundary between water and fuel are schematically shown. When the float 27 rises due to the rise of the water surface WL, the water level sensor 26 outputs a detection signal. The detection signal gives an alarm to the user. When the user loosens the drain plug 25, water is discharged.

The filter 31 is given the performance of removing solid foreign substances having a size intended for the fuel filter device 2. The filter 31 is designed to remove fine solid foreign matters so that a high-pressure pump or the like can maintain its performance over a long period of time. On the other hand, the fiber layer 61 provided in the water aggregator 32 cannot remove the intended solid foreign matter. This is because the fiber layer 61 has a larger hole than the filter 31. The fiber layer 61 is designed to capture and aggregate moisture.

Fuel flows from the inner surface of the fiber layer 61 toward the outer surface. The joining portion 71a positions the inner peripheral surface of the fiber layer 61 at a predetermined position against the pressure of the fuel. The joining portion 71b positions the outer peripheral surface of the fiber layer 61, for example, the end portion 64 at a predetermined position against the pressure of the fuel. Therefore, even if the fuel passes through the fiber layer 61, the crushing and decomposition of the fiber layer 61 are suppressed.

The moisture contained in the fuel is trapped in the fiber layer 61 in the fiber layer 61, aggregates, and grows into large water droplets. Water droplets are released again into the fuel from the outer surface of the fiber layer 61.

<Effect>
According to the embodiments described above, a plurality of advantages are provided by a plurality of characteristic configurations that can be used independently of each other. The fiber layer 61 provides the water aggregator 32 having a thick agglomerated layer and the fuel filter device 2. The fiber layer 61 is provided by a cylindrical roll body of a strip-shaped material 62 that has circulated in two or more rounds. For this reason, the thick fiber layer 61 is formed of the strip-shaped material 62 that is easy to handle. As a result, the water aggregator 32 having a thick agglomerated layer that is easy to manufacture, the filter unit 7 including the water agglomerator 32, and the fuel filter device 2 are provided.

The fiber layer 61 is fixed to the frame 51 by a plurality of joints 71. The plurality of joints 71 provide secure fixing. In addition, the plurality of joints 71 are arranged in a distributed manner. The plurality of joints 71 are integrated with the fibers of the fiber layer 61. For this reason, reliable fixation is possible.

The plurality of bonding portions 71 include a bonding portion 71 a that fixes the fiber layer 61 to the frame 51 on the inner peripheral surface of the fiber layer 61, and a bonding portion 71 b that fixes the fiber layer 61 to the frame 51 on the outer peripheral surface of the fiber layer 61. Have. The joint portion 71b provides a through joint portion. The through joint portion joins the material forming the last layer to the frame 51 through the intervening layer. The penetration joint fixes the position of the last layer while maintaining the thick fiber layer 61. Therefore, damage to the fiber layer 61 due to the flow of fuel is suppressed.

The fiber layer 61 is fixed to the frame 51 on both the inner peripheral surface and the outer peripheral surface. The joint portion 71 a suppresses crushing from the inner peripheral surface of the fiber layer 61. The joint portion 71 b suppresses separation from the outer peripheral surface of the fiber layer 61. In other words, the joint portion 71a suppresses crushing of the fiber layer 61 from the upstream side of the fuel flow. The joint portion 71b suppresses the separation of the fiber layer 61 toward the downstream side of the fuel flow. Thereby, the water aggregator 32 which can fix a thick agglomerated layer with a small number of parts, the filter unit 7 including the water agglomerator 32, and the fuel filter device 2 are provided.

According to the manufacturing method of the water aggregator 32, the belt-shaped material is wound so as to at least partially overlap two or more layers. The last layer is arranged at a distance from the frame 51 with at least one intervening layer. In the joining step, the material forming the last layer is joined to the frame 51 through the intervening layer. According to this method, the fiber layer 61 can be manufactured by a winding process. Moreover, the fiber layer 61 is reliably fixed to the frame by the joining process. In the joining step, the fiber layer 61 is fixed to the frame 51 while maintaining the position of the last layer. Therefore, the thick fiber layer 61 is maintained.

Second Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, the water aggregator 32 is disposed on the dirty side DS. Alternatively, the water aggregator may be disposed on the clean side CS.

11 and 12, the fuel filter device 2 has a filter 231 for removing solid foreign matters. The filter 231 partitions the case 6 into a dirty side DS and a clean side CS. The filter 231 has a pleated cylindrical filter medium. The filter 231 has a seal member such as an O-ring for preventing direct communication between the dirty side DS and the clean side CS.

The water aggregator 232 is disposed on the clean side CS. In other words, the water aggregator 232 is disposed downstream of the filter 231. The water aggregator 232 is disposed inside the filter 231 in the radial direction. The water aggregator 232 includes a frame 51 and a fiber layer 61 fixed to the frame 51. The fiber layer 61 is fixed to the frame 51 by a plurality of joints 71. The fiber layer 61 provides a water aggregation layer. The water aggregator 232 is connected to the cup 22 by the engaging portions 22a and 51a. Also in this embodiment, the engaging portions 22 a and 51 a promote the reuse of the water aggregator 232.

In this embodiment, the fuel flows in the radial direction from the outer peripheral surface of the cylindrical fiber layer 61 toward the inner peripheral surface. Since the fiber layer 61 is supported by the inner frame 51, the pressure accompanying the flow of fuel acts to compress the fiber layer 61. On the other hand, the plurality of joints 71 extending from the frame 51 in the thickness direction of the fiber layer 61 act so as to maintain the thickness of the fiber layer 61. Therefore, also in this embodiment, the thick fiber layer 61 is maintained.

The fuel filter device 2 has a water separation layer 233. The water separation layer 233 is disposed on the downstream side of the water aggregator 232. The water separation layer 233 is disposed between the water aggregator 232 and the outlet 12. Between the water aggregator 232 and the water separation layer 233, a cylindrical cavity for settling water droplets is defined. The water separation layer 233 suppresses the passage of water droplets and promotes the sedimentation of water droplets. The water separation layer 233 is provided by a screen having a property that can be called water repellency or hydrophobicity.

The water separation layer 233 is connected to the water aggregator 232 by a connection mechanism 234. The coupling mechanism 234 is provided by a snap fit mechanism. The connection mechanism 234 makes it possible to take out only the filter 231 while maintaining the state where the water separation layer 233 is connected to the water aggregator 232. Therefore, the connection mechanism 234 promotes reuse of the water separation layer 233.

Third Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. In the above embodiment, the water separation layer 233 is connected to the water aggregator 232. Instead of this, the water separation layer may be connected to the filter 231.

As shown in FIG. 13, the water separation layer 333 is connected to the filter 231 by a connecting mechanism 334. According to this configuration, the reuse of the water aggregator 232 is promoted. On the other hand, replacement of the filter 231 and the water separation layer 333 is prompted.

Fourth Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, the water separation layer 233 is connected to the filter 231 or the water aggregator 232. Alternatively, the water separation layer may be independent.

As shown in FIG. 14, the water separation layer 433 does not have a connection mechanism. In this configuration, the water separation layer 433 is left on the water aggregator 232 by its own weight. However, the user can easily remove the water separation layer 433 from the water aggregator 232. Therefore, the replacement or reuse of the water separation layer 433 can be left to the user.

Fifth Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, the material 62 is wound around the outside of the frame 51. Instead, the material 62 may be wound inside the frame 51.

As shown in FIG. 15, the water aggregator 532 has a frame 51. The water aggregator 532 can be used as the water aggregators 32 and 232 of the preceding embodiment. The frame 51 has a plurality of ribs 55 projecting radially inward. The frame 51 is disposed on the radially outer side of the fiber layer 61. The plurality of support portions 56 are adjacent to the outer peripheral surface of the fiber layer 61.

The strip-shaped material 62 is wound from the inside into a virtual cylindrical cavity formed by a plurality of ribs 55. In the manufacturing method, the strip-shaped material 62 is sequentially arranged from the end 63 into the internal cavity of the frame 51. The end portion 64 is positioned at a position where the end portion 63 is further wound over the position of the end portion 63. The strip-shaped material 62 is stacked from the radially outer side to the radially inner side. Also in this embodiment, the strip-shaped material 62 is sewn in the manufacturing method. Also in this embodiment, the thick fiber layer 61 is formed by the belt-shaped material 62 wound up.

The fiber layer 61 is fixed to the frame 51 by a plurality of joints 71. The fiber layer 61 is fixed on the first rib 55 and the support portion 56 by a joint portion 71a. The joining portion 71 a fixes one layer corresponding to one piece of the material 62. In other words, the joint portion 71a fixes the outermost layer. In yet another aspect, the joint 71a fixes the most upstream layer in the fuel flow. The water aggregator 532 has a plurality of joints 71a for fixing the first layer. The plurality of joint portions 71a are arranged in a distributed manner in the circumferential direction.

The fiber layer 61 is fixed on the last rib 55 by a joint portion 71b. The joint portion 71 b fixes a plurality of layers corresponding to a plurality of materials 62. In other words, the joint 71b fixes the innermost layer. In yet another aspect, the joint 71b secures the most downstream layer of fuel flow. The water aggregator 532 has a plurality of joints 71b for fixing the last layer. The plurality of joints 71b are arranged in a distributed manner in the circumferential direction.

The fiber layer 61 is fixed on some ribs 55 by a joint 71c. The joint portion 71c fixes a plurality of layers. The number of layers fixed by the bonding part 71c is between the number of layers fixed by the bonding part 71a and the number of layers fixed by the bonding part 71b. In the illustrated example, the joint portion 71b fixes two layers. In other words, the joint 71c fixes the middle layer of the fuel flow. The water aggregator 532 has a plurality of joints 71c. The plurality of joint portions 71c are arranged in a distributed manner in the circumferential direction. The plurality of joints 71c are also called intermediate joints. The plurality of joint portions 71c reinforce the thick fiber layer 61 inside thereof.

The plurality of joining portions 71 a securely fix the fiber layer 61 to the frame 51 on the radially outer side of the fiber layer 61. The plurality of joining portions 71a suppresses the crushing of the fiber layer 61 from the radially outer side to the inner side. The plurality of joining portions 71 b securely fix the fiber layer 61 to the frame 51 on the radially inner side of the fiber layer 61. The plurality of joints 71b suppress the decomposition of the inner peripheral surface of the fiber layer 61, in other words, the radially inner side of the most downstream layer.

Also in this embodiment, the thick fiber layer 61 can be formed of a strip-shaped material 62 that is easy to handle. Also in this embodiment, the thick fiber layer 61 is reliably fixed to the frame 51 by the plurality of joint portions 71. Further, the plurality of joints 71a suppresses the crushing of the fiber layer 61 from the upstream side of the fuel flow. The plurality of joints 71b suppress the separation of the fiber layer 61 toward the downstream side of the fuel flow.

Other Embodiments The disclosure herein is not limited to the illustrated embodiments. The disclosure encompasses the illustrated embodiments and variations by those skilled in the art based thereon. For example, the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure may have additional parts that can be added to the embodiments. The disclosure includes those in which parts and / or elements of the embodiments are omitted. The disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scope disclosed is shown by the description of the scope of claims, and should be understood to include all modifications within the meaning and scope equivalent to the description of the scope of claims.

In the above embodiment, a positive pressure system in which the fuel filter device 2 is installed downstream of the low pressure pump is exemplified. Instead of this, a negative pressure system in which the fuel filter device 2 is installed upstream of the low pressure pump may be applied. In the above embodiment, the filter 31 includes the honeycomb element 42. Instead, various types of filter media such as chrysanthemum type and spiral type can be used.

In the above embodiment, the case 6 can be divided into the cap 21 and the cup 22 in two. Instead of this, the case 6 may be configured to be divided into three. Further, only the member corresponding to the lid may be configured to be separable. In any configuration, the filter unit 7 is accommodated in the case 6 in a replaceable manner.

In the above embodiment, the water aggregator has the star-shaped frame 51 with the radial ribs 55. Instead, the water aggregator can use various shapes of frames such as a cage type and a coil type. Further, the frame 51 can have various surface shapes such as concentric step surfaces and a plurality of protrusions in place of the flat surfaces 52b and 53b in order to ensure contact with both end surfaces of the fiber layer 61. . Moreover, in the said embodiment, the outer peripheral surface of the fiber layer 61 is exposed to the radial direction outer surface of a water aggregator. Instead, a net-like or columnar protective member may be provided outside the outer peripheral surface of the fiber layer 61. In the above embodiment, the rib 55 is melted through the one-layer material 62 or the three-layer material. Instead, needles for piercing the material 62 may be provided on the ribs 55a and 55b. The material 62 can be fixed by the needle.

In the above embodiment, the fiber layer 61 is formed by winding the belt-shaped material 62 several times. Instead of this, the number of windings of the strip-shaped material 62 can be set to one round or more so that the fiber layer 61 having a necessary thickness can be obtained.

In the above embodiment, the joining portion 71 is formed by melting the resin material forming the frame 51. Instead, when the fibers forming the fiber layer 61 can be melted, the joint portion 71 may be formed by melting the fiber layer 61. Moreover, you may form the junction part 71 by supplying the adhesive agent of a fluid state between the flame | frame 51 and the fiber layer 61, and making it harden | cure. Even in this case, the plurality of joints 71 can provide reliable fixing capable of withstanding the fuel flow and the pressure difference.

In the above embodiment, the joint portion 71a is provided between the first layer of the strip-shaped material 62 and the plurality of ribs 55, and the joint portion 71b is provided between the third layer of the strip-shaped material 62 and the rib 55b. . Instead of this, only the first joint 71a and the last joint 71b may be provided. Further, only a part of the plurality of joint portions 71a may be provided. Moreover, it is good also considering a part of several junction part 71a as the junction part over the several layers similar to the junction part 71b.

In the above embodiment, the seal is provided by bringing both end faces of the fiber layer 61 into contact with the flat surfaces 52b and 53b. Instead, the frame 51 and the fiber layer 61 may be bonded to provide a seal. For example, an adhesive may be disposed between the frame 51 and the fiber layer 61. For example, a welded part obtained by melting and re-curing the resin material forming the frame 51 may be provided between the frame 51 and the fiber layer 61.

In the above embodiment, the connecting portions provided by the engaging portions 22a and 51a are snap fits. Alternatively, a connection using screws may be provided. Further, the water aggregator 32 and the cup 22 may be permanently connected. For example, the frame 51 of the water aggregator 32 and the cup 22 may be welded or bonded together. In the said embodiment, the connection part which the connection pipe 46 and the cylindrical part 52a provide is the fluid connection which has the sealing performance provided by the insertion relation of a pipe | tube and a pipe | tube. Instead of this, a seal member such as an O-ring or a lip seal may be provided. Moreover, the connection by a screw may be used together. Further, it may be provided by pressing the end faces in the axial direction or press-fitting two members.

Claims (20)

1. A frame (51) which allows fuel flow in the radial direction;
   A roll of a strip-shaped material (62) that is attached to the frame and is a cylindrical fiber layer that agglomerates water in the fuel, and is arranged in two or more rounds so as to overlap two or more layers in the radial direction. A water aggregator comprising a fiber layer (61) including a body, and a plurality of joints (71) for fixing the fiber layer to the frame.
2. A frame (51) which allows fuel flow in the radial direction;
   A roll of a strip-shaped material (62) that is attached to the frame and is a cylindrical fiber layer that aggregates water in the fuel, and is disposed so as to at least partially overlap two or more layers in the radial direction. A fiber layer (61) including a body, and a plurality of joints (71) for fixing the fiber layer to the frame,
   The water aggregator having a plurality of the joint portions having a through joint portion (71b) that joins the material forming the last layer disposed at least one intervening layer from the frame to the frame through the intervening layer. .
3. The water aggregator according to claim 2, wherein the material is arranged in two or more rounds so as to overlap two or more layers in the radial direction.
4. The plurality of joints further includes
   The water aggregator according to claim 2 or 3, further comprising an adjacent joint portion (71a) for joining the material forming the first layer in the radial direction from the frame to the frame.
5. The material has one end (63) in the longitudinal direction and the other end (64),
   The adjacent joint portion (71a) joins the material to the frame in the vicinity of the one end portion (63),
   5. The water aggregator according to claim 4, wherein the penetration joint portion (71 b) joins the material to the frame in the vicinity of the other end portion (64).
6. The frame has a plurality of support portions (56) that are arranged on the radially inner side or the radially outer side of the fiber layer and are adjacent to the inner peripheral surface or the outer peripheral surface of the fiber layer,
   The water aggregator according to any one of claims 1 to 5, wherein each of the plurality of joint portions is provided on each of the plurality of support portions.
7. The water aggregator according to any one of claims 1 to 6, wherein the plurality of joint portions are arranged apart from each other in a circumferential direction and an axial direction.
8. The frame has flat surfaces (52b, 53b) facing both end surfaces of the fiber layer,
   The water aggregator according to any one of claims 1 to 7, wherein the fiber layer has both end faces only in contact with the flat surface.
9. The water aggregator (32, 232, 532) according to any one of claims 1 to 8,
   Filters (31, 231) for removing solid foreign substances from the fuel;
   A fuel filter device comprising a case (6) for defining a fuel passage and containing the water aggregator and the filter.
10. The fuel filter device according to claim 9, further comprising a water separation layer (233, 333, 433) disposed downstream of the water aggregator and preventing water droplets from passing therethrough.
11. In a method of manufacturing a water aggregator having a frame (51) that allows a fuel flow in a radial direction and a cylindrical fiber layer that agglomerates water in the fuel,
    A winding step of forming a roll body of the material by winding a belt-shaped material (62) for aggregating water in the fuel so as to at least partially overlap two or more layers inside or outside the frame; and A bonding step of bonding the fiber layer to the frame;
    The winding step includes a step of disposing a final layer across at least one intervening layer from the frame,
    The method for manufacturing a water agglomerator, wherein the joining step includes a step of joining the material forming the last layer to the frame through the intervening layer.
12. The joining step includes
    The water aggregator according to claim 11, further comprising: an adjacent joining step for joining only the first layer in the radial direction to the frame; and a through joining step for joining the last layer in the radial direction to the frame through the intervening layer. Manufacturing method.
13. Further, the frame includes a step of forming flat surfaces (52b, 53b) facing both end surfaces of the fiber layer,
    The method of manufacturing a water aggregator according to claim 11 or 12, wherein, in the winding step, the material is wound while a longitudinal end surface extending along a longitudinal direction is brought into contact with the flat surface.
14. In a water aggregator (32) that is housed in a case (6) that forms a fuel passage, together with a filter (31) that removes solid foreign matter from the fuel, and agglomerates water in the fuel.
    A water aggregator provided with a case connection part (51a) formed so that a connection state with the case can be maintained even when the filter is removed from the case.
15. A frame (51) that allows the flow of fuel, and a fiber layer (61) that is attached to the frame and agglomerates water in the fuel;
    The water aggregator according to claim 14, wherein the case coupling portion is provided on the frame.
16. Furthermore, a fluid connection part (52a) that provides connection of a fuel passage so as to allow fuel to flow to the water aggregator, and the case connection part, even when the connection in the fluid connection part is released, The water aggregator according to claim 14 or 15, wherein the water aggregator is formed so as to be able to maintain a connected state with the case.
17. The case has a cap and a cup that are detachably connected by a connection mechanism (23),
    The water aggregator according to any one of claims 14 to 16, wherein the case connecting portion is connectable to the cup.
18. The water aggregator according to claim 17, wherein the case coupling portion can release the coupling state with the cup by an operation different from an operation of separating the cap and the cup in the coupling mechanism.
19. A fuel filter device comprising the water aggregator according to any one of claims 14 to 18, the case, and the filter.
20. The fuel filter device according to claim 19, further comprising water separation layers (233, 333, 433) disposed downstream of the water aggregator and suppressing passage of water droplets.

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