JP3662092B2 - Filter element and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a filter element used for a combustion air cleaner or the like applied to an internal combustion engine and a method for manufacturing the same.
[0002]
[Prior art]
As a filter element for a combustion air cleaner applied to an internal combustion engine, a filter element including a filter medium and a holding frame for holding the filter medium is known. A packing for sealing the dusty air side and the clean air side is attached to the filter element around the holding frame. This filter element is usually configured by forming a filter material holding frame by injection molding and fitting a pre-manufactured packing to the holding frame.
[0003]
[Problems to be solved by the invention]
In the manufacture of the filter element described above, since the packing is manufactured in a separate process and then attached to the holding frame, there is a problem that man-hours are large and manufacturing efficiency is deteriorated. Furthermore, since the filter element and the packing are handled as separate parts, there is a problem that the cost is increased.
[0004]
An object of the present invention is to provide a filter element that is easy to manufacture and has a small number of parts, and a method for manufacturing a filter element with high manufacturing efficiency.
[0005]
[Means for Solving the Problems]
Hereinafter, the present invention will be described with reference to the drawings illustrating embodiments of the present invention. However, the present invention is not limited to the illustrated form.
[0006]
The invention of claim 1 is a filter element 1 including a filter medium 2 and a holding frame 3 for holding the filter medium 2, and a packing 4 provided on an outer peripheral surface of the holding frame 3, wherein the holding frame 3 and the packing 4 is integrally formed by one-step injection molding of a thermoplastic elastomer, and a seal lip 6 is formed at the tip of the packing 4 by the elastomer in the injection step. The holding frame obtained by injection molding The above-described object is achieved by the filter element 1 that maintains the shape of the filter medium and uses the elastic force to hold the edge of the filter medium. According to this invention, since the packing 4 is integrally provided around the holding frame 3 by injection molding, the fitting operation of the packing 4 and the number of parts can be reduced, and the filter element 1 can be easily manufactured.
[0007]
According to a second aspect of the present invention, in the filter element according to the first aspect, the filter medium 2 is formed by being folded in a bellows shape so that the fold line extends only in one direction .
[0009]
The invention of claim 3 is a method of manufacturing the filter element 1 including the filter medium 2, the holding frame 3 that holds the filter medium 2, and the packing 4 provided around the holding frame 3, and the holding frame 3. And the packing 4 are integrally molded by one-step injection molding of the thermoplastic elastomer, and by this injection molding, the seal lip 6 is attached to the tip of the packing 4 in the same thermoplasticity as the holding frame 3 and the packing 4. By forming with an elastomer , the above-described object is achieved. According to the present invention, by simultaneously molding the holding frame 3, the packing 4 and the seal lip 6 with one another, the number of steps and the number of parts can be reduced, and the filter element can be manufactured efficiently.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Next, an embodiment of the present invention will be described with reference to the drawings.
[0011]
1 is a perspective view of the filter element 1 of the present invention, FIG. 2 is a sectional view of the filter element 1, and FIG. 3 is a top view of the filter element.
[0012]
As shown in FIG. 1, the filter element 1 includes a filter medium 2, a holding frame 3 that holds the filter medium 2, and a packing 4 that is provided around the holding frame 3.
[0013]
As the filter medium 2, filter paper, woven fabric, nonwoven fabric, or the like that is usually used is used, and is held by the holding frame 2.
[0014]
The holding frame 3 is formed by injection molding so that the filter medium 2 can maintain a constant shape in a combustion air cleaner (not shown). The holding frame 3 is formed integrally with the filter medium 2 by injecting a thermoplastic elastomer described later into a molding die in which the filter medium 2 is disposed. The shape of the holding frame 3 is formed into, for example, a flat plate shape, a polyhedron shape, a cylindrical shape, or a donut shape depending on the shape and material of the filter medium 2. For example, in the case of a flat filter medium 2 as shown in FIGS. 1 to 3, the holding frame 3 is injection-molded around the filter medium 2. Moreover, the rib 5 may be provided by injection molding for reinforcement of the holding frame 3.
[0015]
The packing 4 is provided around the holding frame 3 in order to seal the dusty air side and the clean air side. For the packing 4, it is preferable to use a thermoplastic elastomer having elasticity similar to that of the vulcanized rubber. Thermoplastic elastomers include styrene thermoplastic elastomers, olefin thermoplastic elastomers, urethane thermoplastic elastomers, polyester thermoplastic elastomers, polyamide thermoplastic elastomers, 1,2-polybutadiene thermoplastic elastomers, and vinyl chloride thermoplastics. An elastomer or a fluorinated thermoplastic elastomer can be used. Since these thermoplastic elastomers can be used in an injection molding machine and do not need to be vulcanized unlike rubber, they are suitable as a material for forming the packing 4 by injection molding.
[0016]
The packing 4 is formed integrally with the holding frame 3 by injection molding. At this time, the packing 4 may be injection-molded after the holding frame 3 is injection-molded in advance, or the holding frame 3 and the packing 4 may be simultaneously injection-molded. When the packing 4 is injection-molded after the holding frame 3 is injection-molded, the holding frame 3 and the packing 4 can be integrally formed of different materials. For example, when the holding frame 3 is required to have strength, the holding frame 3 can be formed of a resin having strength, and the packing 4 can be formed of a thermoplastic elastomer having elasticity. When the holding frame 3 and the packing 4 are simultaneously injection-molded, they can be integrally formed of the same material, for example, a thermoplastic elastomer. Therefore, only one injection mold may be used when the holding frame 3 and the packing 4 are molded simultaneously. In addition, since the formation position of the packing 4 provided in the holding frame 3 can take various modes depending on the shape of the filter element 1 and the like, the form shown in the figure, that is, the form provided in the center of the outer periphery of the holding frame 3 It is not limited to. For example, even if it is the bottom part or upper part of the holding frame 3, it should just be provided in the circumference | surroundings of the holding frame 3 and the position which can seal a dusty air side and clean air side.
[0017]
In addition, since the thermoplastic elastomer has good injection moldability, the elongated ribs 5 provided to reinforce the holding frame 3 can be easily formed with good fillability.
[0018]
FIG. 4 is an enlarged sectional view of the packing 4 of the filter element 1 of the present invention. A seal lip 6 is provided at the tip of the packing 4 to enhance the sealing performance. The seal lip 6 can be easily formed by using a thermoplastic elastomer having good injection moldability.
[0019]
【Example】
In the filter element 1 having the shape shown in FIG. 1, a filter paper formed in a wave shape having a length of 170 mm, a width of 130 mm, and a height of 40 mm is used as a filter medium 2, and a holding frame 4 for holding the filter medium 2, The packing 4 projecting substantially in the center of was integrally formed by injection molding. As shown in FIG. 1, the holding frame 3 was formed on the side surface of the filter medium 2 over the entire circumference. The holding frame 3 was reinforced by passing one rib 5 at the center between the upper surface and the lower surface serving as the filtration surface of the filter element 1. The holding frame 3 (including the rib 5) and the packing 4 were simultaneously formed of the same material by one injection molding. The packing 4 was provided with a seal lip 6 to improve the sealing performance. The material used was a thermoplastic elastomer S1422 modified (olefin type) manufactured by Mitsubishi Chemical MKV Corporation. As the injection molding conditions, it is preferable to mold by increasing the injection speed by 10 to 20% from the conventional one.
[0020]
The obtained filter element 1 having a length of 200 mm, a width of 150 mm, and a height of 40 mm was satisfactorily filled with details such as the rib 5 and the seal lip 6 with the thermoplastic elastomer, and was excellent in sealing performance.
[0021]
As described above, according to the filter element of claim 1 and claim 2, by providing the packing for sealing the dusty air side and the clean air side integrally around the holding frame by injection molding, The packing operation and the number of parts can be reduced, and the filter element can be manufactured easily and at low cost. In particular, by forming the holding frame, the packing, and the seal lip with a thermoplastic elastomer, it is possible to easily manufacture a filter element including a packing having excellent sealing properties.
[0022]
According to the filter element manufacturing method of claim 3, the man-hour and the number of parts can be reduced by forming the holding frame, packing and seal lip simultaneously by injection molding, or by forming the packing after forming the holding frame. This reduces the manufacturing efficiency of the filter element.
[Brief description of the drawings]
FIG. 1 is a perspective view of a filter element of the present invention.
FIG. 2 is a cross-sectional view of the filter element of the present invention.
FIG. 3 is a top view of the filter element of the present invention.
FIG. 4 is an enlarged cross-sectional view of the packing of the filter element of the present invention.
[Explanation of symbols]
1 Filter element 2 Filter medium 3 Holding frame 4 Packing 5 Rib 6 Seal lip

Claims (3)

A filter element comprising a filter medium and a holding frame for holding the filter medium, wherein a packing is provided on an outer peripheral surface of the holding frame,
The holding frame and the packing are integrally molded by one-step injection molding of a thermoplastic elastomer,
Furthermore, a sealing lip is formed at the tip of the packing by the elastomer in the injection process,
A filter element characterized by maintaining the shape of the holding frame obtained by injection molding and holding the edge of the filter medium by utilizing its elastic force.   The filter element according to claim 1, wherein the filter medium is formed by being folded in a bellows shape so that a fold line extends only in one direction. A filter element manufacturing method comprising a filter medium, a holding frame for holding the filter medium, and a packing provided around the holding frame,
The holding frame and the packing are integrally formed with a thermoplastic elastomer by one-step injection molding, and a seal lip is formed at the tip of the packing with the same thermoplastic elastomer as the holding frame and packing by this injection molding. A method of manufacturing a filter element, comprising forming the filter element.

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