Air conditioning filter element, molding die and molding method thereof

Abstract

The present invention discloses an air conditioning filter element and its forming mold and forming method. The air conditioning filter element includes a frame, a filter material body and a reinforcement ring made of metal. The frame is made of polyurethane foam material by pouring it into a forming mold, and forms an integrated structure together with the filter material body and the reinforcement ring. The frame includes an outer frame that is rectangular as a whole. The filter material body is folded in a wave shape and arranged in the outer frame to isolate the upper and lower sides of the outer frame. The edge of the filter material body is embedded in the outer frame and is sealed with the outer frame. The reinforcement ring is rectangular and is surrounded by the outer frame. The present invention forms an integrated structure with the frame, the filter material body and the reinforcement ring, and the reinforcement ring is wrapped in the outer frame. The reinforcement ring can make the air conditioning filter element have better strength, and it is not easy to deform when the air conditioning filter element is assembled to the air conditioning filter housing.

Description

Technical Field

[0001] The invention relates to the technical field of automobile accessories, and in particular to an air conditioning filter element and a molding die and a molding method thereof. Background Art

[0002] At present, air conditioners in cars (i.e., car air conditioners) are equipped with air conditioning filters to filter the air entering the car from the outside, remove impurities, dust, tiny particles, etc. in the air, and thus improve the air quality in the car. Existing air conditioning filters usually include an outer frame and a filter material body arranged in the outer frame, wherein the outer frame is generally made of a flexible material and is bonded to the filter material body. Thus, when the air conditioning filter is assembled to the air conditioning filter housing, the product is prone to deformation. Summary of the invention

[0003] The main purpose of the present invention is to provide an air conditioning filter element and a molding die and molding method thereof, aiming to improve the overall strength of the air conditioning filter element.

[0004] In order to achieve the above-mentioned purpose, the present invention proposes an air-conditioning filter element, which includes a frame, a filter material body and a reinforcement ring made of metal. The frame is made of polyurethane foam material by pouring it into a molding mold to form an integrated structure together with the filter material body and the reinforcement ring. The frame includes an overall rectangular outer frame, the filter material body is folded in a wave shape and arranged in the outer frame to isolate the upper and lower sides of the outer frame, the edge of the filter material body is embedded in the outer frame and is sealed with the outer frame, and the reinforcement ring is rectangular, surrounded by the outer periphery of the filter material body and wrapped in the outer frame.

[0005] Preferably, the filter material body is made of non-woven filter paper.

[0006] Preferably, the reinforcement ring is made of aluminum alloy and has a galvanized layer formed on the surface.

[0007] Preferably, the reinforcement ring comprises two long sides that are arranged opposite to each other and two short sides that are arranged opposite to each other, the two long sides are provided with a first reinforcement structure, and the two short sides are provided with a second reinforcement structure.

[0008] Preferably, the first reinforcement structure includes a reinforcement rib extending upward or downward from one side of the long side, and the second reinforcement structure includes a protrusion protruding from one side of the short side.

[0009] Preferably, the reinforcing rib is perpendicular to the long side.

[0010] Preferably, the frame also includes a reinforcing connection portion, which is arranged in the middle of the outer frame, and the two ends of the reinforcing connection portion are respectively connected to the opposite sides of the outer frame, the reinforcing connection portion is arranged along the folding direction of the filter material body and is located on one side of the filter material body, and the inner side of the reinforcing connection portion is connected to the filter material body.

[0011] In order to achieve the above-mentioned purpose, the present invention also proposes a molding mold for an air-conditioning filter element, comprising a lower mold and an upper mold, the lower mold is formed with a plurality of first teeth and a plurality of first columns located around the plurality of first teeth, the plurality of first teeth are used to support and position the wavy filter material body, the plurality of first columns are used to support a reinforcement ring made of metal, the upper mold is formed with a plurality of second teeth and a plurality of second columns located around the plurality of second teeth, the plurality of second teeth are used to position the wavy filter material body, the plurality of second columns are used to press the reinforcement ring, when the lower mold and the upper mold are closed together, a mold cavity for molding a frame is formed between the lower mold and the upper mold, the frame is formed by pouring polyurethane foam material into the mold cavity, and forms an integrated structure together with the filter material body and the reinforcement ring, so that the edges of the filter material body are embedded in the outer frame and sealed with the outer frame, and the reinforcement ring is surrounded by the outer periphery of the filter material body and wrapped in the outer frame.

[0012] Preferably, the lower mold includes a lower mold plate and a lower mold core, the plurality of first teeth are formed on the lower mold core and arranged in a row, the plurality of first columns are formed on the lower mold plate, the upper mold includes an upper mold plate and an upper mold core, the upper mold core includes a first part, a second part and a third part, the plurality of second teeth are formed on the first part and the third part of the upper mold core and arranged in two rows, the second part is located between the first part and the second part to separate the two rows of second teeth, and the plurality of second columns are formed on the upper mold plate.

[0013] In order to achieve the above object, the present invention also provides a molding method of an air conditioning filter element, comprising the steps of:

[0014] Providing a molding die for the aforementioned air conditioning filter element;

[0015] Placing the wavy filter material body on the first teeth of the lower mold, and placing the reinforcement ring made of metal on the first columns of the lower mold;

[0016] The upper mold and the lower mold are closed, so that the plurality of second teeth of the upper mold position the wave-shaped filter material body, and the plurality of second columns of the upper mold press the reinforcing ring, and a mold cavity for forming the frame is formed between the lower mold and the upper mold;

[0017] The polyurethane foam material is poured into the mold cavity, and the mold is opened after cooling to obtain the aforementioned air conditioning filter element.

[0018] The air conditioning filter element and its molding die and molding method proposed by the present invention, in the air conditioning filter element, by forming an integrated structure with the frame, the filter material body and the reinforcement ring, and wrapping the reinforcement ring in the outer frame, the reinforcement ring can make the air conditioning filter element have better strength, and it is not easy to deform when the air conditioning filter element is assembled to the air conditioning filter housing. The molding mold is provided with a first column and a second column, so that the reinforcement ring can be kept in a predetermined position in the mold cavity during frame molding. In this way, after the frame molding is completed, the reinforcement ring can be wrapped in the predetermined position of the outer frame, which is convenient for demoulding the air conditioning filter element, and can make the air conditioning filter element have better strength, and it is not easy to deform when the air conditioning filter element is assembled to the air conditioning filter housing. Compared with the existing open mold air conditioning filter element outer frame body and the filter material structure itself, the closed mold infusion eliminates the production link of sealing the filter material in advance, simplifies the production process, and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural schematic diagram of a preferred embodiment of the air conditioning filter element of the present invention.

[0020] Figure 2 yes Figure 1 The structure diagram of the air conditioning filter element shown is viewed from another angle.

[0021] Figure 3 yes Figure 1 The shown air conditioning filter element is a partial cross-sectional view along the folding direction of the filter material body.

[0022] Figure 4 yes Figure 1 The shown air conditioning filter element is a partial cross-sectional view along a direction perpendicular to the folding direction of the filter material body.

[0023] Figure 5 yes Figure 1 Schematic diagram of the structure of the reinforcement ring in the air conditioning filter element shown.

[0024] Figure 6 yes Figure 5 The structure diagram of the reinforcement ring shown is viewed from another angle.

[0025] Figure 7 It is a structural schematic diagram of a preferred embodiment of a molding die for an air conditioning filter element of the present invention.

[0026] Figure 8 yes Figure 7 Schematic diagram of the structure of the lower mold in the molding mold shown.

[0027] Fig. 9 yes Figure 7 Schematic diagram of the structure of the upper mold in the molding mold shown.

[0028] Fig.10 yes Figure 8 Exploded view of the lower die shown.

[0029] Fig.11 yes Fig. 9 Exploded view of the upper die shown.

[0030] In order to make the technical solution of the present invention clearer and more understandable, it will be further described in detail below with reference to the accompanying drawings. DETAILED DESCRIPTION

[0031] Reference Figures 1 to 6 A preferred embodiment of the present invention provides an air conditioning filter element, the air conditioning filter element 1 includes a frame 11, a filter material body 12 and a reinforcement ring 13 made of metal, the frame 11 is made of polyurethane foam material by pouring it into a molding mold 2, and forms an integrated structure together with the filter material body 12 and the reinforcement ring 13, the frame 11 includes an outer frame 111 that is rectangular as a whole, the filter material body 12 is folded in a wave shape and arranged in the outer frame 111 to isolate the upper and lower sides of the outer frame 111, the edge of the filter material body 12 is embedded in the outer frame 111 and is sealed with the outer frame 111, the reinforcement ring 13 is rectangular, surrounded by the outer periphery of the filter material body 12 and wrapped in the outer frame 111.

[0032] In the air conditioning filter element 1, the frame 11, the filter material body 12 and the reinforcement ring 13 are formed into an integrated structure, and the reinforcement ring 13 is wrapped in the outer frame 111. The reinforcement ring 13 can make the air conditioning filter element 1 have better strength, and it is not easy to deform when the air conditioning filter element 1 is assembled to the air conditioning filter housing.

[0033] In this embodiment, the filter body 12 is made of non-woven filter paper. In other embodiments, the filter body 12 can also be made of other materials that can be used as filter materials.

[0034] In this embodiment, the reinforcing ring 13 is made of aluminum alloy, and a zinc coating is formed on the surface. In other embodiments, the reinforcing ring 13 can also be made of other metal materials, and a zinc coating is formed on the surface.

[0035] The reinforcement ring 13 includes two long sides 131 and two short sides 132 that are opposite to each other. The two long sides 131 are provided with a first reinforcement structure 1311 , and the two short sides 132 are provided with a second reinforcement structure 1321 .

[0036] In this embodiment, the first reinforcement structure 1311 includes a reinforcement rib extending upward or downward from one side of the long side 131 , and the second reinforcement structure 1321 includes a protrusion protruding from one side of the short side 132 . The reinforcement rib is perpendicular to the long side 131 .

[0037] In this embodiment, the frame 11 also includes a reinforcing connection portion 112, which is arranged in the middle of the outer frame 111, and the two ends of the reinforcing connection portion 112 are respectively connected to the opposite sides of the outer frame 111, and the reinforcing connection portion 112 is arranged along the folding direction of the filter material body 12 and is located on one side of the filter material body 12, and the inner side of the reinforcing connection portion 112 is connected to the filter material body 12.

[0038] Reference Figures 7 to 11 The preferred embodiment of the present invention also provides a molding die 2 of the aforementioned air conditioning filter element 1, the molding die 2 includes a lower die 21 and an upper die 22, the lower die 21 is formed with a plurality of first teeth 211 and a plurality of first columns 212 located around the plurality of first teeth 211, the plurality of first teeth 211 are used to support and position the wavy filter body 12, the plurality of first columns 212 are used to support the reinforcement ring 13 made of metal, the upper die 22 is formed with a plurality of second teeth 221 and a plurality of second columns 222 located around the plurality of second teeth 221, the plurality of second teeth 221 are used to support and position the wavy filter body 12, the plurality of first columns 212 are used to support the reinforcement ring 13 made of metal, In order to position the wavy filter material body 12, the multiple second columns 222 are used to press the reinforcement ring 13. When the lower mold 21 and the upper mold 22 are molded together, a mold cavity for forming the frame 11 is formed between the lower mold 21 and the upper mold 22. The frame 11 is formed by pouring polyurethane foam material into the mold cavity to form an integral structure together with the filter material body 12 and the reinforcement ring 13, so that the edges of the filter material body 12 are embedded in the outer frame 111 and sealed with the outer frame 111, and the reinforcement ring 13 is surrounded by the outer periphery of the filter material body 12 and wrapped in the outer frame 111.

[0039] By setting the first column 212 and the second column 222, the reinforcement ring 13 can be maintained at a predetermined position in the mold cavity when the frame 11 is formed. In this way, after the frame 11 is formed, the reinforcement ring 13 can be wrapped in a predetermined position of the outer frame 111, which facilitates the demoulding of the air-conditioning filter element 1 and enables the air-conditioning filter element 1 to have better strength. When the air-conditioning filter element 1 is assembled to the air-conditioning filter housing, it is not easy to be deformed.

[0040] After the air conditioning filter element 1 is formed, a first blind hole 1111 is formed on the outer frame 111 of the frame 11 corresponding to the first column 212 , and a second blind hole 1112 is formed on the outer frame 111 of the frame 11 corresponding to the second column 222 .

[0041] In this embodiment, the lower mold 21 includes a lower mold plate 23 and a lower mold core 24, the multiple first teeth 211 are formed on the lower mold core 24 and arranged in a row, the multiple first columns 212 are formed on the lower mold plate 23, the upper mold 22 includes an upper mold plate 25 and an upper mold core 26, the upper mold core 26 includes a first part 261, a second part 262 and a third part 263, the multiple second teeth 221 are formed on the first part 261 and the third part 263 of the upper mold core 26 and arranged in two rows, the second part 262 is located between the first part 261 and the second part 262, separating the two rows of second teeth 221, and the multiple second columns 222 are formed on the upper mold plate 25.

[0042] The embodiment of the present invention further provides a molding method of an air conditioning filter element 1, comprising the steps of:

[0043] Providing a molding die 2 for the aforementioned air conditioning filter element 1;

[0044] The wave-shaped filter material body 12 is placed on the plurality of first teeth 211 of the lower mold 21 , and the reinforcing ring 13 made of metal is placed on the plurality of first columns 212 of the lower mold 21 ;

[0045] The upper mold 22 and the lower mold 21 are molded together, so that the plurality of second teeth 221 of the upper mold 22 position the wavy filter material body 12, and the plurality of second columns 222 of the upper mold 22 press the reinforcing ring 13, and a mold cavity for molding the frame 11 is formed between the lower mold 21 and the upper mold 22;

[0046] The polyurethane foam material is poured into the mold cavity, and the mold is opened after cooling to obtain the aforementioned air conditioning filter element 1.

[0047] The present application adopts closed mold infusion, which eliminates the production link of sealing the filter material in advance compared with the existing open mold air conditioning filter element's outer frame body and the filter material structure itself, simplifies the production process and improves production efficiency.

[0048] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An air conditioning filter element, characterized in that: The air conditioning filter element comprises a frame, a filter material body and a reinforcement ring made of metal, the reinforcement ring has a galvanized layer formed on the surface, the frame is made of polyurethane foam material by pouring into a molding mold, and forms an integrated structure together with the filter material body and the reinforcement ring, the frame comprises an overall rectangular outer frame, the filter material body is folded in a wave shape and arranged in the outer frame to isolate the upper and lower sides of the outer frame, the edge of the filter material body is embedded in the outer frame and is sealed with the outer frame, and the reinforcement ring is rectangular, surrounded by the outer periphery of the filter material body and wrapped in the outer frame; The reinforcement ring includes two long sides arranged opposite to each other and two short sides arranged opposite to each other, the two long sides are provided with a first reinforcement structure, and the two short sides are provided with a second reinforcement structure; the first reinforcement structure includes reinforcement ribs extending upward or downward from one side of the long side, and the second reinforcement structure includes a protrusion protruding from one side of the short side; the reinforcement ribs are perpendicular to the long sides.

2. The air conditioning filter element according to claim 1, characterized in that: The filter material body is made of non-woven filter paper.

3. The air conditioning filter element according to claim 1, characterized in that: The reinforcement ring is made of aluminum alloy.

4. The air conditioning filter element according to claim 1, characterized in that: The frame also includes a reinforcing connection portion, which is arranged in the middle of the outer frame, and the two ends of the reinforcing connection portion are respectively connected to the opposite sides of the outer frame. The reinforcing connection portion is arranged along the folding direction of the filter material body and is located on one side of the filter material body, and the inner side of the reinforcing connection portion is connected to the filter material body.

5. A method for forming an air conditioning filter element, characterized in that: Includes steps: A molding die is provided, the molding die comprising a lower die and an upper die, the lower die is formed with a plurality of first teeth and a plurality of first columns located around the plurality of first teeth, the plurality of first teeth are used to support and position a wavy filter material body, the plurality of first columns are used to support a reinforcement ring made of metal, the upper die is formed with a plurality of second teeth and a plurality of second columns located around the plurality of second teeth, the plurality of second teeth are used to position the wavy filter material body, the plurality of second columns are used to press the reinforcement ring, when the lower die and the upper die are molded together, a mold cavity for molding a frame is formed between the lower die and the upper die, a frame is integrally molded by pouring polyurethane foam material into the mold cavity, and an integral structure is formed together with the filter material body and the reinforcement ring, so that the edges of the filter material body are embedded in the outer frame of the frame and are sealed and connected to the outer frame, and the reinforcement ring is surrounded by the outer periphery of the filter material body and wrapped in the outer frame; Placing the wavy filter material body on the first teeth of the lower mold, and placing the reinforcement ring made of metal on the first columns of the lower mold; The upper mold and the lower mold are closed, so that the plurality of second teeth of the upper mold position the wave-shaped filter material body, and the plurality of second columns of the upper mold press the reinforcing ring, and a mold cavity for forming the frame is formed between the lower mold and the upper mold; The polyurethane foam material is poured into the mold cavity, and the mold is opened after cooling to obtain the air conditioning filter element as claimed in any one of claims 1 to 4.

6. The molding method of the air conditioning filter element according to claim 5, characterized in that: The lower mold includes a lower mold plate and a lower mold core, the plurality of first teeth are formed on the lower mold core and arranged in a row, the plurality of first columns are formed on the lower mold plate, the upper mold includes an upper mold plate and an upper mold core, the upper mold core includes a first part, a second part and a third part, the plurality of second teeth are formed on the first part and the third part of the upper mold core and arranged in two rows, the second part is located between the first part and the second part to separate the two rows of second teeth, and the plurality of second columns are formed on the upper mold plate.

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