Filter cartridge and method of assembling a filter cartridge

Abstract

This invention relates to a filter element and its assembly method. Utilizing the expansion property of foamed materials after foaming, the foamed material passes through the filter element frame and connects to the core material, thereby securing the filter element frame and core material. Simultaneously, the foamed material can abut against the outer shell, sealing the gap between the filter element and the outer shell. This invention achieves both functions in a single foaming process, significantly simplifying the manufacturing process, eliminating material waste, and reducing costs. Furthermore, the elasticity of the foamed material provides higher shock resistance, further enhancing the shock resistance between the filter element frame and the core material. Finally, the foamed material passing through the filter element frame ensures a stable bond between the foamed material and the frame, preventing displacement of the foamed material and ensuring a proper seal.

Description

Technical Field

[0001] This invention relates to a filter element for separating suspended particles in a fluid and a method for assembling the filter element, and more particularly to a filter element for a truck and a related adhesive application method thereon. Background Technology

[0002] For example, according to Taiwan Patent Application No. I631984, the existing filter element includes a core material and a filter frame. The core material is used to filter fluid, and the fluid passes through both ends of the core material, causing dust in the fluid to adhere to the core material. The filter frame is fitted onto one end of the core material, and the filter frame and the core material are fixed and sealed by an adhesive. In addition, a sealing ring is further provided on the filter element and fitted onto the outside of the filter frame. When the filter element is installed in the housing to form a filter, the sealing ring is used to seal the gap between the filter frame and the housing.

[0003] However, existing filter cartridges have the following drawbacks:

[0004] First, two different components, colloid and sealing ring, are needed to seal the two gaps. The colloid seals the gap between the filter frame and the core material, while the sealing ring seals the gap between the filter frame and the outer shell. Since these are different components, they also need to be assembled separately, making the assembly process cumbersome and difficult to speed up.

[0005] Secondly, in order to solve the problem of the time-consuming and labor-intensive drawback of using a glue gun to apply glue between the core material and the filter frame, the aforementioned patent case adopts the method of first applying a large amount of glue and then letting the filter frame cut the glue. However, this method will generate a large amount of excess glue, and the excess glue is difficult to recycle and reuse because it has been exposed to the outside air. Therefore, the glue application method of the aforementioned patent case will waste a lot of glue and increase costs.

[0006] Third, although the colloid can adhere to the filter element frame and core material, its shock resistance is not ideal, especially when the filter element is installed in a vehicle, it will be in a state of vibration for a long time.

[0007] Fourth, the sealing ring is simply fitted onto the annular groove of the filter element frame, rather than being fixed to the filter element frame. Therefore, when the filter element is installed into the housing, the sealing ring may shift relative to the filter element frame due to compression, thus affecting the sealing effect.

[0008] Therefore, the existing filter elements need to be improved. Summary of the Invention

[0009] In view of the aforementioned shortcomings and deficiencies of the prior art, the present invention provides a filter element and a method for assembling the filter element, which combines the colloid and sealing ring of the prior art into one, thereby simplifying the manufacturing process and enhancing shock resistance and fixation.

[0010] To achieve the aforementioned objectives, the present invention employs a method of designing a filter element, comprising:

[0011] One core material;

[0012] A filter element frame is fitted onto the core material; the filter element frame is formed with a plurality of foam holes, which are arranged in a circumferential and spaced manner; the filter element frame includes a hole portion and a clamping portion; the foam holes are located on the hole portion; the clamping portion protrudes radially outward from the hole portion and extends toward one end of the core material.

[0013] A foam body, the position of which corresponds to the position of the filter element frame, after foaming, the foam body passes through the filter element frame and connects to the core material, and fixes the filter element frame and the core material; the foam body is used to abut against a shell to seal the gap between the filter element and the shell.

[0014] After foaming, the foamed body passes through the foaming holes of the filter element frame and extends between the hole portion and the clamping portion, and is connected to the hole portion and the clamping portion.

[0015] To achieve the above-mentioned objective, the present invention further provides a method for assembling a filter element, comprising the following steps:

[0016] Unexpanded foamed material is injected into a mold, and a filter frame and a core material are placed into the mold.

[0017] The foaming material is foamed, and after foaming, the foaming material passes through the filter core frame and is connected to the core material, and the filter core frame and the core material are fixed; the foamed material, the filter core frame and the core material together form a filter core; the foamed material is used to abut against a shell to seal the gap between the filter core and the shell.

[0018] The filter element is removed from the mold; among which,

[0019] The filter element frame is formed with multiple foaming holes arranged at intervals around each other; after the foaming material is foamed, it passes through the foaming holes and connects to the core material; the filter element frame includes a hole portion and a clamping portion; the foaming hole is located on the hole portion; the clamping portion protrudes radially outward from the hole portion; after the filter element frame is placed in the mold, the clamping portion faces the unfoamed foaming material, and after the foaming material is foamed, it extends upward into the space between the hole portion and the clamping portion, and connects to the hole portion and the clamping portion.

[0020] The advantages of this invention are that, by utilizing the expansion property of foamed materials after foaming, the foamed material passes through the filter core frame and attaches to the core material, thereby fixing the filter core frame and the core material, thus replacing the bonding function of the colloid in the prior art; at the same time, the foamed material has the function of a sealing ring in the prior art after foaming and can be used to abut against the outer shell to seal the gap between the filter core and the outer shell; therefore, this invention replaces the colloid and sealing ring in the prior art with foamed material (foam body), and only requires one foaming molding to have the functions of both colloid and sealing ring, thus greatly simplifying the manufacturing process.

[0021] Furthermore, compared to existing technologies that require discarding large amounts of excess colloid, this invention uses less material and avoids material waste, while also reducing costs.

[0022] In addition, compared with the existing technology that uses colloid to bond the filter frame and core material, the foam material of the present invention has higher material elasticity and shock resistance, which can more effectively improve the shock resistance between the filter frame and the core material.

[0023] Furthermore, compared to the existing sealing rings which are simply fitted onto the filter element frame without being secure, the foamed material of this invention passes through the filter element frame after foaming, thus allowing the foamed material to be securely bonded to the filter element frame, thereby preventing the foamed material from shifting and affecting the sealing effect.

[0024] Finally, core materials are often formed by winding, which makes it easy for the outer diameter to have tolerances. However, this invention uses foamed material to attach to the outer wall of the core material. Therefore, even if the core material has dimensional tolerances, the foaming of the foamed material can effectively absorb the tolerances, so that the core material is firmly bonded to the filter frame.

[0025] Furthermore, the filter element has a support portion protruding around its frame; after foaming, the foamed body is attached to the support portion in a direction away from the core material.

[0026] Furthermore, in the filter element, after foaming, the foam extends between the inner wall surface of the filter element frame and the outer wall surface of the core material.

[0027] Furthermore, in the aforementioned filter element, both the foam body and the filter element frame are located at one end of the core material, and one end face of the foam body and one end face of the filter element frame are flush with the end face of the core material at that end.

[0028] Furthermore, the filter element wherein the foam is polyurethane.

[0029] Furthermore, in the method of assembling the filter element, the filter element frame has a supporting portion protruding around it; after the filter element frame is placed in the mold, the supporting portion is located above the unfoamed foaming material, and the foamed material is attached upward to the supporting portion after foaming.

[0030] Furthermore, in the filter element assembly method, after the foaming material is foamed, the foaming material extends between the inner wall surface of the filter element frame and the outer wall surface of the core material.

[0031] Furthermore, in the filter element assembly method, the filter element frame is located at the bottom end of the core material, and the mold aligns the bottom surface of the foamed material, the bottom surface of the filter element frame, and the bottom surface of the core material.

[0032] Furthermore, in the filter element assembly method, after the filter element frame and the core material are placed into the mold, the filter element frame is pressed down by a fixing fixture before the foaming material is foamed; after the foaming material is foamed, the fixing fixture is removed first, and then the filter element is taken out from the mold. Attached Figure Description

[0033] Figure 1 and Figure 2 This is a three-dimensional view of the filter element of the present invention.

[0034] Figure 3 and Figure 4 This is an exploded view of the filter element components of the present invention.

[0035] Figure 5 This is a perspective view of the mold and fixing fixture of the present invention.

[0036] Figure 6 This is a three-dimensional cross-sectional view of the foaming material and mold of the present invention.

[0037] Figures 7 to 9 This is an action diagram of the assembly method of the present invention.

[0038] Figure 10 This is an enlarged cross-sectional view of the filter element of the present invention. Detailed Implementation

[0039] The following, in conjunction with the accompanying drawings and preferred embodiments of the present invention, further illustrates the technical means employed by the present invention to achieve its intended purpose.

[0040] Please see Figures 1 to 3 As shown, the filter element of the present invention includes a core material 10, a filter element frame 20, and a foam body 30.

[0041] The aforementioned core material 10 can be circular or racetrack-shaped, and its specific shape is not limited.

[0042] The aforementioned filter frame 20 is fitted onto the core material 10.

[0043] Please see Figure 1 , Figure 2 and Figure 10As shown, the position of the aforementioned foam 30 corresponds to the position of the filter element frame 20. After foaming, the foam 30 passes through the filter element frame 20 and connects to the core material 10, fixing the filter element frame 20 and the core material 10. Preferably, after foaming, the foam 30 surrounds the core material 10 along the shape of the filter element frame 20. The foam 30 is used to abut against a housing to seal the gap between the filter element and the housing. The foam 30 is preferably polyurethane, but is not limited thereto.

[0044] In this embodiment, please refer to Figure 3 , Figure 4 and Figure 10 As shown, the filter element frame 20 is formed with a plurality of foaming holes 211, which are arranged in a circumferential manner. After foaming, the foam body 30 passes through the foaming holes 211 and is connected to the core material 10. Preferably, the foaming holes 211 are square holes, but the foaming holes 211 are not limited to square holes or round holes, and can also be long slits, etc.

[0045] Furthermore, the filter element frame 20 includes a perforated portion 21, an outer ring portion 22, an inner ring portion 23, a clamping portion 24, and a supporting portion 25. The aforementioned foaming holes 211 are located on the perforated portion 21. The outer ring portion 22 and the inner ring portion 23 are located at opposite ends of the perforated portion 21, with the outer ring portion 22 being closer to one end of the core material 10 than the inner ring portion 23. In this embodiment, after foaming, the foamed body 30 extends between the inner wall surface of the filter frame 20 and the outer wall surface of the core material 10. Preferably, the foamed body 30 extends simultaneously between the outer ring portion 22 and the core material 10, and also between the inner ring portion 23 and the core material 10. However, it may extend only between one of the outer ring portion 22 and the inner ring portion 23 and the core material 10, or neither may extend between the outer ring portion 22 nor the inner ring portion 23 and the core material 10. In this case, it only extends between the inner wall surface of the hole portion 21 (the portion other than the foaming hole 211) and the outer wall surface of the core material 10. In addition, in this embodiment, the inner diameter of the inner ring portion 23 is larger than the inner diameter of the outer ring portion 22, thereby facilitating the formation of the foaming hole 211 during the manufacturing of the filter frame 20, but this is not a limitation.

[0046] The clamping portion 24 protrudes radially outward from the perforated portion 21 and extends toward one end of the core material 10. After foaming, the foamed body 30 extends into the space between the perforated portion 21 and the clamping portion 24, and connects to the perforated portion 21 (the portion other than the foaming holes 211) and the clamping portion 24. By clamping the foamed body 30 through the perforated portion 21 and the clamping portion 24, the bond between the foamed body 30 and the filter frame 20 can be strengthened. In this embodiment, the clamping portion 24 extends radially outward and obliquely toward one end of the core material 10, but it is not limited to this. It can also extend radially outward first and then turn to extend toward one end of the core material (similar to an L-shape).

[0047] The support portion 25 surrounds the end of the clamping portion 24. After foaming, the foam body 30 is attached to the support portion 25 in the direction away from the core material 10. In other words, the support portion 25 can support the foam body 30 in the direction towards the core material 10.

[0048] In this embodiment, the foam body 30 and the filter frame 20 are both located at one end of the core material 10, and one end face of the foam body 30 and one end face of the filter frame 20 are flush with the end face of the core material 10 at that end (e.g., Figure 10 (as shown), but not limited thereto, the foam 30 and filter frame 20 may also be located in other positions, such as the middle section of the core material 10, etc.

[0049] The filter element assembly method of the present invention includes the following steps:

[0050] Please see Figures 5 to 7 As shown, firstly, unfoamed foaming material 31 is injected into a mold 40, and then a filter element frame 20 and a core material 10 are placed into the mold 40. Preferably, the mold 40 has a retaining groove 41 and a foaming groove 42, the foaming groove 42 surrounding the retaining groove 41 and spaced apart from the retaining groove 41, the bottom ends of the filter element frame 20 and the core material 10 are placed in the retaining groove 41, and the foaming material 31 is injected into the foaming groove 42. The structure of the filter element frame 20 is preferably the same as described above, so it will not be repeated here.

[0051] Please see Figure 8 As shown, in this embodiment, after the filter frame 20 and the core material 10 are placed in the mold 40, the filter frame 20 is pressed down by a fixing fixture 50. Preferably, the fixing fixture 50 includes a pressure plate 51 and a plurality of fixing seats 52. After the pressure plate 51 presses down on the filter frame 20 around the mold, the screws 521 of the fixing seats 52 are then pressed down against the pressure plate 51.

[0052] Please see Figure 9 and Figure 10 As shown, the foaming material 31 is then foamed into a foam body 30. After foaming, the foaming material 31 passes through the filter core frame 20 (with foaming holes 211) and is connected to the core material 10, and the filter core frame 20 and the core material 10 are fixed. The foamed foaming material 31 (foam body 30), the filter core frame 20, and the core material 10 together form a filter element. By pressing down the fixing fixture 50, the position of the filter core frame 20 can be stabilized, thereby ensuring the shape of the foamed material 31 after foaming.

[0053] Please see Figure 7 and Figure 10As shown, in this embodiment, after the filter frame 20 is placed in the mold 40, the clamping part 24 of the filter frame 20 faces the foaming material 31, and the supporting part 25 is located above the foaming material 31. After foaming, the foaming material 31 extends upward into the space between the hole part 21 and the clamping part 24 and connects to the hole part 21 and the clamping part 24, and connects upward to the supporting part 25. In addition, after foaming, the foaming material 31 extends into the space between the inner wall surface of the filter frame 20 and the outer wall surface of the core material 10.

[0054] Please see Figure 9 and Figure 10 As shown, in this embodiment, the bottom of the abutment groove 41 of the mold 40 and the bottom of the foaming groove 42 are aligned. Therefore, after foaming, the bottom surface of the foaming material 31 (foam body 30), the bottom surface of the filter frame 20, and the bottom surface of the core material 10 are aligned. However, this is not a limitation. The bottom of the abutment groove 41 may also be lower than the bottom of the foaming groove 42, and the filter frame 20 may be supported elsewhere. In this way, the foaming material 31 can fix the filter frame 20 to a location other than the bottom end of the core material 10.

[0055] In this embodiment, the foamed material 31 (foam body 30) is used to axially abut against the outer shell, but this is not a limitation; the foamed material 31 (foam body 30) can also be used to radially abut against the outer shell. Furthermore, regardless of whether the foamed material 31 (foam body 30) abuts against the outer shell axially or radially, the foamed material 31 (foam body 30) may protrude from the filter frame 20, be flush with a portion of the filter frame 20, or not protrude from the filter frame 20, depending on the shape of the outer shell. The only requirement is that after foaming, it can abut against the outer shell to achieve a sealing effect.

[0056] Finally, after the foaming material 31 has foamed, the fixing fixture 50 is removed first, and then the filter element (foam body 30, filter element frame 20 and core material 10) is taken out from the mold 40, thus completing the assembly of the filter element.

[0057] The present invention utilizes the expansion property of foam material 31 after foaming, so that the foam material 31, after foaming, passes through the foaming holes 211 of the filter core frame 20 and connects to the core material 10, thereby fixing the filter core frame 20 and the core material 10. At the same time, it can also abut against the outer shell to seal the gap between the filter core and the outer shell. Moreover, it can achieve both of the aforementioned functions in a single foaming process, thus greatly simplifying the manufacturing process, avoiding material waste, and reducing costs.

[0058] In addition, the material elasticity of foam material 31 (polyurethane) has higher shock resistance and can effectively improve the shock resistance between filter frame 20 and core material 10.

[0059] Finally, after the foamed material 31 is foamed, it passes through the filter core frame 20 (foaming holes 211), which allows the foamed material 31 to be firmly bonded to the filter core frame 20, thereby preventing the foamed material 31 from shifting and affecting the sealing effect.

[0060] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the technical solution of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A filter element, characterized in that, Include One core material; A filter element frame is fitted onto a core material; the filter element frame is formed with a plurality of foamed pores, which are arranged in a circumferential and spaced manner; the filter element frame includes a perforated portion and a clamping portion; the foamed pores are located on the perforated portion; the clamping portion protrudes radially outward from the perforated portion and extends toward one end of the core material; the filter element frame includes an outer ring portion and an inner ring portion, which are respectively located at both ends of the perforated portion; A foam body, the position of which corresponds to the position of the filter element frame, after foaming, the foam body passes through the filter element frame and connects to the core material, and fixes the filter element frame and the core material; the foam body is used to abut against a shell to seal the gap between the filter element and the shell. After foaming, the foamed body passes through the foaming holes of the filter element frame and extends between the hole portion and the clamping portion, and is connected to the hole portion and the clamping portion.

2. The filter element as described in claim 1, characterized in that, The filter element frame has a protruding support portion around it; after foaming, the foam body is attached to the support portion in the direction away from the core material.

3. The filter element as described in claim 1, characterized in that, After foaming, the foam extends into the space between the inner wall of the filter element frame and the outer wall of the core material.

4. The filter element as described in claim 1, characterized in that, The foam and the filter frame are both located at one end of the core material, and one end face of the foam and one end face of the filter frame are flush with the end face of the core material.

5. The filter element as described in claim 1, characterized in that, The foam is made of polyurethane.

6. A method for assembling a filter element, characterized in that, Includes the following steps: Unexpanded foamed material is injected into a mold, and a filter frame and a core material are placed into the mold. The foaming material is foamed, and after foaming, the foaming material passes through the filter core frame and is connected to the core material, and the filter core frame and the core material are fixed; the foamed material, the filter core frame and the core material together form a filter core; the foamed material is used to abut against a shell to seal the gap between the filter core and the shell. The filter element is removed from the mold; among which, The filter element frame is formed with multiple foaming holes arranged at intervals around each other; after the foaming material is foamed, it passes through the foaming holes and connects to the core material; the filter element frame includes a hole portion and a clamping portion; the foaming hole is located on the hole portion; the clamping portion protrudes radially outward from the hole portion; after the filter element frame is placed in the mold, the clamping portion faces the unfoamed foaming material, and after the foaming material is foamed, it extends upward into the space between the hole portion and the clamping portion, and connects to the hole portion and the clamping portion.

7. The filter element assembly method as described in claim 6, characterized in that, The filter element frame has a supporting part protruding around it; after the filter element frame is placed in the mold, the supporting part is located above the foamed material that has not yet been foamed, and the foamed material is attached to the supporting part after it is foamed.

8. The filter element assembly method as described in claim 6, characterized in that, After the foaming material is foamed, it extends into the space between the inner wall of the filter element frame and the outer wall of the core material.

9. The filter element assembly method as described in claim 6, characterized in that, The filter element frame is located at the bottom of the core material, and the mold aligns the bottom surface of the foamed material, the bottom surface of the filter element frame, and the bottom surface of the core material.

10. The filter element assembly method as described in claim 6, characterized in that, After the filter element frame and the core material are placed into the mold, a fixing fixture is used to press down the filter element frame before the foaming material is foamed. After the foaming material is foamed, the fixing fixture is removed first, and then the filter element is taken out of the mold.

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