Novel filter element foaming mold and foaming method
By improving the design of the filter element foaming mold, the overlapping mold structure and plastic material are used to solve the problems of high mold cost, difficulty in handling flashes and unstable foaming, and efficient and stable filter element production is achieved.
Patent Information
- Application Number
- CN202510719436.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-30
- Publication Date
- 2025-07-25
AI Technical Summary
There are problems such as high mold cost, difficult process flicker processing and unstable foaming quality in the production of existing air filter elements, resulting in low production efficiency and unstable product quality.
The upper and lower mold structures are adopted with overlapping, and the guide grooves and limiting parts are provided in the lower mold. Combined with the ventilation structure and the reinforcement plate of the inner and outer mold parts, the mold design is optimized to facilitate cast material forming and demolding, and molds made of plastic are used to reduce costs.
It improves the stability and production efficiency of product quality, reduces equipment costs, increases equipment utilization, and simplifies the mold release process.
Smart Images
Figure CN120363394A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of filter element foaming of air filters, and particularly relates to a novel filter element foaming mold and a foaming method. Background Art
[0002] In the field of engine intake air filtration systems, the production of air filter elements usually follows a relatively traditional process flow. This process relies on special metal molds. By injecting a mixed reactant of a chemical foaming agent into the mold, polyurethane (PU) material is formed under specific temperature, pressure and other conditions, and then a pressure holding operation is carried out to finally obtain the required air filter element product. For a long time, this production method has met the production requirements of air filter elements to a certain extent and has been widely used in the manufacture of engine intake air filtration system products. However, this process also has some obvious deficiencies as follows: 1. High cost: The special metal foaming mold adopts a one-cavity-per-mold structure design. This design mode requires extremely high manufacturing precision of the mold, and the corresponding production process is complex, resulting in a substantial increase in the production cost of the mold. At the same time, the supporting production line also needs to be specially customized and adapted, further increasing the equipment procurement and installation costs, bringing a heavy economic burden to relevant manufacturing enterprises, requiring enterprises to make additional large investments, seriously reducing the economic benefits of enterprises, and being at a disadvantage in the market competition.
[0003] 2. Difficult subsequent treatment problems caused by mold design defects: There is a relatively obvious defect in the design of existing metal foaming molds, that is, process flash is likely to be generated inside the filter paper frame. However, in subsequent production processes, it is extremely difficult to deal with these process flashes. Due to the special position of the flash, existing treatment processes and equipment are difficult to remove it efficiently and accurately, which not only increases the defective rate in the production process, but also may lead to unstable product quality and affect the performance and reliability of the final product.
[0004] 3. Unstable foaming quality: Due to the design problems of the mold itself and the existence of process flash, the flow and filling state of the mixed reactant are disturbed during the foaming process. This results in an uneven internal structure of the foamed filter element, with different pore sizes and uneven distributions, thereby affecting key indicators such as the filtration performance and strength of the filter element. The unstable foaming quality not only reduces the product qualification rate, but also may cause problems in the engine intake air filtration system during actual use, posing a potential threat to the normal operation of the engine.
[0005] Therefore, there is still room for urgent improvement in the existing filter element foaming solutions, and it should be optimized to improve the reliability of the filter element foaming solution and enhance the quality of filter element products. Therefore, a more reasonable technical solution needs to be proposed to solve the technical problems existing in the prior art. Summary of the Invention
[0006] To overcome at least one of the above-mentioned defects, the present invention provides a new type of filter element foaming mold and foaming method, aiming to solve the problems that a dedicated production line and a dedicated metal mold are required during the foaming process, and a demolding agent needs to be sprayed before each foaming, thereby solving the problems of low economic efficiency of enterprises, difficult treatment of foaming flash, and the technical problem of one cavity per mold.
[0007] To achieve the above object, the foaming mold disclosed by the present invention can adopt the following technical solutions: A new type of filter element foaming mold includes an upper mold and a lower mold arranged in a stacked manner. The lower mold is provided with a lower cavity for product forming, and the lower mold is also provided with a guiding groove, which is arranged along the edge of the lower cavity and extends outward from the lower cavity. The upper mold includes an upper cavity corresponding to and cooperating with the lower cavity. A guiding gap communicating with the guiding groove is formed between the upper cavity and the lower cavity. The lower surface of the upper mold tightly covers and seals the guiding groove extending to the outside of the lower cavity. A plurality of lower limiting members are provided on the outer edge of the lower mold to tightly press against the edge of the upper mold. The upper surface of the upper mold forms an inner limiting portion and an outer limiting portion, and the bottom surface of the lower mold respectively forms an inner pressing portion tightly pressing against the inner limiting portion and an outer pressing portion tightly pressing against the outer limiting portion.
[0008] For the above-mentioned disclosed foaming mold, the forming cavity is formed by the lower cavity of the lower mold. When the material liquid is poured into the lower cavity, it can follow the lower cavity and the guiding groove to form a regular shape. After covering the upper mold, the edge of the material liquid is restricted, which is convenient for forming a product that more conforms to the regular shape. The above-mentioned disclosed foaming mold can be stacked longitudinally, that is, after the upper mold and the lower mold are assembled, a lower mold can be continuously placed above the upper mold, and an upper mold can be continuously set for mold closing, so the space utilization rate can be improved.
[0009] The guiding gap formed between the upper mold and the lower mold is convenient for the pouring material to flow upward into the upper cavity during mold closing. The pouring material entering the upper cavity can be surface-formed under the blocking of the filter paper.
[0010] In some solutions, the number of lower cavities provided in the lower mold can be multiple, and the number of upper cavities correspondingly provided in the upper mold also corresponds one by one.
[0011] Further, during the pouring process, to enable the pouring material to flow and form better in the lower cavity and the guiding groove, the structure of the mold can be optimized. Here, one feasible option for optimization is proposed: several ventilation structures are formed on the mold, and the ventilation structures communicate from the lower cavity to the outside of the mold and / or from the guiding groove to the outside of the mold. When adopting the above solution, the ventilation structure includes ventilation grooves or ventilation holes. In some solutions, the ventilation grooves or ventilation holes are arranged at intervals on the edge of the lower cavity and also at intervals along the guiding groove, so as to meet the requirements of uniform flow of the pouring material for pouring and forming.
[0012] Further, the upper mold is used to cooperate with the lower mold for mold closing to maintain the sealing of the forming structure of the lower cavity and the guiding groove, and can be configured in various forms, and its structure is not uniquely limited. Here, one feasible option for optimization is proposed: the upper mold includes an inner mold part, and at least one inner mold part corresponds to the lower cavity and forms an upper cavity; the upper mold further includes an outer mold part corresponding to and cooperating with the lower limiting part, and a gap is formed between the inner mold part and the outer mold part.
[0013] Further, to maintain the relative stability of the inner mold part and the outer mold part, the inner mold and the outer mold part are strengthened by adjusting the gap structure: reinforcing rib plates are arranged in the gap, one end of the reinforcing rib plate is connected to the inner mold part, and the other end is connected to the outer mold part, and the reinforcing rib plates are arranged at intervals along the extending direction of the gap. When adopting the above solution, the reinforcing rib plates are integrally formed with the inner mold part and the outer mold part.
[0014] Furthermore, the gap extends at multiple positions on the upper mold. In addition to being arranged at the edge of the upper cavity, it is also arranged at other positions on the upper mold. Therefore, when extending to different positions, the setting direction of the reinforcing rib plates in the gap is also adjusted correspondingly and changed, and its structure is not uniquely limited. Here, one feasible option for optimization is proposed: the reinforcing rib plates include transverse rib plates and longitudinal rib plates. When adopting the above solution, both the transverse rib plates and the longitudinal rib plates are perpendicular to the inner mold part and the outer mold part.
[0015] Further, to facilitate the foaming of the product, the inner mold part can be configured in various forms, and its structure is not uniquely limited. Here, one feasible option for optimization is proposed: an inwardly buckled positioning plate is formed at the upper end of the inner mold part, and the positioning plate is used to cooperate with the setting of filter paper. When adopting the above solution, the positioning plate is integrally formed with the inner mold part.
[0016] Further, lower templates can be continuously stacked above the upper template. The specific stacking structure can adopt various forms, and its structure is not uniquely limited. Here, one feasible option is optimized and proposed: the inner limiting part is formed on the inner mold part, the outer limiting part is formed on the outer mold part, and both the inner limiting part and the outer limiting part include limiting protrusions. When adopting the above solution, both the inner limiting part and the outer limiting part are annular convex strips, which can be polygonal convex strips in some solutions and circular convex strips in other solutions.
[0017] Further, after pouring the product into the lower cavity and curing and forming, demolding is required. To improve the convenience of demolding, the lower cavity can be optimized and adjusted. Specifically, various solutions can be adopted. Here, one feasible option is optimized and proposed: an inner coating is provided in the lower cavity, and the inner coating is used to keep the inner wall of the lower cavity smooth. When adopting the above solution, the inner coating can improve the demolding efficiency, avoid using demolding agents, and also reduce costs.
[0018] Further, when the upper mold is stacked on the lower mold, the positions need to be aligned and kept stable. Therefore, the matching structure of the upper mold and the lower mold can be adjusted. Here, one feasible option is optimized and proposed: the lower limiting member includes a plurality of limiting plates, which are arranged at intervals along the outer edge of the lower mold and are used to fit and press against the outer edge of the upper mold. When adopting the above solution, the limiting plates can be integrally formed with the lower mold.
[0019] The above content discloses a foaming mold, and the present invention also provides a foaming method, which will be described below.
[0020] A new type of filter element foaming method, using the foaming mold described above, includes: Configure the foaming mold, select the corresponding upper mold and lower mold for matching setting; Mix PUA material and PUB material in proportion and inject them into the lower cavity of the lower mold; Set filter paper in the upper cavity of the upper mold and cover the upper mold on the lower mold; After the upper mold and the lower mold are closed, place them in the circular flow transfer press and apply pressure; Control the movement of the circular flow transfer press to cure the mixture, and the production of the filter element is completed.
[0021] Compared with the prior art, some beneficial effects of the disclosed technical solution of the present invention include: By improving the foaming mold, the lower mold and the upper mold can limit and guide the castable when forming, and exhaust the internal air, so the quality of the molded product is more stable and reliable; the foaming mold can be overlapped in space, and multiple products can be formed at the same time, which greatly improves the efficiency of production and processing, improves equipment utilization, and saves resources. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only represent some embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.
[0023] Figure 1 It is a schematic diagram of the overall structure of a single-layer foaming mold and an enlarged schematic diagram of its local structure.
[0024] Figure 2 for Figure 1 Schematic diagram of the top view structure.
[0025] Figure 3 for Figure 1 Schematic diagram of the front view structure.
[0026] Figure 4 for Figure 2 Schematic diagram of the cross-section of the AA junction and the enlarged diagram of the local structure.
[0027] Figure 5 It is a structural diagram of the lower die matching product and an enlarged diagram of the local structure.
[0028] Figure 6 It is a schematic diagram of the overall structure of the lower mold and an enlarged schematic diagram of the local structure.
[0029] Figure 7 This is a schematic diagram of the overall structure of the product.
[0030] Figure 8 It is a schematic diagram of the structure of the stacked multi-layer foaming mold.
[0031] In the above drawings, the meanings of the symbols are as follows: 1. Upper mold; 101. Inner mold part; 102. Outer mold part; 103. Inner limiting part; 104. Outer limiting part; 105. Positioning plate; 106. Upper cavity; 2. Lower mold; 201. Lower cavity; 3. Product; 4. Horizontal rib plate; 5. Longitudinal rib plate; 6. Lower limiting piece; 7. Guide groove; 8. Ventilation structure. DETAILED DESCRIPTION
[0032] The following further elaborates on this embodiment in conjunction with the accompanying drawings and specific embodiments.
[0033] In view of the inconvenient use, low processing efficiency, and poor product precision of the foaming mold in the prior art, the following embodiments are optimized to overcome the defects existing in the prior art.
[0034] Embodiment 1 As Figures 1 to 8 shown, this embodiment provides a new type of filter element foaming mold, which includes an upper mold 1 and a lower mold 2 arranged in a stacked manner. The lower mold 2 is provided with a lower cavity 201 for forming the product 3, and the lower mold 2 is also provided with a guiding groove 7, which is arranged along the edge of the lower cavity 201 and extends outward from the lower cavity 201; the upper mold 1 includes an upper cavity 106 corresponding to and cooperating with the lower cavity 201, and a guiding gap communicating with the guiding groove 7 is formed between the upper cavity 106 and the lower cavity 201. The lower surface of the upper mold 1 tightly covers and closes the guiding groove 7 extending outside the lower cavity 201; several lower limiting members 6 are provided on the outer edge of the lower mold 2 to tightly press against the edge of the upper mold 1, and an inner limiting portion 103 and an outer limiting portion 104 are formed on the upper surface of the upper mold 1. The bottom surface of the lower mold 2 respectively forms an inner pressing portion tightly pressing against the inner limiting portion 103 and an outer pressing portion tightly pressing against the outer limiting portion 104.
[0035] In the foaming mold disclosed in this embodiment, a forming cavity is formed through the lower cavity 201 of the lower mold 2. When the liquid material is poured into the lower cavity 201, it can follow the lower cavity 201 and the guiding groove 7 to form a regular shape. After covering the upper mold 1, the edge of the liquid material is restricted, which is convenient for forming a product 3 that more conforms to the regular shape. As Figure 8 shown, the above-disclosed foaming mold can be stacked longitudinally, that is, after the upper mold 1 and the lower mold 2 are assembled, a lower mold 2 can be continuously placed above the upper mold 1, and an upper mold 1 can be continuously set for mold closing, so the space utilization rate can be improved.
[0036] As Figure 4 shown, the guiding gap formed between the upper mold 1 and the lower mold 2 can facilitate the pouring material to flow upward into the upper cavity 106 during mold closing, and the pouring material entering the upper cavity 106 can be surface-formed under the blockage of the filter paper.
[0037] In some solutions, the number of lower cavities 201 provided in the lower mold 2 can be multiple, and the number of upper cavities 106 correspondingly provided in the upper mold 1 also corresponds one by one.
[0038] During the pouring process, in order to make the pouring material flow and form better in the lower cavity 201 and the guiding groove 7, the structure of the mold can be optimized. This embodiment is optimized and one feasible option is adopted: As Figure 5 、 Figure 6As shown, a number of ventilation structures 8 are formed on the mold. The ventilation structures 8 communicate from the lower cavity 201 to the outside of the mold and / or from the guiding groove 7 to the outside of the mold. When adopting the above solution, the ventilation structure 8 includes ventilation grooves or ventilation holes. In some solutions, the ventilation grooves or ventilation holes are arranged at intervals on the edge of the lower cavity 201 and also at intervals along the guiding groove 7, so as to meet the requirements of uniform flow of the casting material for casting molding.
[0039] The upper mold 1 is used to cooperate with the lower mold 2 for mold closing, maintaining the sealing of the forming structure of the lower cavity 201 and the guiding groove 7. It can be constructed in various forms, and its structure is not uniquely limited. In this embodiment, it is optimized and one feasible option is adopted: such as Figure 1 、 Figure 4 As shown, the upper mold 1 includes an inner mold part 101. At least one inner mold part 101 corresponds to the lower cavity 201 and forms an upper cavity 106; the upper mold 1 further includes an outer mold part 102 corresponding and cooperating with the lower limiting member 6. A gap is formed between the inner mold part 101 and the outer mold part 102.
[0040] In order to maintain the relative stability of the inner mold part 101 and the outer mold part 102, the inner mold and the outer mold part 102 are strengthened by adjusting the gap structure: such as Figure 1 、 Figure 2 As shown, reinforcing rib plates are arranged in the gap. One end of the reinforcing rib plate is connected to the inner mold part 101, and the other end is connected to the outer mold part 102. The reinforcing rib plates are arranged at intervals along the extending direction of the gap. When adopting the above solution, the reinforcing rib plates are integrally formed with the inner mold part 101 and the outer mold part 102.
[0041] The gap extends at multiple positions of the upper mold 1. In addition to being arranged at the edge of the upper cavity 106, it is also arranged at other positions of the upper mold 1. Therefore, when extending to different positions, the setting direction of the reinforcing rib plates in the gap is also correspondingly adjusted and changed. Its structure is not uniquely limited. In this embodiment, it is optimized and one feasible option is adopted: the reinforcing rib plates include transverse rib plates 4 and longitudinal rib plates 5. When adopting the above solution, the transverse rib plates 4 and the longitudinal rib plates 5 are both perpendicular to the inner mold part 101 and the outer mold part 102.
[0042] In order to facilitate the foaming of the product 3, the inner mold part 101 can be constructed in various forms, and its structure is not uniquely limited. In this embodiment, it is optimized and one feasible option is adopted: such as Figure 1 As shown, a positioning plate 105 with an inward buckle is formed at the upper end of the inner mold part 101. The positioning plate 105 is used to cooperate with the setting of filter paper. When adopting the above solution, the positioning plate 105 is integrally formed with the inner mold part 101.
[0043] Above the upper mold 1 plate, the lower mold 2 plates can be continuously stacked. The specific stacking structure can adopt various forms, and its structure is not uniquely limited. In this embodiment, optimization is carried out and one of the feasible options is adopted: such as Figure 1 , Figure 4 As shown, the inner limiting portion 103 is formed on the inner mold portion 101, the outer limiting portion 104 is formed on the outer mold portion 102, and both the inner limiting portion 103 and the outer limiting portion include limiting protrusions. When adopting the above scheme, both the inner limiting portion 103 and the outer limiting portion 104 are annular convex strips. In some schemes, they can be polygonal convex strips, and in other schemes, they can also be circular convex strips.
[0044] After pouring the product 3 into the lower cavity 201 and curing and forming, demolding is required. In order to improve the convenience of demolding, the lower cavity 201 can be optimized and adjusted. Specifically, various schemes can be adopted. In this embodiment, optimization is carried out and one of the feasible options is adopted: an inner coating is provided in the lower cavity 201, and the inner coating is used to keep the inner wall of the lower cavity 201 smooth. When adopting the above scheme, the inner coating can improve the demolding efficiency, avoid using demolding agents, and also reduce costs.
[0045] When the upper mold 1 is stacked on the lower mold 2, the positions need to be aligned and kept stable. Therefore, the matching structure of the upper mold 1 and the lower mold 2 can be adjusted. In this embodiment, optimization is carried out and one of the feasible options is adopted: as Figure 1 shown, the lower limiting member 6 includes a plurality of limiting plates, and the limiting plates are arranged at intervals along the outer edge of the lower mold 2 and are used to fit and press against the outer edge of the upper mold 1. When adopting the above scheme, the limiting plates can be integrally formed with the lower mold 2.
[0046] Embodiment 2 The content of the above Embodiment 1 discloses a foaming mold. This embodiment also provides a foaming method, which will be described below.
[0047] A new type of filter element foaming method, using the foaming mold described above, includes: S01: Configure the foaming mold, select the corresponding upper mold 1 and lower mold 2 for matching settings; S02: Mix the PUA material and the PUB material in proportion and inject them into the lower cavity 201 of the lower mold 2; S03: Set a filter paper in the upper cavity 106 of the upper mold 1 and cover the upper mold 1 on the lower mold 2; S04: After the upper mold 1 and the lower mold 2 are closed, place them in a circular flow transfer press and apply pressure; S05: Control the movement of the circular flow transfer press to cure the mixture, and the production of the filter element is completed.
[0048] Preferably, in this embodiment, both the upper mold 1 and the lower mold 2 are made of plastic.
[0049] Preferably, in this embodiment, the raw materials are injected into the lower cavity 201 through a mixer.
[0050] The above are the implementation manners listed in this embodiment. However, this embodiment is not limited to the above optional implementation manners. Those skilled in the art can obtain many other implementation manners by arbitrarily combining the above manners. Anyone can obtain various other forms of implementation manners under the inspiration of this embodiment. The above specific implementation manners should not be construed as limiting the protection scope of this embodiment. The protection scope of this embodiment shall be defined by the claims.
Claims
1. A new type of filter element foaming mold, characterized in that: It includes an upper mold (1) and a lower mold (2) arranged in a stacked manner. The lower mold (2) is provided with a lower cavity (201) for forming a product (3). The lower mold (2) is also provided with a guiding groove (7), and the guiding groove (7) is arranged along the edge of the lower cavity (201) and extends to the outside of the lower cavity (201). The upper mold (1) includes an upper cavity (106) corresponding to and cooperating with the lower cavity (201). A guiding gap communicating with the guiding groove (7) is formed between the upper cavity (106) and the lower cavity (201). The lower surface of the upper mold (1) tightly covers and seals the guiding groove (7) extending to the outside of the lower cavity (201). A plurality of lower limiting members (6) are provided on the outer edge of the lower mold (2) to tightly press against the edge of the upper mold (1). The upper surface of the upper mold (1) forms an inner limiting portion (103) and an outer limiting portion (104). The bottom surface of the lower mold (2) respectively forms an inner pressing portion tightly cooperating with the inner limiting portion (103) and an outer pressing portion tightly cooperating with the outer limiting portion (104).
2. The novel filter element foaming mold according to claim 1, wherein: A plurality of ventilation structures (8) are formed on the mold. The ventilation structures (8) communicate from the lower cavity (201) to the outside of the mold, and / or communicate from the guiding groove (7) to the outside of the mold.
3. The novel filter element foaming mold according to claim 1, wherein: The upper mold (1) includes an inner mold part (101). At least one inner mold part (101) corresponds to the lower cavity (201) and forms an upper cavity (106). The upper mold (1) also includes an outer mold part (102) corresponding to and cooperating with the lower limiting member (6). A gap is formed between the inner mold part (101) and the outer mold part (102).
4. The novel filter element foaming mold according to claim 3, characterized in that: Reinforcing rib plates are arranged in the gap. One end of the reinforcing rib plate is connected to the inner mold part (101), and the other end is connected to the outer mold part (102). The reinforcing rib plates are arranged at intervals along the extending direction of the gap.
5. The novel filter element foaming mold according to claim 4, characterized in that: The reinforcing rib plates include transverse rib plates (4) and longitudinal rib plates (5).
6. The novel filter element foaming mold according to claim 3, wherein: An inwardly buckled positioning plate (105) is formed at the upper end of the inner mold part (101), and the positioning plate (105) is used for cooperatively arranging a filter paper.
7. The novel filter element foaming mold according to claim 3 or 4, characterized in that: The inner limiting portion (103) is formed on the inner mold part (101), and the outer limiting portion (104) is formed on the outer mold part (102). Both the inner limiting portion (103) and the outer limiting portion include limiting protrusions.
8. The novel filter element foaming mold according to claim 1, wherein: An inner coating is provided in the lower cavity (201), and the inner coating is used to keep the inner wall of the lower cavity (201) smooth.
9. The novel filter element foaming mold according to claim 1, characterized in that: The lower limiting member (6) includes a plurality of limiting plates, and the limiting plates are arranged at intervals along the outer edge of the lower mold (2) and are used for tightly fitting and pressing against the outer edge of the upper mold (1).
10. A new method for foaming a filter element, which uses the foaming mold described in any one of claims 1 to 9, is characterized in that, It includes: Configure a foaming mold, select corresponding upper mold (1) and lower mold (2) for cooperative arrangement; Mix PUA material and PUB material in proportion and inject them into the lower cavity (201) of the lower mold (2); Set a filter paper in the upper cavity (106) of the upper mold (1) and cover the upper mold (1) on the lower mold (2); After the upper mold (1) and the lower mold (2) are closed, place them in a loop-shaped transfer press and apply pressure; Control the movement of the loop-shaped transfer press to cure the mixed material, and thus complete the production of the filter element.