Integrally-molded elbow end cap and gas filter cartridge using the same

Abstract

The utility model discloses an integral moulding elbow pipe end cover and use gas filter core of this end cover relates to motor car filter technical field. The end cover includes air inlet end cover body and flow guide elbow pipe, and the inner connecting surface vertical section of flow guide elbow pipe is right angle shape, makes horizontal core mould and vertical core mould can be taken out from import and export respectively without obstruction, realizes flow guide elbow pipe integral injection molding, air inlet end cover body is equipped with the positioning wide convex rib and spacing narrow convex rib of alternate distribution periphery, realizes multidimensional assembly positioning, and the reinforcing rib is established between flow guide elbow pipe and connecting round plate to promote structural stability. This design eliminates the assembly gap of split type structure, reduces the risk of leakage, reduces the number of mould, shortens the production cycle, and reduces the production cost. The matched gas filter core realizes gas filtration through the filter layer between the center framework and the outer framework, has the advantages of low flow resistance, high filtration efficiency and good assembly precision, and is suitable for vehicle gas filtration system.

Description

Technical Field

[0001] This utility model relates to automotive filter technology, and more particularly to the structure of the filter element end cap of a fuel filter. Background Technology

[0002] In gas filters (especially automotive gas filtration systems), the intake end cap is the core component connecting the gas intake pipe and the filter housing. Its structural design directly affects filtration efficiency, assembly sealing, and production economy.

[0003] like Figure 1 As shown, existing intake end caps typically integrate a guide bend 1 (used to guide the gas smoothly into the filter layer, avoiding uneven filtration caused by airflow impact) and an assembly positioning structure (used for precise docking with the filter housing to ensure no gas leakage). Among them, the arc design of the guide bend 1 is the key to achieving smooth airflow guidance, while the assembly positioning structure is the basis for ensuring the coaxiality and perpendicularity of the end cap and the housing. Together, they determine the overall performance of the filter.

[0004] The inlet axis of the flow guide bend 1 is perpendicular to the axis of the filter element, and the outlet axis of the flow guide bend 1 coincides with the axis of the filter element. The bend of the flow guide bend 1 is arc-shaped. The side wall of the flow guide bend 1 that is relatively closer to the center O of the arc is called the inner arc surface 2, and the side wall of the flow guide bend 1 that is relatively farther from the center O of the arc is called the outer arc surface 3.

[0005] The shortcomings of existing technologies are described below.

[0006] (a) Major shortcomings: Performance and process defects caused by the separate molding of the intake bend.

[0007] Existing intake end caps with guide bends generally adopt a split structure of "end cap body + cover plate", specifically as follows:

[0008] Structural defects: The bent pipe section needs to be assembled by splicing the end cap body and the independent cover plate (the bent pipe section needs to be assembled from two parts, and cannot be formed as one piece), which increases the number of molds (at least two sets of molds) and complicates the assembly process (requiring additional welding or snap-fitting).

[0009] Performance defects: Small gaps may occur at the joints of the separate units due to assembly errors, leading to the risk of gas leakage; after long-term use, the joints may experience sealing failure due to vibration and thermal expansion and contraction, affecting the safety of the filtration system.

[0010] Economic drawbacks: The split molding process extends the production cycle by more than 30% and increases the cost of parts by about 25%.

[0011] The main technical reason for the above-mentioned shortcomings is that existing technologies focus on the compatibility between the "flow guiding function of the arc-shaped bend" and "single-direction core pulling of the mold," assuming that the inside of the bend must be a continuous arc surface to achieve smooth airflow guidance, but ignoring the limitation of the corner structure on the mold core pulling direction—the inner arc surface 2 of the traditional arc corner only allows core pulling in a single direction (vertical or horizontal) (core pulling refers to pulling out the mold that matches the flow guiding bend 1 from inside the flow guiding bend 1), and the inner arc surface 2 of the bend makes it impossible to complete the overall molding by core pulling, so a split design is necessary. Specifically, the flow guiding bend 1 requires two mold bodies: a vertical core mold and a horizontal core mold. Of the two mold bodies, one mold body must match and fit the inner arc surface 2.

[0012] If the horizontal mandrel (which can only be pulled out horizontally from the inlet of the guide bend 1) matches and fits the inner arc surface 2, then in the horizontal rightward direction ( Figure 1 When the core mold is pulled out from the right (in the middle), the horizontal core mold will be blocked by the inner arc surface 2 and cannot be pulled out.

[0013] If the vertical mandrel (which can only be pulled out vertically from the outlet of the guide bend 1) matches and fits the inner arc surface 2, then in the vertical downward direction ( Figure 1 When the vertical core mold is pulled out from the bottom (in the middle), it will be blocked by the inner arc surface 2 and cannot be pulled out.

[0014] This phenomenon means that existing technologies can only produce bent pipe end caps with a split structure of "end cap body + cover plate", and cannot produce bent pipe end caps with an integrated structure (because it would cause one of the two mold bodies, the vertical core mold and the horizontal core mold, to be unable to be extracted). When the bent pipe end cap is opened for extraction during the molding process, and then the bent pipe end cap is bonded or welded to the end cap body, structural defects such as gaps and irregular protrusions are likely to appear at the joint.

[0015] (ii) Minor shortcomings: assembly accuracy defects caused by the single-dimensional design of the positioning structure.

[0016] Existing intake end cap assembly and positioning structures mostly consist of symmetrically distributed ribs or locating pins in a single direction, which can only achieve single-dimensional positioning in the radial (along the axial direction) or circumferential (rotational direction around the axis) direction. Specifically:

[0017] Assembly defects: When there is an angular deviation between the housing and the end cap, single-dimensional positioning cannot limit circumferential or radial offset, resulting in uneven compression of the sealing gasket and further exacerbating the risk of air leakage.

[0018] Efficiency drawback: The need to repeatedly adjust the angle during assembly leads to a longer production line cycle time.

[0019] III. Necessity of Improvement

[0020] In existing technologies, the split-form structure of the intake bend suffers from a contradiction between the arc-shaped airflow guiding function and the limitations of mold core pulling, resulting in relatively poor sealing performance, high cost, and low efficiency. Furthermore, the single-dimensional design of the positioning structure, due to its reliance on traditional error-tolerant mechanisms, is incompatible with the assembly precision requirements of the one-piece molded end cap. As the requirements for safety and economy in automotive gas systems increase, there is an urgent need to overcome these technical bottlenecks through structural innovation: on the one hand, it is necessary to develop a one-piece moldable bend structure to address the inherent defects of the split design; on the other hand, it is necessary to optimize the positioning structure to achieve multi-dimensional precise assembly. Utility Model Content

[0021] The purpose of this utility model is to provide an integrated ejector bend end cap. Its related structure of the flow guide bend ensures that after the flow guide bend is integrally injection molded, both the horizontal core mold and the vertical core mold can be extracted from the flow guide bend without obstruction, so as to produce an integrally molded air inlet end cap with a flow guide bend, avoiding the defects caused by the split connection structure.

[0022] To achieve the above objectives, the present invention provides an integrated ejection bend end cap, comprising an air inlet end cap body, wherein the air inlet end cap body is provided with a flow guide bend, the outlet axis of the flow guide bend is arranged vertically, the inlet axis is arranged horizontally, and the inlet and outlet are connected through the bend; the bend has a center O, the inner wall of the flow guide bend relatively close to the center O is called the inner connecting surface, and the inner wall of the flow guide bend relatively far from the center O is called the outer arc surface, and the vertical cross section of the inner connecting surface is right-angled.

[0023] A connecting circular plate is provided at the top of the vertical section surrounding the guide bend above the intake end cover body. The circumferential surface of the connecting circular plate is provided with an annular groove, which is used to accommodate an annular sealing ring and form a seal between the guide bend and the housing of the gas filter.

[0024] A reinforcing rib is provided between the guide bend and the connecting circular plate.

[0025] The circumferential surface of the air intake end cover body is provided with four positioning ribs, including two wide positioning ribs and two narrow limiting ribs; the wide positioning ribs and the narrow limiting ribs are evenly distributed alternately on the circumferential surface of the air intake end cover body.

[0026] This utility model also discloses a gas filter element using an integrated molded bent tube end cap, including a central frame and an outer frame arranged coaxially, the central frame being fitted inside the outer frame, and a filter layer being provided between the central frame and the outer frame; the central frame and the outer frame are connected downward to a lower end cap, and the central frame and the outer frame are connected upward to an air inlet end cap body, the central frame being connected upward to the outlet of the guide bend tube, and the filtered gas passing through the outer frame to the gas outlet of the gas filter.

[0027] This utility model has the following advantages:

[0028] Improved sealing performance and safety: The integrated flow guide bend structure eliminates the assembly gap at the joint of the "end cap body + cover plate" in the traditional split design, fundamentally reducing the risk of gas leakage; at the same time, it avoids the sealing failure caused by vibration and thermal expansion and contraction during long-term use, significantly improving the safety of the filtration system.

[0029] Simplified production process and reduced costs: The guide bend 1 can be injection molded with a single mold, reducing the number of molds by at least one compared to the traditional split structure. The assembly process is simplified (no welding or snap-fit ​​is required), shortening the production cycle and reducing the cost of parts.

[0030] Optimize assembly accuracy and efficiency: The wide positioning ribs (which can be used to limit radial offset) and the narrow limiting ribs (which can be used to limit circumferential rotation) set in the circumferential direction of the air intake end cover work together to achieve multi-dimensional precise positioning, solve the assembly angle deviation problem caused by traditional single-dimensional positioning, reduce assembly adjustment time, and improve production line cycle time.

[0031] Enhanced structural stability and yield: The reinforcing rib design between the guide bend 1 and the connecting circular plate effectively reduces the probability of deformation during molding after high-temperature injection molding, avoids the reduction in production efficiency due to waiting for cooling, and improves the product yield.

[0032] Improved filtration performance: The right-angled inner connecting surface is not directly facing the intake airflow; instead, the outer arc surface 3 faces the intake airflow. The combination of the outer arc surface 3 of the guide bend 1 and the right-angled inner connecting surface ensures smooth airflow while reducing flow resistance, optimizing the uniformity of gas distribution in the filter layer, and improving filtration efficiency. Attached Figure Description

[0033] Figure 1 This is a cross-sectional structural diagram of a gas filter element with an existing bent pipe end cap.

[0034] Figure 2 This is a cross-sectional structural diagram of a gas filter element using the integrated molded bent tube end cap of this utility model.

[0035] Figure 3 yes Figure 2 Rear view.

[0036] Figure 4 yes Figure 2 A three-dimensional image.

[0037] I. Main structural components of the end cap

[0038] Existing technology flow guide bend (reference numeral 1); This utility model flow guide bend (reference numeral 5); Inlet end cap body (reference numeral 4); Flow guide bend outlet (reference numeral 6); Flow guide bend inlet (reference numeral 7).

[0039] II. Inner wall of the bend and positioning structure components

[0040] The prior art inner arc surface (reference numeral 2); the present invention inner connecting surface (reference numeral 8); the prior art outer arc surface (reference numeral 3); the present invention outer arc surface (reference numeral 9); positioning wide rib (reference numeral 13); limiting narrow rib (reference numeral 14).

[0041] III. End Cap Auxiliary Sealing and Reinforcing Components

[0042] Connecting circular plate (reference numeral 10); annular sealing ring (reference numeral 11); reinforcing rib (reference numeral 12); sealing gasket (reference numeral 19).

[0043] IV. Main structural components of the filter element

[0044] Central frame (reference numeral 15); outer frame (reference numeral 16); filter layer (reference numeral 17); lower end cap (reference numeral 18). Detailed Implementation

[0045] like Figures 2 to 4 As shown, the integrated ejection bend end cap of this utility model includes an air inlet end cap body 4. The air inlet end cap body 4 is provided with a flow guide bend 5. The axis of the outlet 6 of the flow guide bend 5 is arranged vertically, and the axis of the inlet 7 is arranged horizontally. The inlet 7 and the outlet 6 are connected through the bend. The bend has a center O. The inner wall of the flow guide bend 5 that is relatively close to the center O is called the inner connecting surface 8, and the inner wall of the flow guide bend 5 that is relatively far from the center O is called the outer arc surface 9. The vertical cross section of the inner connecting surface 8 is right-angled.

[0046] Figure 2 The red line in the image marks the boundary between the horizontal and vertical core molds during the casting process. This boundary clearly shows that the horizontal core mold only matches and fits with the horizontal segment of the inner connecting surface 8, and the vertical core mold only matches and fits with the vertical segment of the inner connecting surface 8. Whether the horizontal core mold is pulled out to the right or the vertical core mold is pulled out downwards, there will be no obstruction. If in Figure 1 Setting the dividing line between the horizontal and vertical core molds at the same location will cause the horizontal and vertical core molds to be blocked by the inner arc surface 2 when they are pulled out due to the presence of the inner arc surface 2 (both the horizontal and vertical core molds need to match and fit half of the inner arc surface 2). The pulling action can easily damage the guide bend 5 (the guide bend 5 is still in a high temperature and soft state when the mold is pulled out).

[0047] This invention replaces the inner arc surface 2 with a right-angled inner connecting surface 8, so that the horizontal and vertical core molds of the guide bend 5 no longer need to match and fit with the inner arc surface 2 between the horizontal and vertical sections. The horizontal core mold only matches and fits with the horizontal section of the inner wall of the guide bend 5 and the upper part of the outer arc surface 9, and the vertical core mold only matches and fits with the vertical section of the inner wall of the guide bend 5 and the lower part of the outer arc surface 9. In this way, after integral injection molding, the horizontal core mold can be pulled out horizontally from the inlet 7 of the guide bend 5 without obstruction, and the vertical core mold can be pulled out downward from the outlet 6 of the guide bend 5 without obstruction. Thus, it is no longer necessary to set the guide bend 5 as an "end cap body + cover plate" structure, realizing the integral molding of the guide bend, eliminating the assembly gap at the split connection, reducing the risk of leakage, and avoiding the sealing failure at the split connection due to vibration and thermal expansion and contraction during long-term use.

[0048] By adopting this utility model, the number of molds for the flow guide bend 5 is reduced from at least two sets to one set, thereby reducing the assembly process, significantly shortening the production cycle, and reducing the cost of the air outlet end cap and filter element.

[0049] A connecting circular plate 10 is provided at the top of the vertical section surrounding the guide bend 5 above the intake end cover body 4. The circumferential surface of the connecting circular plate 10 is provided with an annular groove, which is used to accommodate the annular sealing ring 11 and form a seal between the guide bend 5 and the housing of the gas filter. The setting of the connecting circular plate 10 and the annular groove facilitates the formation of a sealed assembly between the filter element and the housing of the gas filter.

[0050] A reinforcing rib 12 is provided between the flow guide bend 5 and the connecting circular plate 10. When the flow guide bend 5 is molded after injection molding, it is still at a high temperature and has high flexibility. Without the reinforcing rib 12, the flow guide bend 5 is prone to deformation during molding (if it is allowed to cool down before molding, the waiting time is too long, resulting in low production efficiency). The reinforcing rib 12 can significantly reduce the probability of deformation of the flow guide bend 5 and improve the yield rate.

[0051] The circumferential surface of the air intake end cover body 4 is provided with four positioning ribs, including two wide positioning ribs 13 and two narrow limiting ribs 14; the wide positioning ribs 13 and the narrow limiting ribs 14 are evenly distributed alternately on the circumferential surface of the air intake end cover body 4.

[0052] This utility model uses the positioning wide rib 13 and the limiting narrow rib 14 to cooperate with the corresponding limiting structure on the filter housing and position the air intake end cover body 4. For example, the positioning wide rib 13 limits radial offset and the limiting narrow rib 14 limits circumferential rotation, thus solving the problem of assembly angle deviation caused by traditional single-dimensional positioning.

[0053] The present invention also discloses a gas filter element using the above-mentioned integrated molded bent tube end cap, including a central frame 15 and an outer frame 16 arranged coaxially. The central frame 15 is fitted inside the outer frame 16, and a filter layer 17 is provided between the central frame 15 and the outer frame 16. The central frame 15 and the outer frame 16 are connected downward to a lower end cap 18, and the central frame 15 and the outer frame 16 are connected upward to an air inlet end cap body 4. The central frame 15 communicates upward with the outlet 6 of the guide bend 5, and the filtered gas passes through the outer frame 16 to the gas outlet of the gas filter.

[0054] The assembly process is as follows:

[0055] 1. Pre-installation of filter element unit.

[0056] Assemble the frame and filter layer 17 on the lower end cover 18. Place the central frame 15 in the center, and fill the space between the central frame 15 and the outer frame 16 with filter layer 17 material (such as filter paper or filter screen). Install the outer frame 16, ensuring the inner side of the filter layer 17 is tightly against the outer wall of the central frame 15, and the outer side is fixed to the inner wall of the outer frame 16 (this can be achieved through bonding or welding). The filter layer 17, central frame 15, and outer frame 16 are all bonded to the lower end cover 18.

[0057] The intake end cover is assembled by connecting the bottom of the intake end cover body 4 to the upper end of the filter element body: the upper opening of the central frame 15 is connected to the outlet 6 of the guide bend 5, and the upper surface of the outer frame 16 is sealed to the lower contact surface of the intake end cover body 4 (the seal can be strengthened by sealant or welding).

[0058] An annular sealing ring 11 is embedded in the annular groove of the circular plate 10 connected above the air intake end cover body 4 to ensure that the sealing ring fits the groove wall completely without wrinkles.

[0059] Place the sealing gasket 19 on the sealing gasket mounting surface (located below the sealing groove) of the air intake end cover body 4.

[0060] II. Assembly of the filter element unit and the filter housing (integral insertion and positioning)

[0061] The positioning ribs cooperate with the housing; the pre-assembled filter element unit (including the air inlet end cover, frame, filter layer 17, and lower end cover 18) is vertically placed into the filter housing: the positioning wide rib 13 and the limiting narrow rib 14 cooperate with the corresponding limiting structure on the filter housing and position the air inlet end cover body 4, so as to achieve multi-dimensional precise positioning.

[0062] Sealing and fixing; after the filter element unit is fully inserted into the housing, the annular sealing ring 11 is compressed between the annular groove of the connecting circular plate 10 and the inner wall of the top of the housing, forming a radial seal;

[0063] The air intake end cap is locked to the housing using a snap-fit, bolt, or threaded structure on the top of the housing to ensure that the overall assembly is secure (the specific fixing method needs to be determined according to the housing design).

[0064] After assembly, an airtightness test must be performed (e.g., introduce 0.3MPa compressed air and hold the pressure for 5 minutes without leakage) to ensure that the compression of the annular sealing ring 11 and the sealing gasket meets the design requirements (usually the compression rate is 20%-30%).

[0065] Through the above process, efficient assembly and reliable sealing of the filter element can be achieved, giving full play to the structural advantages of the integrated molded bent tube end cap.

[0066] The working process of this utility model is as follows:

[0067] 1. Gas introduction stage:

[0068] Unfiltered gas enters from the horizontal inlet 7 of the guide bend 5 and flows along the channel formed by the outer arc surface 9 and the right-angle inner connecting surface 8. The inner connecting surface 8 is not directly opposite the flow, and the airflow achieves a smooth transition through the outer arc surface 9 when it turns (from horizontal to vertical), avoiding pressure loss and uneven impact on the filter layer 17 caused by turbulence.

[0069] 2. Filtering stage:

[0070] The gas enters the interior of the central frame 15 through the vertical outlet 6 of the guide bend 5, and then permeates outward through the pores in the wall of the central frame 15 to the filter layer 17. The filter layer 17 filters impurities in the gas.

[0071] 3. Gas output stage:

[0072] The purified gas passes through filter layer 17 and finally flows out through the outlet on the filter housing under the constraint of the filter housing, entering the subsequent gas system. During this process, the multi-dimensional positioning structure of the inlet end cap ensures that there is no relative displacement between the filter element and the housing, and the annular sealing ring 11 and the sealing gasket together ensure that there is no leakage at the connection, achieving a stable and efficient filtration function.

[0073] The above embodiments are only used to illustrate and not limit the technical solutions of this utility model. Although the utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the utility model without departing from the spirit and scope of the utility model. Any modifications or partial substitutions should be covered within the scope of the claims of this utility model.

Claims

1. An integral ejection bend end cap, comprising an air inlet end cap body, wherein the air inlet end cap body is provided with a flow guide bend, the outlet axis of the flow guide bend is arranged vertically, the inlet axis is arranged horizontally, and the inlet and outlet are connected through a bend; the bend has a center O, the inner wall of the flow guide bend relatively close to the center O is called the inner connecting surface, and the inner wall of the flow guide bend relatively far from the center O is called the outer arc surface, characterized in that: The vertical cross-section of the inner connecting surface is right-angled.

2. The integrated demolded bent tube end cap according to claim 1, characterized in that: A connecting circular plate is provided at the top of the vertical section surrounding the guide bend above the intake end cover body. The circumferential surface of the connecting circular plate is provided with an annular groove, which is used to accommodate an annular sealing ring and form a seal between the guide bend and the housing of the gas filter.

3. The integrated demolded bent tube end cap according to claim 2, characterized in that: A reinforcing rib is provided between the guide bend and the connecting circular plate.

4. The integrated demolded bent tube end cap according to claim 1, characterized in that: The circumferential surface of the air intake end cover body is provided with four positioning ribs, including two wide positioning ribs and two narrow limiting ribs; the wide positioning ribs and the narrow limiting ribs are evenly distributed alternately on the circumferential surface of the air intake end cover body.

5. A gas filter element, using the integrated molded bent tube end cap as described in claim 1, characterized in that: It includes a central frame and an outer frame arranged coaxially. The central frame is fitted inside the outer frame, and a filter layer is provided between the central frame and the outer frame. The central frame and the outer frame are connected downward to a lower end cover, and the central frame and the outer frame are connected upward to the air inlet end cover body. The central frame is connected upward to the outlet of the guide bend pipe, and the filtered gas passes through the outer frame to the outlet of the gas filter.

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