Automobile air cleaner with light-weight structure

Abstract

The utility model discloses a kind of automobile air cleaner with light weight structure, air filter upper shell, air filter lower shell and filter core;The cavity for accommodating filter core is provided in the air filter lower shell, and part of main body structure of the air filter upper shell, air filter lower shell is made by carbon fiber material compression bonding.The present scheme combines full carbon fiber and traditional air filter case, forms the light weight automobile air cleaner of half carbon fiber type, to solve the problems, such as the weight of traditional air cleaner is big, durability is poor, and the cost of full carbon fiber air cleaner is high, market acceptance is poor.

Description

Technical Field

[0001] This utility model relates to the field of automotive air filtration technology, and in particular to an automotive air filter with a lightweight structure. Background Technology

[0002] Air filters are an important component of a car engine's intake system, primarily used to filter particulate matter in the air and prevent it from entering the engine and causing wear.

[0003] Currently, automotive air filters typically use paper filter elements and plastic or metal housings. While they offer some filtration, they suffer from drawbacks such as heavy weight, poor durability, and susceptibility to corrosion. With the development of lightweighting technologies in the automotive industry, reducing the weight of air filters has become an industry trend. Carbon fiber composites, due to their high strength, low density, and corrosion resistance, have become an ideal material for lightweight design. However, for air filters made entirely of carbon fiber, especially for complex structural components, the cost is too high, making them unfriendly to the market. Therefore, considering both full carbon fiber and traditional air filters, this paper explores the possibility of fabricating carbon fiber materials into injection-molded inserts for use in air filters, creating a semi-carbon fiber product. Utility Model Content

[0004] The purpose of this invention is to provide an automotive air filter with a lightweight structure to address the above-mentioned shortcomings, thus solving the problems of heavy weight and poor durability of traditional air filters, and high cost and poor market acceptance of all-carbon fiber air filters.

[0005] This utility model is achieved through the following solution:

[0006] A lightweight automotive air filter includes an upper air filter housing, a lower air filter housing, and a filter element; the lower air filter housing has a cavity for accommodating the filter element, and parts of the main structure of the upper and lower air filter housings are made of carbon fiber material.

[0007] Based on the above-mentioned structure of a lightweight automotive air filter, the upper housing of the air filter includes an air intake chamber, an air intake pipe, and a connecting frame; the air intake chamber and the air intake pipe are integrally formed, the air intake pipe is located at the circumferential position at the bottom of the air intake chamber, and the connecting frame is provided with a first mating part for fixing to the lower housing of the air filter.

[0008] Based on the above-mentioned structure of a lightweight automotive air filter, the air intake chamber and air intake pipe are made of carbon fiber material, and the connecting frame is fixedly connected to the bottom of the air intake chamber by injection molding.

[0009] Based on the above-described structure of a lightweight automotive air filter, the air intake chamber specifically includes a supporting base frame, a first vertical plate, a second supporting vertical plate, a first side plate, a second side plate, and an inclined plate; the first vertical plate and the second vertical plate are arranged in parallel, the first side plate and the second side plate are arranged in parallel, and the first side plate and the second side plate are disposed between the first vertical plate and the second vertical plate; the first vertical plate, the second supporting vertical plate, the first side plate, and the second side plate are all perpendicular to the supporting base frame, and the inclined plate is disposed on the end face of the first vertical plate, the second supporting vertical plate, the first side plate, and the second side plate away from the supporting base frame.

[0010] Based on the above-mentioned structure of a lightweight automotive air filter, the length of the first vertical plate is not greater than the length of the second vertical plate, and the projection of the first side plate and the second side plate in the vertical plane is a triangular structure; the air intake pipe is disposed on the end of the first side plate near the second vertical plate.

[0011] Based on the above-mentioned structure of a lightweight automotive air filter, the supporting base frame is generally rectangular, and a first adhesive permeation hole is provided on the circumferential position of the supporting base frame; the first adhesive permeation hole is evenly spaced in a plurality on the supporting base frame.

[0012] Based on the structure of the lightweight automotive air filter described above, the first mating part is a first threaded hole, and multiple first threaded holes are evenly arranged along the circumferential position of the support frame.

[0013] Based on the above-mentioned structure of a lightweight automotive air filter, the lower housing of the air filter includes an air outlet chamber, an air outlet pipe, and a fixing frame; the air outlet pipe is disposed on the air outlet chamber, the fixing frame is disposed at the top of the air outlet chamber, and auxiliary supports are disposed in different directions on the fixing frame; the fixing frame is also provided with a second mating part that cooperates with the first mating part.

[0014] Based on the above-mentioned lightweight automotive air filter structure, the air outlet chamber and air outlet pipe are made of carbon fiber material, and the fixing frame and auxiliary bracket are fixedly connected to the top of the air outlet chamber by injection molding.

[0015] Based on the structure of the lightweight automotive air filter described above, a second adhesive perforation hole is provided on the connection between the air outlet chamber and the fixed frame, and multiple second adhesive perforation holes are provided along the circumferential position of the air outlet chamber.

[0016] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0017] 1. This solution uses carbon fiber material to press together the main structure of the upper and lower housings of the air filter, which can greatly reduce the weight of the car air filter and improve fuel efficiency. It is lighter than traditional paper filter elements and plastic or metal shells. At the same time, it is simpler to manufacture and lower in cost than air filters made entirely of carbon fiber material. It is a compromise optimization solution.

[0018] 2. This solution is low-cost and lightweight: It adopts a composite mode of semi-carbon fiber and plastic injection molding, which reduces the weight of the traditional air filter plastic shell by more than 40%, which is conducive to reducing the overall vehicle weight and improving fuel efficiency.

[0019] 3. High market acceptance: The design structure takes into account a low-cost strategy. This structural form can not only meet the requirements of automotive lightweighting, but also improve the aesthetics of the product, while taking into account the convenience of maintenance and repair, which is conducive to the overall market acceptance. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of the entire utility model;

[0021] Figure 2 This is a cross-sectional structural diagram of the entire utility model;

[0022] Figure 3 This is a schematic diagram of the structure of the first adhesive-permeable hole in this utility model;

[0023] Figure 4 This is a schematic diagram of the structure of the second adhesive perforation hole in this utility model;

[0024] Figure Descriptions: 1. Upper housing of air filter; 2. Lower housing of air filter; 3. Filter element; 11. Inlet chamber; 12. Inlet pipe; 13. Connecting frame; 14. First mating part; 111. Supporting bottom frame; 112. First vertical plate; 113. Second vertical plate; 114. First side plate; 115. Second side plate; 116. Inclined plate; 117. First adhesive perforation hole; 21. Outlet chamber; 22. Outlet pipe; 23. Fixing frame; 24. Second mating part; 25. Second adhesive perforation hole; 26. Auxiliary bracket; 27. Bottom support frame. Detailed Implementation

[0025] All features disclosed in this specification, or all steps in all disclosed methods or processes, may be combined in any way, except for mutually exclusive features and / or steps.

[0026] Any feature disclosed in this specification (including any appended claims and abstract) may be replaced by other equivalent or similar features, unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is merely one example of a series of equivalent or similar features.

[0027] In the description of this utility model, it should be understood that the terms "upper", "lower", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0028] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature.

[0029] Example 1

[0030] like Figures 1-4 As shown, this utility model provides a technical solution:

[0031] An automotive air filter with a lightweight structure includes, but is not limited to, an upper air filter housing 1, a lower air filter housing 2, and a filter element 3; the lower air filter housing 2 has a cavity for accommodating the filter element 3, and a portion of the main structure of the upper air filter housing 1 and the lower air filter housing 2 is made of carbon fiber material.

[0032] Based on the above structure, this solution uses carbon fiber material to press together the main structure of the upper housing 1 and the lower housing 2 of the air filter. This can greatly reduce the weight of the car air filter and improve fuel efficiency. Compared with traditional paper filter element 3 and plastic or metal shell, it is lighter in weight. At the same time, compared with air filters made of all carbon fiber materials, it is simpler to manufacture and has a lower cost. It is a compromise optimization solution.

[0033] As an example, the upper housing 1 of the air filter may include an air intake chamber 11, an air intake pipe 12 and a connecting frame 13; the air intake chamber 11 and the air intake pipe 12 are integrally formed, the air intake pipe 12 is located at the circumferential position at the bottom of the air intake chamber 11, and the connecting frame 13 is provided with a first mating part 14 for fixing to the lower housing 2 of the air filter.

[0034] Based on the above structure, external gas enters the intake chamber 11 from the intake pipe 12, is temporarily stored in the intake chamber 11, and finally passes through the filter element 3 before being discharged into the engine from the lower housing 2 of the air filter. By setting the first mating part 14, the upper housing 1 of the air filter and the lower housing 2 of the air filter can be quickly assembled.

[0035] As an example, the air intake chamber 11 and the air intake pipe 12 are made of carbon fiber material and the connecting frame 13 is fixedly connected to the bottom of the air intake chamber 11 by injection molding.

[0036] The air intake chamber 11 may specifically include a supporting base frame 111, a first vertical plate 112, a second supporting vertical plate 113, a first side plate 114, a second side plate 115, and an inclined plate 116; the first vertical plate 112 and the second vertical plate are arranged in parallel, the first side plate 114 and the second side plate 115 are arranged in parallel, and the first side plate 114 and the second side plate 115 are located between the first vertical plate 112 and the second vertical plate; the first vertical plate 112, the second supporting vertical plate 113, the first side plate 114, and the second side plate 115 are all arranged perpendicular to the supporting base frame 111, and the inclined plate 116 is located on the end face of the first vertical plate 112, the second supporting vertical plate 113, the first side plate 114, and the second side plate 115 away from the supporting base frame 111.

[0037] The length of the first vertical plate 112 is not greater than the length of the second vertical plate. The projections of the first side plate 114 and the second side plate 115 in the vertical plane are triangular structures. The air intake pipe 12 is located on the end of the first side plate 114 near the second vertical plate.

[0038] Based on the above structure, by specially setting the air intake chamber 11, the entire air intake structure presents a structure where the cavity near the air intake pipe 12 is large and the cavity away from the air intake pipe 12 is small, thus enabling efficient air intake and filtration. The main structure is relatively simple, so carbon fiber is used for pressing, which can effectively reduce costs. The relatively complex connecting frame 13 and the first mating part 14 are made by injection molding, which can effectively reduce the manufacturing difficulty and processing cost, making the semi-carbon fiber structure more cost-effective.

[0039] As an example, the support base frame 111 is a rectangular structure, and a first adhesive penetration hole 117 is provided in the circumferential position of the support base frame 111; the first adhesive penetration hole 117 is evenly spaced in multiple places on the support base frame 111.

[0040] Based on the above structure, since the connecting frame 13 needs to be connected to the supporting base frame 111 by injection molding, in order to ensure the stability of the connection, multiple first through-holes 117 are provided on the supporting base frame 111. This can improve the injection molding and encapsulation capabilities when the connecting frame 13 is injection molded, making the connection between the two more stable.

[0041] As an example, the first mating part 14 can be a first threaded hole, and multiple first threaded holes are evenly arranged at the circumferential position of the support frame.

[0042] Based on the above structure, the upper housing 1 and the lower housing 2 of the air filter can be quickly connected by a threaded connection.

[0043] As an example, the lower housing 2 of the air filter may include an air outlet chamber 21, an air outlet pipe 22, and a fixing frame 23; the air outlet pipe 22 is disposed on the air outlet chamber 21, the fixing frame 23 is disposed at the top of the air outlet chamber 21, and auxiliary supports 26 are disposed in different directions of the fixing frame 23; the fixing frame 23 is also provided with a second mating part 24 that cooperates with the first mating part 14.

[0044] Based on the above structure, the filter element 3 is located at the top of the air outlet chamber 21. The gas to be filtered passes through the filter element 3 and is filtered, then temporarily stored in the air outlet chamber 21, and finally discharged through the air outlet pipe 22. The fixing frame 23 is used to fix it to the upper housing 1 of the air filter and the auxiliary support 26.

[0045] As an example, the air outlet chamber 21 and the air outlet pipe 22 are made of carbon fiber material, and the fixing frame 23 and the auxiliary bracket 26 are fixedly connected to the top of the air outlet chamber 21 by injection molding.

[0046] Based on the above structure, this solution uses carbon fiber material to press together the main body of the air filter upper shell 1 and air filter lower shell 2, which have simple structures, while the other complex parts are formed by injection molding. This can reduce the overall weight and reduce the overall manufacturing cost.

[0047] As an example, the overall structure of the air outlet chamber 21 is similar to that of the air inlet chamber 11, and will not be described in detail here. A second adhesive penetration hole 25 is provided on the connection between the air outlet chamber 21 and the fixing frame 23. Multiple second adhesive penetration holes 25 are provided along the circumferential position of the air outlet chamber 21.

[0048] Based on the above structure, multiple second through-holes 25 are provided on the air outlet chamber 21, which can improve the injection molding and encapsulation capabilities of the fixed frame 23 during injection molding, making the connection between the fixed frame 23 and the lower housing 2 of the air filter more stable.

[0049] As an example, a bottom support frame 27 is also provided at the bottom of the lower housing 2 of the air filter. This solution is supported by the bottom support frame 27 and two auxiliary support frames.

[0050] The preparation method of this solution is as follows: Air filter upper housing 1: A simple-shaped insert is made of carbon fiber composite material. Through holes are machined around the edge of the insert to improve the overmolding strength. Then, the insert is placed in a plastic injection mold and overmolding is performed to solve the molding of complex parts (such as housing mounting structure, sealing structure, etc.).

[0051] Filter element 3: The same filter element 3 used in the market is adopted to ensure cost control and improve market acceptance.

[0052] Air filter lower housing 2: A simple-shaped insert is made of carbon fiber composite material. Through holes are machined around the edge of the insert to improve the overmolding strength. Then, the insert is placed in a plastic injection mold for injection molding to solve the molding of complex parts (such as housing mounting structure, sealing structure, etc.).

[0053] Other parts: Use market-available components to ensure cost control and increase market acceptance.

[0054] Manufacturing method:

[0055] (1) Preparation of carbon fiber insert for upper housing of air filter: carbon fiber prepreg is placed in a vacuum mold and hot-pressed to form carbon fiber insert housing. After cooling, it is taken out from the mold and the edge of the housing is opened to leave it for injection molding structure to improve the connection strength.

[0056] (2) Preparation of the upper shell 1 of the air filter: The part after the opening treatment in (1) is placed in a plastic injection mold, and the plastic particles are injection molded into one piece under high temperature and high pressure. During the molding process, the plastic particles in the molten state generate a certain clamping force with the carbon fiber insert, and at the same time, the plastic particles also form a "hook" structure through additional openings to further improve the connection strength.

[0057] (3) Preparation of carbon fiber insert for lower housing of air filter: carbon fiber prepreg is placed in a vacuum mold and hot-pressed to form carbon fiber insert housing. After cooling, it is taken out from the mold and the edge of the housing is opened to leave it for injection molding structure to improve the connection strength.

[0058] (4) Preparation of the lower housing 2 of the air filter: The part after the opening treatment in (3) is placed in a plastic injection mold, and the plastic particles are injection molded into one piece under high temperature and high pressure. During the molding process, the plastic particles in the molten state generate a certain clamping force with the carbon fiber insert, and at the same time, the plastic particles also form a "hook" structure through additional openings to further improve the connection strength.

[0059] (5) Assembly: Assemble the general parts: filter element 3 (foamed filter element 3, injection molded filter element 3, etc.), self-tapping screws (connection structure between upper and lower housings, not limited to self-tapping screw connection) and rubber pads, bushings, etc. (auxiliary installation parts) to complete the semi-carbonized air filter assembly product.

[0060] (6) Performance verification: The semi-carbon fiber air filter assembly is tested for filtration efficiency, system resistance and system durability to ensure that it meets the design objectives.

[0061] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A lightweight automotive air filter, characterized in that: It includes an upper housing (1) of an air filter, a lower housing (2) of an air filter, and a filter element (3); the lower housing (2) of the air filter is provided with a cavity for accommodating the filter element (3), and part of the main structure of the upper housing (1) and the lower housing (2) of the air filter is made of carbon fiber material.

2. The automotive air filter with a lightweight structure as described in claim 1, characterized in that: The upper housing (1) of the air filter includes an air inlet chamber (11), an air inlet pipe (12) and a connecting frame (13); the air inlet chamber (11) and the air inlet pipe (12) are integrally formed, the air inlet pipe (12) is located at the circumferential position at the bottom of the air inlet chamber (11), and the connecting frame (13) is provided with a first mating part (14) for fixing to the lower housing (2) of the air filter.

3. The automotive air filter with a lightweight structure as described in claim 2, characterized in that: The air intake chamber (11) and air intake pipe (12) are made of carbon fiber material and the connecting frame (13) is fixedly connected to the bottom of the air intake chamber (11) by injection molding.

4. The automotive air filter with a lightweight structure as described in claim 3, characterized in that: The air intake chamber (11) specifically includes a supporting base frame (111), a first vertical plate (112), a second supporting vertical plate (113), a first side plate (114), a second side plate (115), and an inclined plate (116); the first vertical plate (112) and the second vertical plate are arranged in parallel, the first side plate (114) and the second side plate (115) are arranged in parallel, and the first side plate (114) and the second side plate (115) are arranged between the first vertical plate (112) and the second vertical plate; the first vertical plate (112), the second supporting vertical plate (113), the first side plate (114), and the second side plate (115) are all arranged perpendicular to the supporting base frame (111), and the inclined plate (116) is arranged on the end face of the first vertical plate (112), the second supporting vertical plate (113), the first side plate (114), and the second side plate (115) away from the supporting base frame (111).

5. A lightweight automotive air filter as described in claim 4, characterized in that: The length of the first vertical plate (112) is not greater than the length of the second vertical plate. The projection of the first side plate (114) and the second side plate (115) in the vertical plane is a triangular structure. The air intake pipe (12) is located on the end of the first side plate (114) near the second vertical plate.

6. The automotive air filter with a lightweight structure as described in claim 5, characterized in that: The supporting base frame (111) is a rectangular structure, and a first adhesive permeable hole (117) is provided in the circumferential position of the supporting base frame (111); the first adhesive permeable hole (117) is evenly spaced in multiple places on the supporting base frame (111).

7. A lightweight automotive air filter as described in claim 6, characterized in that: The first mating part (14) is a first threaded hole, and the first threaded hole is evenly arranged in multiple positions along the circumferential position of the support frame.

8. The automotive air filter with a lightweight structure as described in claim 7, characterized in that: The lower housing (2) of the air filter includes an air outlet chamber (21), an air outlet pipe (22), and a fixing frame (23); the air outlet pipe (22) is disposed on the air outlet chamber (21), the fixing frame (23) is disposed at the top of the air outlet chamber (21), and auxiliary supports (26) are disposed on the fixing frame (23) in different directions; the fixing frame (23) is also provided with a second mating part (24) that works in conjunction with the first mating part (14).

9. A lightweight automotive air filter as described in claim 8, characterized in that: The air outlet chamber (21) and air outlet pipe (22) are made of carbon fiber material and the fixed frame (23) and auxiliary bracket (26) are fixedly connected to the top of the air outlet chamber (21) by injection molding.

10. A lightweight automotive air filter as described in claim 9, characterized in that: A second adhesive perforation hole (25) is provided on the connection between the air outlet cavity (21) and the fixed frame (23), and multiple second adhesive perforation holes (25) are provided along the circumferential position of the air outlet cavity (21).

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