Air filter element for a motor vehicle

Abstract

The utility model relates to a new structure air filter element for car, including polyurethane outer frame and the filter core connected in the outer frame, the filter core is by filter paper folding and constitutes, at least one plastic support strip perpendicular with filter paper folding direction is adhered on the air outlet surface of filter core through hot melt adhesive. The plastic support strip is by semicircle annular support strip and the rectangle reinforcing rib of connection on semicircle annular support strip upper end constitutes, the plastic support strip is adhered on the filter core through hot melt adhesive filled in semicircle annular support strip. The utility model increases the plastic support strip on the air outlet surface of filter core to increase the structural strength of filter core, to satisfy the requirement of filter core wet capacity, and the plastic support strip adapts various size filter core, once opens the mould, can satisfy various filter core demand, and the mould cost is low.

Description

Technical Field

[0001] This utility model relates to a novel structure for automotive air filters. Background Technology

[0002] Traditional automotive air filters typically consist of a polyurethane (PU) frame and filter paper. With continuous improvements in automotive engines and varying vehicle operating environments, major automakers now have very sophisticated requirements for the structure and performance of automotive air filters. Therefore, in recent years, automakers have imposed requirements on the moisture resistance of automotive filters, demanding that the filter not crack or collapse after being submerged in water for four hours, and that it not exhibit severe wrinkling or bending after a water spray test. To ensure the filter does not deform after submersion or water spray testing, many manufacturers improve the moisture resistance of the filter paper or add metal or plastic mesh to the air outlet surface to enhance the filter's structural strength. However, due to the increasing horsepower and intake airflow of many modern engine models, simply improving the moisture resistance of the filter paper is insufficient to meet the moisture resistance test requirements. Generally, adding metal or plastic mesh is used to meet these requirements. If a metal mesh filter is used, there is a risk of rust; therefore, the metal mesh must meet salt spray test requirements. This approach increases the cost of cutting, electroplating, and bonding processes, as well as the cost of the salt spray test. If plastic mesh is used, an injection mold is required. Moreover, the size of the plastic mesh is fixed, and the mold must be custom-made and cannot be borrowed, resulting in a large mold-making cost.

[0003] Chinese utility model patent 201720388558.0 discloses an air filter element, including a filter paper core installed in a PU fixing frame. A stabilizing paper strip is provided at the center of the back of the filter paper core, perpendicular to the folding direction. Rear adhesive strips are provided on both sides of the stabilizing paper strip, parallel to it. The stabilizing paper strip on the back of the filter paper core is added to ensure key assembly dimensions and make the filter paper core more neatly arranged. The rear adhesive strips provide stability to the entire filter paper core, preventing deformation. However, this patented structure still cannot increase the filter paper's resistance to deformation when wet or soaked, because the paper strip and adhesive strip soften after soaking in water, failing to provide effective support. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to provide a new structure of automotive air filter element. The air filter element has a plastic support strip added to the air outlet surface to increase the structural strength of the filter element, so as to meet the requirements of the filter element's moisture resistance. Moreover, the plastic support strip is compatible with filter elements of various sizes. It can meet the needs of various filter elements with one mold and the mold opening cost is low.

[0005] The technical solution to the above technical problems is: a new structure of automotive air filter element, including a polyurethane outer frame and a filter element connected in the outer frame. The filter element is made of folded filter paper, and at least one plastic support strip perpendicular to the folding direction of the filter paper is bonded to the air outlet surface of the filter element by hot melt adhesive.

[0006] Furthermore, the plastic support strip is composed of a semi-circular support strip and a rectangular reinforcing rib connected to the upper end of the semi-circular support strip. The plastic support strip is bonded to the filter element by hot melt adhesive filled inside the semi-circular support strip.

[0007] Furthermore, the outer diameter of the semi-circular support strip is 9.5-10.5mm, the thickness is 1.5-2.5mm, and the cross-sectional dimensions of the rectangular reinforcing rib are (1.5-2.5)×(1.5-2.5)mm.

[0008] Furthermore, at least one hot melt adhesive strip perpendicular to the folding direction of the filter paper is provided on the air inlet surface of the filter element.

[0009] By adopting the above technical solution, this utility model has the following beneficial effects: 1. A high-strength plastic support strip is bonded to the air outlet (clean side) of this filter element to increase its structural strength. This plastic support strip will not soften when wetted or submerged in water, and can always provide sufficient support strength to meet the filter element's moisture-bearing capacity requirements. The plastic support strip is composed of a semi-circular support strip and a rectangular reinforcing rib. Hot melt adhesive is filled into the semi-circular groove of the semi-circular support strip before it is bonded to the air outlet surface of the filter element, ensuring the stability of the plastic support strip's adhesion. This allows the semi-circular support strip to be firmly bonded to the filter element. Combined with the rectangular reinforcing rib, it provides sufficient support to the filter element under wetted or submerged conditions, ensuring that the filter element will not arch, wrinkle, or bend.

[0010] 2. The novel automotive air filter element structure of this invention effectively avoids the cumbersome processes, electroplating, and testing costs associated with metal mesh, as well as the limitations of plastic mesh, where a single mold can only meet the needs of one type of filter element, resulting in high manufacturing costs. In contrast, the plastic support strip of this invention is adaptable to various filter element sizes. It can be cut to fit different filter element dimensions, requiring only one mold to meet various filter element needs. This design is convenient, flexible, low-cost, easy to operate, and highly adaptable, aligning with lean manufacturing principles.

[0011] The technical features of the novel automotive air filter of this utility model will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0012] Figure 1 Top view of the novel automotive air filter of this utility model.

[0013] Figure 2 : Figure 1 AA sectional view.

[0014] Figure 3 : Front view of the plastic support strip of Embodiment 1 of this utility model.

[0015] Figure 4 : Figure 3 BB cross-sectional view.

[0016] In the diagram: 1-Polyurethane outer frame, 2-Filter element, 3-Plastic support strip, 31-Semi-circular support strip, 32-Rectangular reinforcing rib, 4-Hot melt adhesive. Detailed Implementation

[0017] This section will describe in detail the specific embodiments of the present utility model. The preferred embodiments of the present utility model are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present utility model, but they should not be construed as limiting the scope of protection of the present utility model.

[0018] Example 1: A novel structure for automotive air filters, such as... Figures 1-4 As shown, the filter includes a polyurethane outer frame 1 and a filter element 2 connected within the frame. The filter element 2 is constructed from folded filter paper. A plastic support strip 3, perpendicular to the folding direction of the filter paper, is bonded to the center of the air outlet surface of the filter element 2 using hot melt adhesive. The plastic support strip consists of a semi-circular ring support strip 31 and a rectangular reinforcing rib 32 connected to the upper end of the semi-circular ring support strip. The semi-circular ring support strip 31 and the rectangular reinforcing rib 32 are integrally molded. The plastic support strip is bonded to the filter element using hot melt adhesive 4 filled in the lower groove of the semi-circular ring support strip 31. The outer diameter of the semi-circular ring support strip is 10mm, and its thickness is 2mm. The cross-sectional dimensions of the rectangular reinforcing rib are 2×2mm. The plastic support strip is designed to be 350mm long, which meets the dimensions of over 98% of filter elements on the market. The required length is obtained by cutting to fit the filter element.

[0019] As a variation of this embodiment, two hot melt adhesive strips perpendicular to the folding direction of the filter paper can also be provided on the air inlet surface of the filter element, with the two hot melt adhesive strips being parallel to each other. The main function of providing the hot melt adhesive strips is to shape the filter element and make it stand up.

[0020] As a variation of this embodiment, the number of plastic support strips 3 is adjusted and determined according to the width of the filter element. Two or three plastic support strips can be evenly bonded to the filter paper to enhance the structural strength of the filter element and meet the requirements of moisture resistance.

[0021] Moisture-bearing capacity comparison test: Test example: The filter element described in Example 1 is used, and two hot melt adhesive strips perpendicular to the folding direction of the filter paper are provided on the air inlet surface of the filter element. The two hot melt adhesive strips are parallel to each other.

[0022] Comparative example: Its structure differs from the test example in that it does not have plastic support strips.

[0023] (1) Water immersion test: The original air intake resistance of the filter element was measured at the rated flow rate of 485 kg / h; the filter element was soaked in room temperature water for 4 hours; the filter element was removed and drained for 15 minutes before being put into an air filter; the filter element was dried with 1.2 times the rated flow rate; e) The filter element resistance was measured at the rated flow rate.

[0024] Requirements: The filter paper and sealant must not be cracked or collapsed; at the rated flow rate, the filter element resistance increase should not exceed 0.5 kPa.

[0025] Test results: The air inlet surface of the comparative sample showed obvious collapse and bending, and the air outlet surface showed obvious arching. The water resistance of the comparative sample did not meet the requirements of the industry standard.

[0026] No obvious cracking, collapse, or arching was observed on the air inlet and outlet surfaces of the test example. Furthermore, the filter element resistance increment was no more than 0.5 kPa at the rated flow rate. The water immersion performance of the test example met the requirements of the industry standard, indicating that the plastic support strip in the test example effectively increased the strength of the filter element when immersed in water.

[0027] (2) Water spray resistance test: At the rated flow rate, add water with a water gun at a distance of 40 mm upstream of the air inlet pipe, with a water concentration of 50 g / m³. 3 Based on a filter area of ​​1.18m² 2 The total water consumption is 1.18L (1L / m²). 2 Add water.

[0028] Requirements: After passing the water spray test, there should be no cracking of the filter paper, detachment of the filter element sealing seat from the filter paper, or adhesive detachment. The filtration performance should meet the requirements of this standard.

[0029] Subjective evaluation is also required: slight wrinkles are allowed on the dirty air side of the filter element, but severe wrinkles or bends are not allowed, and deformation is not allowed on the clean air side of the filter element.

[0030] Test results: The comparative sample showed obvious collapse, wrinkles or bending on the air inlet and outlet surfaces, and the water resistance of the comparative sample did not meet the requirements of the industry standard.

[0031] No obvious cracks, collapses, wrinkles or bends were observed on the air inlet and outlet surfaces of the test example. The water resistance of the test example met the requirements of the industry standard, indicating that the plastic support strip in the test example effectively increased the strength of the filter element under water spray conditions.

Claims

1. A novel automotive air filter element, comprising a polyurethane outer frame (1) and a filter element (2) connected within the outer frame, wherein the filter element is constructed from folded filter paper, characterized in that: At least one plastic support strip (3) perpendicular to the folding direction of the filter paper is bonded to the air outlet surface of the filter element by hot melt adhesive.

2. The novel automotive air filter element according to claim 1, characterized in that: The plastic support strip is composed of a semi-circular ring support strip (31) and a rectangular reinforcing rib (32) connected to the upper end of the semi-circular ring support strip. The plastic support strip is bonded to the filter element by hot melt adhesive filled in the semi-circular ring support strip.

3. The novel automotive air filter element according to claim 2, characterized in that: The outer diameter of the semi-circular support bar is 9.5-10.5mm, and the thickness is 1.5-2.5mm. The cross-sectional dimensions of the rectangular reinforcing rib are (1.5-2.5)×(1.5-2.5)mm.

4. The novel automotive air filter element according to claim 2, characterized in that: At least one hot melt adhesive strip perpendicular to the folding direction of the filter paper is provided on the air inlet surface of the filter element.

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