Filter Device

Abstract

To provide a filter device capable of preventing clogging of a filter member.SOLUTION: A filter device 1 comprises at least one filter member 30, 40 formed by overlapping at least three filter materials in a laminar manner. At least one of inner filter materials 32, 42 arranged inside the filter materials 30, 40 is a relief filter material 33, 43 having at least one relief part that allows foreign matter to pass through without being captured so as to avoid clogging of the filter device 1.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a filter device, and in some embodiments, to a fuel filter device used in a fuel supply system that supplies fuel to an engine of a vehicle such as an automobile. [Background technology]

[0002] Japanese Patent Application Laid-Open Publication No. 2020-1004 discloses a filter device attached to a fuel pump installed in an automobile fuel tank. The filter device is formed into a flat bag shape by welding two filter members arranged above and below each other at their peripheries. Each filter member is configured by stacking multiple layers of filter media. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-1004 Summary of the Invention [Problem to be solved by the invention]

[0004] In the filter device of the above publication, the peripheral portions of the filter media of each filter element are welded together to form a single unit. In this configuration, if even one of the multiple filter media forming the layers becomes clogged, the entire filter element becomes clogged. Therefore, a filter device that makes it difficult for the filter elements to become clogged is desired. [Means for solving the problem]

[0005] The filter device according to one embodiment includes at least one filter member formed by stacking at least three or more layers of filter media. At least one of the inner-layer filter media arranged inside the filter member is an escape filter media having at least one escape portion that allows foreign matter to pass through without being captured. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a diagram showing a state in which a filter device according to an embodiment is connected to a fuel pump; [Figure 2] FIG. 2 is a cross-sectional view of the filter device. [Figure 3] FIG. 2 is an enlarged cross-sectional view showing the structure of a filter member. [Figure 4] FIG. [Figure 5] FIG. 10 is an exploded perspective view showing a modified example of the escape filter medium. DETAILED DESCRIPTION OF THE INVENTION

[0007] <Filter device> Various embodiments will be described below with reference to Figures 1 to 5. The filter device 1 shown in Figure 1 is a fuel filter device provided in a fuel supply system that supplies fuel to an automobile engine. The filter device 1 is disposed in a fuel tank and attached to the intake port of a fuel pump 2. The fuel pump 2 draws fuel from the fuel tank through this filter device 1, thereby being able to supply clean fuel from which foreign matter has been removed to the engine.

[0008] 2, the filter device 1 has a bag-shaped filter body 10, the inside of which is connected to the intake port of the fuel pump 2 via a connecting pipe 3. Fuel in the fuel tank passes through the inside of the filter device 1 and is drawn into the fuel pump 2.

[0009] The filter body 10 is formed into a flat shape by an upper filter member 30 and a lower filter member 40. The upper filter member 30 and the lower filter member 40 are welded together along their respective peripheral edges to form a bag shape (welded portion 50).

[0010] <Inner frame member> As shown in FIG. 2 , the filter device 1 has an inner rib member 20 disposed between the upper filter member 30 and the lower filter member 40. The inner rib member 20 may be made of resin and has a horizontally extending flat plate portion 21 and multiple protrusions 22 extending downward from various portions of the flat plate portion 21. When negative pressure is applied inside the filter body 10 due to suction from the fuel pump 2, the inner rib member 20 supports the filter body 10 to prevent it from collapsing. That is, the inner rib member 20 is sandwiched between the upper filter member 30 and the lower filter member 40, thereby maintaining the distance between the upper filter member 30 and the lower filter member 40. This allows the inner rib member 20 to maintain the internal volume of the filter body 10. This allows fuel to flow thoroughly inside the filter body 10.

[0011] <Connection to fuel pump> As shown in Fig. 2, the flat plate portion 21 is welded to the flange 3a of the connecting pipe 3 from below. The flat plate portion 21 is welded to the flange 3a using, for example, ultrasonic welding. By this welding, the upper filter member 30 is sandwiched between the flange 3a and the flat plate portion 21 and welded together. As a result, the filter body 10 is assembled integrally with the connecting pipe 3. The inner frame member 20 has an outlet 23 for connecting the connecting pipe 3, as shown in Figs. 2 and 4.

[0012] <Upper filter member> The upper filter member 30 and the lower filter member 40 are each formed by stacking multiple layers of filter media, as shown in Figure 3. Each filter media is made of, for example, a substantially circular nonwoven fabric. The upper filter member 30 has two outer layer filter media 31 that form its outer periphery, and one or more inner layer filter media 32 positioned between these outer layer filter media 31.

[0013] In one embodiment, there may be six inner-layer filter media 32. These are referred to as the first inner layer 32a, the second inner layer 32b, the third inner layer 32c, the fourth inner layer, the fifth inner layer 32d, and the sixth inner layer 32e in order (from upstream to downstream) along the direction in which the drawn fuel passes through the upper filter member 30. The upper filter member 30 also has an opening 34 that communicates with the outlet 23 of the inner rib member 20. The fuel that has flowed into the filter device 1 is sucked into the fuel pump 2 through the opening 34 and the outlet 23.

[0014] <Relief filter media> As shown in Figures 3 and 4, at least one of the inner-layer filter media 32 (e.g., the fourth inner layer) is configured as a release filter media 33 to prevent clogging in the upper filter member 30. The release filter media 33 has four openings 33a arranged circumferentially on its surface. The ratio of the openings 33a to the total area of ​​the release filter media 33 is configured to be, for example, approximately 8%. Fuel flowing from the outside of the filter device 1 through the upper filter member 30 into the interior of the filter device 1 passes through each opening 33a. The outer-layer filter media 31 and the inner-layer filter media 32 excluding the release filter media 33 are integrated at the welding portion 50. Meanwhile, the release filter media 33 are configured to be slightly smaller than the inner-layer filter media 32, forming a gap 33b between the periphery of the release filter media 33 and the welding portion 50. These openings 33a and gaps 33b form a space inside the upper filter member 30. Therefore, the escape filter material 33 can suppress an increase in pressure loss in the upper filter member 30 and make the upper filter member 30 less likely to become clogged.

[0015] <Fineness of the filter material> The mesh size of each inner-layer filter material 32 can be gradually increased from the upstream side to the downstream side, except for the escape filter material 33. That is, in each inner-layer filter material 32, the first inner layer 32a is the coarsest mesh, and the sixth inner layer 32e is the finest mesh. As a result, as fuel passes through the upper filter member 30, the inner-layer filter materials 32 capture foreign matter in order of size. Note that each outer-layer filter material 31 can be a filter material with a coarser mesh than the first inner layer 32a. Each outer-layer filter material 31 serves to capture, for example, frayed fibers generated in each inner-layer filter material 32, preventing them from escaping to the outside of the upper filter member 30.

[0016] The escape filter material 33 can be made of a filter material with a finer mesh than the fifth inner layer 32d located one stage downstream. In this case, the escape filter material 33 is more likely to capture finer foreign matter than the fifth inner layer 32d and is more likely to clog before the fifth inner layer 32d. However, the openings 33a and gaps 33b allow fuel passing through the upper filter member 30 without being filtered. Therefore, the openings 33a and gaps 33b function as escape sections that allow fuel to pass through even if the escape filter material 33 becomes clogged. In this way, the escape filter material 33 improves the filtering performance of the upper filter member 30 and makes the upper filter member 30 less likely to clog. The escape filter material 33 is made of a filter material with a coarser mesh than the sixth inner layer 32e.

[0017] <Lower filter member> 3 and 4, the lower filter member 40 also has outer-layer filter media 41 and inner-layer filter media 42. In one embodiment, the number of inner-layer filter media 42 may also be six. Fuel drawn into the fuel pump 2 passes through the lower filter member 40 from bottom to top. In this direction (from upstream to downstream), the inner-layer filter media 42 are referred to as the first inner layer 42a, second inner layer 42b, third inner layer 42c, fourth inner layer, fifth inner layer 42d, and sixth inner layer 42e.

[0018] <Relief filter media> As shown in Figures 3 and 4, at least one of the inner-layer filter media 42 (e.g., the fourth inner layer) is configured as a release filter media 43 to prevent clogging in the lower filter member 40. The release filter media 43 has six openings 43a arranged circumferentially within its surface. The ratio of the openings 43a to the total area of ​​the release filter media 43 is configured to be approximately 20%. Fuel flowing from the outside of the filter device 1 through the lower filter member 40 into the interior of the filter device 1 passes through each opening 43a. The release filter media 43 is configured to be slightly smaller than each inner-layer filter media 42, forming a gap 43b between the periphery of the release filter media 43 and the welded portion 50. These openings 43a and gaps 43b form a space inside the lower filter member 40. As a result, the escape filter medium 43 can suppress an increase in pressure loss in the lower filter member 40 and also make the lower filter member 40 less likely to become clogged.

[0019] <Fineness of the filter material> The mesh size of each inner-layer filter material 42 can be gradually increased from the upstream side to the downstream side, except for the escape filter material 43. That is, in each inner-layer filter material 42, the first inner layer 42a is the coarsest mesh, and the sixth inner layer 42e is the finest mesh. Each outer-layer filter material 41 is made of a filter material with a coarser mesh than the first inner layer 42a. Each outer-layer filter material 41 serves to capture, for example, loose fibers generated in each inner-layer filter material 42, preventing them from escaping to the outside of the lower filter member 40.

[0020] The escape filter material 43 is also made of a filter material with a finer mesh than the fifth inner layer 42d located one stage downstream. Therefore, the escape filter material 43 is more likely to capture finer foreign matter than the fifth inner layer 42d and is more likely to clog before the fifth inner layer 42d. However, the openings 43a and gaps 43b function as escape sections, allowing fuel passing through the lower filter member 40 to pass unfiltered. Therefore, even if the escape filter material 43 becomes clogged, fuel can still pass through. In this way, the escape filter material 43 also improves the filtering performance of the lower filter member 40, making it less likely for the lower filter member 40 to become clogged. The escape filter material 43 is made of a filter material with a coarser mesh than the sixth inner layer 42e.

[0021] 5, each escape filter medium 133, 143 may have a configuration in which its periphery is integrated with the welded portion 50 and does not have gaps 33b, 43b. Therefore, the escape filter medium 133, 143 is made to be approximately the same size as each outer-layer filter medium 31, 41 and each inner-layer filter medium 32, 42 excluding the escape filter medium 133, 143. The escape filter medium 133, 143 is configured to have only openings 133a, 143a as escape portions. The openings 133a, 143a are open in a strip shape and are arranged side by side at a predetermined interval.

[0022] <Advantages> To summarize the above, the filter device 1 includes at least one filter member 30, 40, which is formed by stacking at least three or more filter media in layers. At least one of the inner-layer filter media 32, 42 arranged inside the filter member 30, 40 is an escape filter media 33, 43, which has an escape portion that allows foreign matter to pass through without being captured. This configuration creates a space inside the filter member 30, 40 due to the escape portion. Furthermore, even if the escape filter media 33, 43 becomes clogged, the escape portion can prevent the escape filter media 33, 43 from becoming blocked. This reduces pressure loss in the filter member 30, 40 and makes the filter member 30, 40 less likely to become clogged.

[0023] Furthermore, at least one of the relief portions is an opening hole 33a, 43a formed in the relief filter medium 33, 43. With this configuration, the relief portion can be formed with a simple configuration of drilling a hole in the relief filter medium 33, 43.

[0024] Furthermore, the filter members 30, 40 are integrally formed by a welded portion 50 where the ends of each filter material are fixed to one another. The escape filter material 33, 43 is configured not to be fixed to the welded portion 50. At least one of the escape portions is a gap 33b, 43b formed between the escape filter material 33, 43 and the welded portion 50. With this configuration, the escape portion can be formed without processing such as drilling holes in the escape filter material 33, 43. Furthermore, by not welding the escape filter material 33, 43, the thickness of the welded portion 50 can be made thin. This makes it easier to form the welded portion 50.

[0025] In addition, the escape filter media 33, 43 have finer mesh than the filter media arranged one downstream of the escape filter media 33, 43. Due to this configuration, the escape filter media 33, 43 are more likely to clog before the filter media one downstream.

[0026] The filter device 1 is a fuel filter device used in a fuel supply system that supplies fuel to a vehicle engine. It is also connected to the intake port of a fuel pump 2 that pumps fuel from a fuel tank to the engine. By using the filter device 1, clogging of the filter members 30, 40 can be prevented when filtering fuel drawn into the fuel pump 2, thereby improving filtering performance.

[0027] <Other embodiments> In another embodiment, the filter device can be applied to various filters other than fuel filters, such as air filters and drainage filters, etc. Furthermore, the filter device can be applied to fuel filters for motorcycles, ships, etc. in addition to fuel filters for automobiles.

[0028] In another embodiment, the bag-shaped filter body may not be flat, but may be cylindrical, spherical, or any other shape. While the filter body is shown constructed by welding two filter members, it may also be formed into a bag shape by folding a single filter medium in half and welding the peripheral edges. In another embodiment, the filter body may not be bag-shaped, but may be layered and comprised of only one filter member.

[0029] In another embodiment, each filter material of the filter member may be a filter material other than a nonwoven fabric.

[0030] In another embodiment, the outer layer filter material of the filter member located most downstream may be made of the finest mesh of all the filter materials. The outer layer filter material may also have relief portions such as openings.

[0031] In another embodiment, the filter element may have any number of inner layer filter materials other than six. The inner layer filter material may be configured with only one escape filter material. While the example in which the mesh size of each inner layer filter material gradually decreases from the upstream side to the downstream side along the fuel flow direction has been shown, the mesh size of the filter material on the upstream side may be finer. Furthermore, the inner layer filter materials do not necessarily have to be configured with filter materials of different mesh sizes, and all or any of the inner layer filter materials may be configured with the same mesh size.

[0032] In another embodiment, the escape filter material may not have an opening, and the escape portion may be formed only in the gap between the escape filter material and the fixed portion. The gap formed between the escape filter material and the fixed portion may be configured to be provided in a part of the periphery of the escape filter material. The number and shape of the openings may be any configuration other than those described in the embodiment.

[0033] In another embodiment, the escape filter material may be made of a different material from the other inner layer filter materials and outer layer filter materials excluding the escape filter material. The escape filter material may be provided in any layer within the filter member. The escape filter material may be provided in not only one layer but also two or more layers. In this case, the escape filter materials may be provided adjacent to each other, or other inner layer filter materials without escape portions may be sandwiched between the escape filter materials. When multiple escape filter materials are provided, each escape filter material may have an opening hole and / or a gap with the fixing portion as an escape portion. Alternatively, one of the escape filter materials may have only an opening, and the other escape filter material may have only a gap with the fixing portion.

[0034] In another embodiment, the relief filter media may be finer than any of the other inner layer filter media that do not have relief portions.

[0035] Although various embodiments have been described above, the present disclosure is not limited to these embodiments, and various other modifications, substitutions, improvements, and the like are possible for those skilled in the art. [Explanation of symbols]

[0036] 1. Filter device 2 fuel pumps 30 Upper filter member 32 Inner layer filter material 33 Relief filter material 33a Opening hole 33b Gap 40 Lower filter member 42 Inner layer filter material 43 Relief filter material 43a Opening hole 43b Gap 50 Welded area

Claims

1. 1. A filter device, comprising: At least one filter member is provided, which is made up of at least three or more filter media stacked in layers, At least one of the inner layer filter materials disposed inside the filter member is an escape filter material having an escape portion that allows foreign matter to pass through without capturing it, The filter member is integrally formed by a fixing portion where the ends of each filter material other than the escape filter material are fixed to each other, The escape filter material is configured not to be fixed to the fixing portion, The filter device, wherein the relief portion is a gap formed between the relief filter material and the fixed portion.

2. 2. The filter device according to claim 1, The relief filter medium has another relief portion, The filter device, wherein the other relief portion is an opening hole formed in the relief filter material.

3. 3. The filter device according to claim 1 or 2, The filter device wherein the escape filter medium has finer mesh than the filter medium disposed in the layer immediately downstream of the escape filter medium.

4. The filter device according to any one of claims 1 to 3, The filter device is a fuel filter device used in a fuel supply system that supplies fuel to an engine of a vehicle, A filter device connected to the intake port of a fuel pump that supplies fuel from the fuel tank to the engine.

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