JPH0237205B2 - KAAFUIRUTAAEREMENTOOYOBISONOSEIZOHOHO - Google Patents

Description

[Detailed description of the invention]

The present invention relates to an improvement in a car filter element and a method for manufacturing the same, and more particularly to a car filter element that has excellent dust collection efficiency and retention capacity and durability, and a method for manufacturing the same. Conventionally, air filter elements for automobiles are made by pleating and molding a 2- to 3-layer nonwoven fabric sheet in a zigzag pattern in order to provide mechanical strength and increase oversurface area. Air filters are often fixed with resin plates or metal plates, but the thickness of the filter material is limited and cannot be made thicker even if the crimping process, which is performed to increase the excess area, is intended to extend the life of the air filter. Another disadvantage is that if the air filter is thin, the dust load on the filter becomes large and the life of the air filter becomes short. In order to solve these problems, the present invention has developed a car filter that has a slightly smaller overarea than the chrysanthemum-folding type, but has an overvolume several tens of times, greatly extending its life, and which is extremely easy to mold. The present invention provides an element and a method for manufacturing the same. An embodiment of the present invention will be described in detail below with reference to the drawings. As shown in FIGS. 1, 2, and 3, the cylindrical bodies are placed close to each other on a lathe or on a horizontal surface on the outer peripheral surface of a perforated punched metal cylindrical body 2 in which a large number of holes 1 are provided at appropriate intervals. A synthetic fiber such as polyester, polyamide, polypropylene, polyurethane, polyvinylidene chloride, etc. having a thickness of 1 to 6 denier, Chemical fibers such as coarse rayon and acetate, or mixed fibers made by mixing at least one of these, are intertwined and bonded to each other, and have a thickness of about 1 to 15 mm (preferably 3 mm).
~10mm) bonded fiber fleece is impregnated with a thermoplastic elastomer binder such as NBR or SBR containing crosslinkable resin such as melanin or catalyst, or a thermoplastic resin binder such as acrylic resin or polyurethane resin.
Dry solid content coverage is 20-60% of fiber weight
The wet resin or elastomer-impregnated fleece 4 that has passed through the mangle is wound so that (DPU%) is applied while applying tension using a tension adjustment roll. After forming it and winding it up to a predetermined thickness (3 to 8 cm, for example 6 cm) while gradually increasing the tension so as to lower the density in the thickness direction, it is then subjected to dry heat treatment and molded in that state,
A roll body 7 is obtained in which a molded fleece overlayer 6 whose apparent density gradually changes from dense to coarse in the thickness direction is formed on the outer periphery of the cylindrical body 2. Next, as shown in FIG. 4, radial grooves 8 (e.g., V-shaped,
After providing U-shaped, wavy, uneven grooves in the axial direction of the roll body at regular intervals, the roll body is cut into slices, for example, 4 cm wide, as shown by dotted lines 9, to form the wheel 1 shown in Fig. 5.
form 0. A sixth wheel is provided on both sides of the wheel 10.
A car filter element is formed by stacking ring-shaped synthetic resin plates 11 punched out so that the inner diameter shown in the figure matches the inner diameter of the perforated cylindrical body and fixing them with heat fusion or adhesive. The wheel width and the thickness of the molded fleece overlayer can be freely changed depending on the application. Furthermore, since the molded fleece overlayer is a cylindrical molded body, it is also possible to use it without using reinforcing materials such as perforated punch metal or ring-shaped synthetic resin plates. The car filter element formed in this way has a high apparent density in the inner layer (0.2 to 0.4 g/cm ³ ), and the density gradually decreases to (00.1 to 0.05 g/cm ³ ) in the outer layer.
As a result, it is possible to efficiently collect dust from minute particles to coarse particles, and the overvolume is several tens of times larger than that of conventional chrysanthemum-shaped elements. In addition, as shown in the test results in the following table, the amount of dust retained is several times greater and the service life is greatly improved, making it particularly excellent as an air cleaner for internal combustion engines for automobiles, and reducing maintenance costs.

[Table] Furthermore, according to the manufacturing method of the present invention, the folding process such as the chrysanthemum folding process is omitted, making the molding process very easy, and the invention has excellent effects such as obtaining elements with uniform performance. It is.

[Brief explanation of drawings]

Fig. 1 is a perspective view of a perforated punched metal cylindrical body used in the present invention, Fig. 2 is a side view showing an example of the car filter element manufacturing process of the present invention, and Fig. 3 is a block diagram showing an overview of the same manufacturing process. 4 is a perspective view of the same molded fleece layer forming roll body, FIG. 5 is a perspective view of the same cut wheel, and FIG. 6 is a perspective view of the same car filter element. 1...hole, 2...perforated punched metal cylindrical body,
3... Rubber roll, 4... Resin or elastomer impregnated fleece, 5... Dense layer, 6... Molded fleece overlayer, 7... Roll body, 8... Radial grooves,
9...Dotted line, 10...Wheel, 11...Ring-shaped synthetic resin plate.

Claims (1)

[Claims] 1. A wheel having a fleece overlayer formed by spirally winding a resin-impregnated bonded fleece around the outer periphery of a perforated punched metal cylinder, the formed fleece overlayer extending from the inner layer to the outer layer. The density gradually changes from dense to coarse in the thickness direction, and radial grooves are provided on the outer periphery of the molded fleece overlayer from the surface layer to the inner layer at regular intervals in the axial direction of the wheel. A car filter element characterized by having a ring-shaped resin plate fixed to the surface. 2 Molded fleece superlayer consists of a fleece with a thickness of 3 to 10 mm made of chemical fibers, synthetic fibers, or mixed fibers of these with a fineness of 1 to 6 deniers, and a binder mainly composed of thermoplastic resin, elastomer, or thermosetting resin. A car filter element according to claim 1, characterized in that: 3 While rotating the perforated punched metal cylinder, bonding mainly made of thermoplastic resin or elastomer is applied to the outer periphery of the cylinder with a bonded fiber fleece made of chemical fibers, synthetic fibers, or mixed fibers thereof having a thickness of 1 to 6 deniers. Wrap the wet fleece impregnated with 20 to 60% (DPU%) of the agent, and wrap it so that the density of the finished molding becomes progressively denser to coarser from the inner layer to the outer layer, and tighten while changing the tension. After that, the cylindrical body is dried and heated to form a roll body having a molded fleece overlayer whose density is successively changed from dense to coarse around the outer periphery of the cylinder, and further, from the surface layer to the outer periphery of the molded fleece overlayer of the roll body. After providing radial grooves in the axial direction of the roll body that reach the inner layer, the roll body is cut into wheels, and ring-shaped synthetic resin plates are attached to both sides of the molded fleece layer of the wheels using heat or adhesive. The manufacturing method of the car filter element is characterized by: