CN109416006B - Moisture collector, fuel filter device, and method for manufacturing moisture collector - Google Patents

Moisture collector, fuel filter device, and method for manufacturing moisture collector Download PDF

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Publication number
CN109416006B
CN109416006B CN201780041715.3A CN201780041715A CN109416006B CN 109416006 B CN109416006 B CN 109416006B CN 201780041715 A CN201780041715 A CN 201780041715A CN 109416006 B CN109416006 B CN 109416006B
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China
Prior art keywords
frame
fuel
moisture
layer
fiber layer
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CN201780041715.3A
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Chinese (zh)
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CN109416006A (en
Inventor
秋元靖雄
加藤崇文
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Kyosan Denki Co Ltd
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Kyosan Denki Co Ltd
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Priority claimed from JP2016133710A external-priority patent/JP6658361B2/en
Priority claimed from JP2016133711A external-priority patent/JP2018003758A/en
Application filed by Kyosan Denki Co Ltd filed Critical Kyosan Denki Co Ltd
Publication of CN109416006A publication Critical patent/CN109416006A/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M37/00—Apparatus or systems for feeding liquid fuel from storage containers to carburettors or fuel-injection apparatus; Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines
    • F02M37/22—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system
    • F02M37/24—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system characterised by water separating means
    • F02M37/26—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system characterised by water separating means with water detection means
    • F02M37/28—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system characterised by water separating means with water detection means with means activated by the presence of water, e.g. alarms or means for automatic drainage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M37/00—Apparatus or systems for feeding liquid fuel from storage containers to carburettors or fuel-injection apparatus; Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines
    • F02M37/22—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system
    • F02M37/32—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system characterised by filters or filter arrangements
    • F02M37/34—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system characterised by filters or filter arrangements by the filter structure, e.g. honeycomb, mesh or fibrous
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M37/00—Apparatus or systems for feeding liquid fuel from storage containers to carburettors or fuel-injection apparatus; Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines
    • F02M37/22—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system
    • F02M37/32—Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines, e.g. arrangements in the feeding system characterised by filters or filter arrangements
    • F02M37/42—Installation or removal of filters

Abstract

The fuel filter device (2) comprises a water trap (32). The moisture condenser has a frame (51) and a fiber layer (61). The fiber layer is a cylindrical roll of a band-shaped material. The strip-like material is wound over two turns. The tape-like material forms a thick fibrous layer. The fiber layer is fixed to the frame by a plurality of joints. A plurality of joints secure both the most upstream and the most downstream layers of the strip material to the frame. The housing (6) can be separated into a lid (21) and a bowl (22) for replacing the filter (31). The water trap is connected to the cup body by means of engagement portions (22a, 51 a).

Description

Moisture collector, fuel filter device, and method for manufacturing moisture collector
Cross reference to related applications
The present application is filed on the basis of Japanese patent application No. 2016-.
Technical Field
The disclosure in the present specification relates to a water content collector that aggregates water content contained in fuel, a fuel filter device, and a method for manufacturing the water content collector.
Background
Patent documents 1 to 5 disclose several fuel filtration devices. These fuel filtration devices include: a filter for removing solid foreign matters generated by filtering the fuel and a moisture separator for aggregating and separating moisture contained in the fuel. At least a part of the performance of separating moisture from the fuel can be evaluated by the performance of aggregating moisture to become large water droplets, that is, the moisture aggregation performance. The large water droplets have the advantage that they can be readily separated by gravity separation, impact separation, separation using water repellent layers () of the body regions of the body. In patent documents 1 to 5, an attempt is made to aggregate moisture by a moisture aggregate layer using a moisture aggregate. The prior art described in the prior art documents is incorporated by reference into the present application as a description of technical elements in the present specification.
Documents of the prior art
Patent document
Patent document 1: japanese unexamined patent publication No. 2010-223028
Patent document 2: U.S. patent application publication No. 2014/0102969 specification
Patent document 3: U.S. Pat. No. 8360251
Patent document 4: U.S. Pat. No. 7887704
Patent document 5: U.S. patent application publication No. 2014/0284268 specification
Disclosure of Invention
In order to exhibit high moisture aggregation performance, a thick aggregate layer may be required in some cases. However, thick agglomerated layers have several different issues.
One view is that a thick aggregate layer is difficult to fix firmly. In the fuel flow, it is necessary to maintain the thickness and the large surface area thereof while suppressing the cracking and decomposition of the thick condensed layer.
Another view is that it is difficult to produce a thicker single agglomerated layer. A thick single aggregate layer makes processing in the manufacturing process and handling in the manufacturing process difficult. Therefore, a thicker single aggregate layer requires special attention in the manufacturing process.
Further, when the fuel filter device includes a filter for removing solid foreign matter and a moisture collector for collecting moisture, there are several problems.
In one aspect, the filter is preferably replaceable due to reduced performance or failure. Also, the moisture trap may also suffer performance degradation or failure, sometimes requiring it to be replaceable. Furthermore, the filter replacement time and the moisture trap replacement time may differ in some cases. Therefore, it is desirable to remove the filter from the water trap and replace it.
In another view, the user or operator may pay attention to environmental load or economy. In this case, it is required to provide a replacement method with a small environmental load or an economically advantageous replacement method. For example, there is a need for an easily understandable structure, which can only replace the filter.
In the above viewpoint or other viewpoints not mentioned, further improvement of the moisture trap and the fuel filter device is required.
The invention aims to provide a water content agglomerator with a thick agglomeration layer, a fuel filter device and a method for manufacturing the water content agglomerator.
It is another object of the present invention to provide a water trap having a thick trap layer that is easy to manufacture, a fuel filter device, and a method of manufacturing the water trap.
It is still another object of the present invention to provide a water trap, a fuel filter device, and a method of manufacturing the water trap, which can fix a thick trap layer with a small number of members.
It is yet another object of the present invention to provide a water trap that can be used during different life cycles than a filter.
Another object of the present invention is to provide a fuel filter device capable of facilitating only filter replacement.
The present invention provides a moisture agglomerator, comprising: a frame that allows fuel to flow radially; a fiber layer which is a cylindrical fiber layer attached to a frame for condensing water in fuel and includes a roll of a band-shaped material arranged in two or more turns so as to overlap two or more layers in a radial direction; and a plurality of joints that secure the fiber layers to the frame. The moisture collector of the present invention provides a fibrous layer from a roll of ribbon material. The material is arranged in two or more turns so as to overlap two or more layers in the radial direction. The thick fiber layer is formed using a tape-like material. Further, since the ribbon-shaped material is used, manufacturing advantages can be obtained in terms of easy handling and reduction of waste.
The present invention provides a moisture agglomerator, comprising: a frame that allows fuel to flow radially; a fiber layer which is a cylindrical fiber layer attached to a frame and used for condensing water in fuel, and which includes a roll body of a band-shaped material arranged so as to at least partially overlap two or more layers in a radial direction; and a plurality of joints that secure the fiber layers to the frame; wherein the plurality of joints have a penetration joint that joins a material forming a last layer, which is disposed apart from the frame by at least one intermediate layer, to the frame through the intermediate layer. The water agglomerator of the present invention has a cylindrical fiber layer. The fabric layer is secured to the frame by a plurality of joints. Multiple engagement portions may provide secure fixation. The plurality of joints have penetration joints. The through-joint part joins a material forming the last layer, which is disposed apart from the frame by at least one intermediate layer, to the frame through the intermediate layer. The through-joints secure the last layer to the frame while maintaining the thick fiber layers. Therefore, breakage of the fiber layer due to the flow of the fuel can be suppressed.
The present invention provides a fuel filter device, comprising: the above-mentioned moisture trap; a filter that removes solid foreign matter from the fuel; and a housing that houses the moisture trap and the filter while defining the fuel passage.
The present invention provides a method for manufacturing a water segregator, wherein the water segregator comprises: a frame that allows fuel to flow radially; and a cylindrical fiber layer for aggregating moisture in the fuel; a method of making a moisture trap, comprising: a winding step of winding a belt-like material in which moisture in the fuel is condensed, inside or outside the frame, so as to form a roll of the material while at least partially overlapping two or more layers; and a bonding step of bonding the fiber layer to the frame; wherein the winding step includes a step of disposing a last layer from the frame with at least one intermediate layer interposed therebetween; and the bonding process has a step of bonding the material forming the last layer to the frame through the intermediate layer. In the method of manufacturing the water collector of the present invention, the tape-like material is wound to at least partially overlap two or more layers. As a result, the last layer is arranged to be spaced apart from the frame by at least one intermediate layer. In the joining process, the material forming the last layer is joined to the frame via the intermediate layer. According to this method, the fiber layer can be manufactured by a winding process. And, the fiber layer is reliably fixed to the frame by the joining process.
Further, the water content in the fuel can be condensed by the water content condenser of the present invention. The water trap is housed within a housing forming a fuel passage, along with a filter that removes solid foreign matter from the fuel. The water trap has a housing coupling portion formed so as to be able to maintain a connected state with the housing even in a state where the filter is removed from the housing. According to the water trap of the present invention, even if the filter is removed from the housing, the coupled state between the water trap and the housing can be maintained by the housing coupling portion. The moisture trap will remain even if the filter is removed. As a result, the filter can be replaced without being replaced at the same time. The moisture trap may be used during a different life cycle than the filter.
The fuel filtering device comprises a water collector, a shell and a filter. Even if the filter is removed from the housing, the fuel filter device can maintain the coupled state between the moisture trap and the housing by the housing coupling portion. The fuel filter device may be shown with only the filter replaceable.
The various modes disclosed in the present specification adopt different technical means to achieve respective purposes. The accompanying drawings, which are incorporated in and constitute a part of this specification, and are not intended to limit the scope of the claims. The objects, features and effects disclosed in the present specification will become more apparent by referring to the following detailed description and accompanying drawings.
Drawings
Fig. 1 is a block diagram of a fuel supply apparatus in a first embodiment;
FIG. 2 is a cross-sectional view of a fuel filter assembly;
FIG. 3 is a longitudinal cross-sectional view of a moisture coalescer of the fuel filter device;
FIG. 4 is a transverse cross-sectional view of a moisture coalescer of the fuel filter device;
FIG. 5 is a sectional view showing a 1 st fixing part;
FIG. 6 is a sectional view showing a 1 st fixing part;
FIG. 7 is a sectional view showing a 1 st fixing part;
FIG. 8 is a sectional view showing a 2 nd fixing part;
fig. 9 is a sectional view showing a 2 nd fixing part;
fig. 10 is a sectional view showing a modification of the 2 nd fixing portion;
FIG. 11 is a cross-sectional view of a fuel filter assembly according to a second embodiment;
FIG. 12 is an exploded view of a fuel filter assembly according to a second embodiment;
FIG. 13 is an exploded view of a fuel filter assembly according to a third embodiment;
FIG. 14 is an exploded view of a fuel filter assembly according to a fourth embodiment;
FIG. 15 is a transverse cross-sectional view of the moisture collector of the fifth embodiment.
Detailed Description
The following describes various embodiments with reference to the drawings. In various embodiments, functionally and/or structurally corresponding parts and/or associated parts are labeled with the same reference numerals or with reference numerals differing in digits greater than hundred. Corresponding parts and/or associated parts may refer to the description in the other embodiments.
First embodiment
< Fuel supply apparatus >
Fig. 1 shows a cross section of a fuel filter device 2 in a fuel supply device 1 mounted on a vehicle. In the figure, the flow direction of the fuel is indicated by thick arrows. The fuel supply apparatus 1 supplies fuel from a fuel Tank (TNK)3 to an internal combustion Engine (ENG)4 as a fuel consumption device. One example of the internal combustion engine 4 is a diesel engine that uses light oil as fuel. The type of the internal combustion engine 4 is not limited. For example, internal combustion engines using various hydrocarbon fuels such as gasoline and biodiesel are used. The internal combustion engine 4 is used as a power source of the machine. For example, the internal combustion engine 4 provides a power source for vehicle running. The internal combustion engine 4 is provided with a high-pressure pump and a fuel injection valve as a part of the fuel supply apparatus 1.
The fuel supply apparatus 1 has a low-pressure pump for pumping fuel in a fuel tank 3. The low-pressure pump is provided between the fuel filter device 2 and the fuel tank 3, or between the fuel filter device 2 and the internal combustion engine 4. In the illustrated example, the low-pressure pump is housed in the fuel tank 3. The fuel pressurized by the low-pressure pump is supplied to the fuel filter device 2. The fuel filter 2 filters the fuel. The fuel filtered by the fuel filter device 2 is supplied to the internal combustion engine 4 via the high-pressure pump and the fuel injection valve.
< Fuel Filter device >
The fuel filter device 2 includes a housing 6 and a filter unit 7. The housing 6 houses a filter unit 7. The housing 6 has a fuel inlet 11 and a fuel outlet 12. The case 6 has a lid 21 and a cup 22. The cover 21 provides a holder for fixing the fuel filter device 2. The holder is used to fix the fuel filter device 2 to the vehicle. The cover 21 and the bowl 22 are separable for replacement of the filter unit 7. By removing the cup body 22 from the cover body 21, the filter unit 7 is exposed, i.e., becomes replaceable. The housing 6 is made of metal or resin. The cover 21 is made of metal, for example, aluminum alloy. The cup body 22 is made of resin.
In fig. 2, a cross section of the fuel filter device 2 is shown. The housing 6 has an inlet passage 13 extending from the inlet 11. The inlet passage 13 provides a portion of the dirty side region DS through which unfiltered fuel flows. The housing 6 has an outlet passage 14 extending from the outlet 12. The outlet passage 14 provides a part of the clean side region CS through which the filtered fuel flows. The housing 6 provides a fuel flow path that communicates the inlet 11 and the outlet 12. The lid body 21 and the cup body 22 define a cavity as a fuel passage inside thereof. The lid body 21 and the cup body 22 define a space including the dirty side area DS and the clean side area CS. The dirty side area DS communicates with the inlet passage 13. The clean side region CS communicates with the outlet passage 14.
The housing 6 is also a member that provides a container that houses the filter unit 7. The housing 6 can be opened to remove the filter unit. The lid body 21 and the cup body 22 are detachably configured. The cover 21 provides a fixedly arranged first housing part. The cup 22 provides a removable second housing portion.
A coupling mechanism 23 for detachably coupling the lid body 21 and the cup body 22 is provided between the lid body 21 and the cup body 22. The connection mechanism 23 is provided by a screw mechanism including female threads provided on the lid body 21 and male threads provided on the cup body 22. The attachment mechanism 23 may include a sealing member that provides a seal between the sealing cover 21 and the cup 22.
The bottom of the cup body 22 is provided with a drain hole 24 and a drain bolt 25. The drain hole 24 and the drain plug 25 provide a drain mechanism for draining accumulated water and foreign matter accumulated in the bottom of the cup body 22.
A water level sensor 26 is provided at the bottom of the cup 22. When the level of the accumulated water at the bottom of the cup body 22 reaches a set level, the water level sensor 26 outputs a detection signal. A water level sensor 26 having a float 27 and a support post 28. The support post 28 is configured to extend upwardly from the bottom of the cup 22. The buoy 27 may float along the support column 28. The float 27 floats with the water level. For example, the support column 28 houses a magnetic switch. The float 27 houses a permanent magnet therein. Thus, when the float 27 reaches a predetermined height, the magnetic switch outputs a detection signal.
And a filter unit 7 detachably attached to the holder 6. The filter unit 7 can be replaced. The filter unit 7 is attached to the open end of the bowl 22. The cup body 22 with the filter unit 7 attached thereto is inserted into the lid body 21, and the lid body 21 and the cup body 22 are connected by the connecting mechanism 23, whereby the filter unit 7 is positioned at a correct position. When the filter unit 7 is positioned at the correct position, the dirty side area DS and the clean side area CS are separated.
The filter unit 7 has a basic element for providing the basic function of the fuel filter device 2 and an additional element for providing an additional function. The basic element is a filter 31 for removing solid foreign matter by filtering fuel. The additional element is a moisture separator for separating moisture in the fuel. The moisture separator comprises: an agglomeration stage in which water in the fuel is captured, water droplets are formed and made larger, and a separation stage in which the water droplets are separated from the fuel. The coagulation stage is provided by a moisture coagulant 32 having a fibrous layer that traps moisture. The separation stage is provided by a settling separation chamber which allows the water droplets to settle. A settling separation chamber is defined within the housing 6. The water separator is disposed in the dirty side region DS.
The filter 31 has a frame 41. The frame 41 is a member that separates the dirty side area DS from the clean side area CS when disposed between the lid body 21 and the cup body 22. Also, the frame 41 is a member for defining a filter passage that allows fuel to flow from the dirty side area DS to the clean side area CS.
The frame 41 is also a member for supporting the element 42. The element 42 is formed of a filter medium for removing foreign matter in the fuel. The filter forming element 42 is a fibrous product that may be referred to as paper. The filter medium removes foreign matter by flowing fuel in the thickness direction thereof. The element 42 is configured to traverse the filtration channel. An element 42 for filtering the fuel flowing through the filter passage. The element 42 is formed in a substantially cylindrical shape. The element 42 includes a plurality of cylinders formed of filter material. The plurality of cartridges are bundled into a cylindrical shape. The plurality of cartridges filter the fuel by flowing the fuel in an axial direction of the cylinder. The element 42 is an axial flow filter. In the illustrated example, the fuel flows from the lower end to the upper end of the element 42.
The frame 41 has a cover portion 43, a connecting portion 44, and a center tube 45. The hood 43 is connected to the member 42 to cover the outflow end of the member 42. The radially outer edge of the hood 43 contacts the casing provided by the lid 21 and the cup 22 in a sealed state.
The connection portion 44 is connected to the wall surface of the housing 6 in a sealing manner. On the connecting portion 44, a lip seal serving as a seal member is provided. A connecting portion 44 is positioned on the housing 6 between the opening of the inlet channel 13 and the opening of the outlet channel 14. The connection portion 44 is also a member for separating the dirty side region DS from the clean side region CS.
The center tube 45 is a cylindrical member extending axially through the center of the element 42. The center tube 45 is defined at an inner portion thereof with an inlet passage formed to extend axially from a radially inner side of the connecting portion 44. The center tube 45 is a passage member that forms a fuel passage for passing the fuel before being filtered by the element 42. The central tube 45 has a connecting tube 46 connected to the water trap 32. The connection pipe 46 may also be referred to as a first connection portion, which is detachably connected to the moisture condenser 32 to supply the fuel to the moisture condenser 32. The connecting pipe 46 is provided on the outer surface of the projecting portion of the central pipe 45 projecting from the element 42. Further, the center tube 45 has an opening 47 at its top end. The center pipe 45, which is also an opening defining member, defines an opening 47 as a fuel passage in the tank body. An opening 47 is formed in the center of the housing defined by the lid 21 and the cup 22.
The filter unit 7 is held between the lid 21 and the cup 22. The cover 43 is held between the connecting portion 44 and the lid 21, and between the outer edge of the cover 43 and the cup 22.
The water trap 32 is formed as a member having a cylindrical appearance. The water coalescer 32 has a frame 51 and a fibrous layer 61. The frame 51 has a plurality of openings in the radial direction to allow the fuel to flow in the radial direction. The frame 51 supports the fiber layer 61. The frame 51 may also be referred to as a cage support or reel. The frame 51 has an upper side end plate 52 and a lower side end plate 53. The end plates 52, 53 are joined by snap-fitting, bonding or welding. The frame 51 is made of resin. This resin is a thermoplastic resin.
The housing 6 and the moisture condenser 32 have a coupling mechanism for coupling the housing 6 and the moisture condenser 32. The coupling mechanism includes an engaging portion 22a provided in the cup 22 and an engaging portion 51a provided in the frame 51. The engaging portions 22a, 51a provide a snap mechanism that can be engaged or disengaged by elastic deformation of the resin material. And an engaging mechanism for coupling the housing 6 and the moisture condenser 32 so that the moisture condenser 32 is retained in the bowl 22 when the filter unit 7 is removed from the housing 6. The coupling strength of the coupling mechanism provided by the engaging portions 22a, 51a is stronger than the coupling strength provided by the coupling pipe 46.
When the filter 31 is pulled out upward from the bowl 22, the engaging portions 22a and 51a maintain the connected state between the bowl 22 and the moisture condenser 32, and the connecting pipe 46 separates the filter 31 and the moisture condenser 32. This configuration may facilitate reuse of the water partial collector 32 and replacement of only the filter 31. The water trap 32 is less likely to be clogged than the filter 31. The moisture trap 32 is more durable than the filter 31 for long periods of time. This structure can suppress the cost due to replacement.
The fiber layer is cylindrical. The fibre layer 61 is held on the frame 51. The fabric layer 61 is mounted to the frame 51. The fiber layer 61 is also referred to as an aggregate layer. The fiber layer 61 provides a moisture aggregation member for aggregating moisture in the fuel. The fiber layer 61 captures and aggregates fine water droplets dispersed in the fuel. The fiber layer 61 captures moisture and makes water droplets large. The fiber layer 61 releases the aggregated and enlarged water droplets into the fuel again, and allows them to settle in the cup 22. The fiber layer 61 is formed of fibers having physical and chemical properties suitable for capturing water droplets.
The fibrous layer 61 provides voids larger than the filtering material of the filter 31. The filter 31 has small holes to remove the minimum foreign materials required. On the other hand, the fiber layer 61 cannot remove the minimum foreign matter required. The fibrous layer 61 has larger pores. The thickness of the fiber layer 61 is much larger than the thickness of the filter medium of the filter 31 in the flow direction. In addition, the fiber layer 61 is softer than the filter medium of the filter 31 due to its high porosity and thickness.
As for the fiber layer 61, patent documents 1 to 5 can be referred to. The disclosures of patent documents 1 to 5 are incorporated herein by reference. For example, the fiber layer 61 is a hydrophilic fiber such as rayon.
< moisture trap >
Fig. 3 and 4 are cross-sectional views showing the moisture trap 32. Fig. 3 shows a cross-section along the line III-III in fig. 4.
Fig. 4 shows a cross-section along line IV-IV in fig. 3. The frame 51 has a shape similar to a reel that takes up a long strip of material. The frame 51 has two end plates 52, 53. The end plates 52, 53 are disposed opposite to each other. The frame 51 has a mandrel 54 arranged between the end plates 52, 53. Mandrel 54 is also the core of the core for fiber layer 61. The mandrel 54 has a number of gaps to allow fuel to flow through the fiber layers 61. The mandrel 54 provides a plurality of channels extending radially.
The end plate 52 is also referred to as an upper member (upper member). The end plate 52 is a circular ring-shaped plate. The end plate 52 has a cylindrical portion 52 a. The cylindrical portion 52a is provided at the center of the end plate 52. The cylindrical portion 52a is coupled to the center tube 45 by receiving the center tube 45. The cylindrical portion 52a defines an inlet port formed for receiving fuel from the center tube 45. The water trap 32 can be separated from the filter unit 7 by the cylindrical portion 52 a. Therefore, only the filter 31 or only the moisture condenser 32 may be replaced. The cylindrical portion 52a is also a part of the spindle 54.
The end plate 52 provides an annular flat surface 52 b. The flat surface 52b is located radially outward of the cylindrical portion 52 a. The flat surface 52b provides a contact seal that prevents leakage between the end face of the fiber layer 61 and the end plate 52 by contacting the end face of the fiber layer 61. Between the flat surface 52b and the fiber layer 61, no bonding portion such as an adhesive or a re-cured layer is provided.
The end plate 53 is also referred to as a lower member (lower member). The end plates 52 and 53 are joined to form the illustrated frame 51. The end plate 53 has a conical portion 53a at the center. The conical portion 53a provides a downwardly facing downward sloping surface while expanding radially outward. The downwardly sloping surfaces help to create a downward flow. The downward flow may promote settling of the water droplets.
The end plate 53 has an annular flat surface 53b opposite the flat surface 52 b. The flat surface 53b is located radially outward of the conical portion 53 a. The two flat surfaces 52b, 53b are opposed to each other in the up-down direction. The two flat surfaces 52b, 53b are opposed to each other in the width direction of the fiber layer 61. The flat surface 53b provides a contact seal that prevents leakage between the end face of the fiber layer 61 and the end plate 53 by contacting with the end face of the fiber layer 61. Between the plane 53b and the fiber layer 61, no bonding portion such as an adhesive or a re-cured layer is provided.
The flat surfaces 52b, 53b are opposed to both end surfaces of the fiber layer 61. In other words, the fiber layer 61 has both end faces that are in contact with only the flat faces 52b, 53 b.
The end plate 53 has a downward wall 53c extending downward facing the outside edge portion thereof. The downward wall 53c may promote the water droplets to grow and release into the fuel.
Further, the end plate 53 has a plurality of ribs 55. The rib 55 has a plate shape. The plurality of ribs 55 are arranged in a radial shape. The plurality of ribs 55 are provided apart from each other in the circumferential direction. Between the plurality of ribs 55, a plurality of channels extending in the radial direction are defined. The plurality of ribs 55 are provided by 8 ribs including a winding start rib 55a and a winding end rib 55 b. A plurality of ribs 55 are also part of the mandrel 54.
The end plate 53 has a plurality of support portions 56. The plurality of support portions 56 are arranged in a distributed manner on the radially outer edge of the plurality of ribs 55. The support portion 56 is a projection projecting radially outward. The plurality of support portions 56 are arranged apart from each other in the axial direction. The plurality of support portions 56 are arranged apart from each other in the circumferential direction. The radially outer side surface of the support portion 56 is a curved surface. The radially outer side surface of the support portion 56 contacts the inner surface of the fiber layer 61. The plurality of support portions 56 provide a contact surface for receiving and supporting the fiber layers 61.
A fiber layer 61 is disposed radially outward of the frame 51. The fiber layer 61 is cylindrical. The fiber layer 61 is formed in a substantially polygonal tubular shape corresponding to the plurality of ribs 55. The fiber layer 61 has an inner peripheral surface, an outer peripheral surface, and two end surfaces. The inner peripheral surface provides an inlet face for fuel. The outer peripheral surface provides an outlet face for the fuel. The two end faces are abutted against the end plates 52, 53. The two end faces provide sealing surfaces.
The fiber layer 61 has a plurality of layers in the flow direction. The layers are in direct contact with each other. Each layer is formed from the same fibers. The fiber layer 61 is formed of a tape-like material 62. The strip material 62 may be obtained by cutting a long strip base material into a predetermined length or by cutting from a square base material. Therefore, the waste of material is reduced as compared with the case where a circular plate is cut out from the base material. The material 62 is a nonwoven. The material 62 may be referred to as cotton. The material 62 has a fiber density much lower than the material of the filter 31. The material 62 has a softness that can be rolled onto the frame 51.
The fiber layer 61 is disposed on the mandrel 54. The fiber layer 61 is disposed radially outward of the mandrel 54. The material 62 has a shape that may be referred to as a spiral or vortex. The fiber layer 61 includes a cylindrical roll of the tape-like material 62. The fibrous layer 61 may be provided by a roll only. The fibrous layer 61 is provided by a stack of continuous strip-like material 62. The fibrous layer 61 may have additional layers in addition to the roll of material 62.
Material 62 is laminated to mandrel 54. The material 62 is configured to at least partially overlap two or more layers in the radial direction. The material 62 is arranged in two or more turns so as to overlap two or more layers in the radial direction. The material 62 is configured in more than three turns to form a three-layer overlap. The material 62 is laminated in two or more layers, making it possible to form the thick fiber layer 61 in the fuel passing direction.
The material 62 is arranged along an imaginary circumferential surface provided by the mandrel 54. The material 62 is wrapped around the mandrel 54 more than two times. The material 62 may also be wrapped around the mandrel 54 more than three times. The two adjacent layers stacked up in the fiber layer 61 are in direct contact. This mechanism makes it possible to form a thick fiber layer 61.
Material 62 has an end 63 and an end 64. The inner end 63 is a winding start end. The outer end 64 is a winding end. The end 63 and the end 64 are disposed between two circumferentially adjacent ribs 55a and 55 b. The material 62 has a shift portion between the two ribs 55a, 55b from the inside layer to the outside layer. The change is a portion of the material 62 that is bent into a step. The plurality of changing portions are collectively arranged between the two ribs 55a and 55 b. This arrangement makes it possible to make the outer peripheral surface of the fiber layer 61 close to a circular shape.
The frame 51 and the fiber layer 61 are joined at a plurality of joints 71. The joints 71 are dotted (dot) on the inner surface or the outer surface of the fiber layer 61. In other words, when the fiber layer 61 is viewed from the radially outer side, the joint portions 71 are dotted. The joint portion 71 is a resolidified portion formed by melting the material of the frame 51, penetrating into the fiber layer 61, and resolidifying again. In the joint 71, the frame 51 and the fiber layer 61 are inseparably joined together.
The plurality of joining portions 71 are arranged in a dispersed manner on the cylindrical outer peripheral surface of the fiber layer 61. The plurality of joining portions 71 are uniformly dispersed. The plurality of joint portions 71 are dispersed in the axial direction and the circumferential direction.
As shown in fig. 3, the plurality of engaging portions 71 includes a plurality of engaging portions 71 that are provided apart from each other in the axial direction. In the figure, 4 engaging portions 71 arranged in the axial direction are shown. As shown in fig. 4, the plurality of engaging portions 71 includes a plurality of engaging portions 71 that are provided apart from each other in the circumferential direction. In the figure, 8 engaging portions 71 arranged in the circumferential direction are shown. The plurality of joint portions 71 are arranged at equal intervals in the axial direction and the circumferential direction. In the illustrated example, the plurality of joints 71 are configured similarly to a dot pattern (polkadots pattern) of 4 × 8 ═ 32.
The plurality of joints 71 join the innermost layer (innermost material 62) to the frame 51. The joint 71 joins at least one layer with the frame 51. The plurality of engaging portions 71 are disposed at the distal ends of the plurality of ribs 55.
As shown in fig. 4, the plurality of engaging portions 71 have engaging portions 71a and engaging portions 71 b. The joint portion 71a joins the material 62, which forms the first layer in the radial direction, from the frame 51 to the frame 51. The engagement portion 71a is also referred to as an abutment engagement portion. The joining portion 71a joins the material 62 to the frame 51 near the one end 63. The joint portion 71a joins the innermost layer to the frame 51. The joint portion 71a fixes the layer located most upstream of the fuel flow to the frame 51. On the first layer, a plurality of joint portions 71a are provided.
The joining portion 71b joins the material 62 forming the last layer, which is disposed at a distance 51 from the frame by at least one intermediate layer, to the frame 51 through the intermediate layer. The joint portion 71b is also referred to as a through joint portion. The joining portion 71b joins the material 62 to the frame 51 near the other end portion 64. The joint portion 71b joins the outermost layer to the frame 51. The joint portion 71b joins the outermost layer to the frame 51. The joint 71b fixes the layer located most downstream of the fuel flow to the frame 51. The joining portion 71b is provided only in the vicinity of the end portion 64 where the winding of the material 62 is finished.
The engaging portion 71b may engage a plurality of layers with the frame 51. For example, the joint portion 71b may join all the layers to the frame 51. The joint 71b fixes the plurality of layers to the frame 51. The joint portion 71b fixes the entire fiber layer 61 to the frame 51 in the thickness direction of the fiber layer 61. In other words, the joint 71b stitches the fiber layer 61 to the frame 51. The joining portion 71b joins the three-layer material 62 to the frame 51.
The engaging portion 71a is provided on the winding start rib 55 a. The engagement portion 71a is the initial engagement position. The engaging portion 71b is provided on the winding-finished rib 55 b. The joint portion 71b is the final joint position after winding, which forms the overlapping portion.
The plurality of joints 71 secure the material 62 to the frame 51 in the circumferential, axial, and radial directions. The extension piece between the end portion 63 and the engagement portion 71a maintains the illustrated shape by its own rigidity. The extension piece between the end portion 64 and the engagement portion 71b maintains the illustrated shape by its own rigidity. These extension pieces also maintain the shape as shown in contact with the adjacent layer when the fuel flows, i.e., in a normal use state.
The plurality of joining portions 71 dispersed along the inner or outer peripheral surface of the fiber layer 61 contributes to secure fixation. Also, the joint portion 71 as a re-solidified portion provides reliable fixation. The plurality of joining portions 71a can suppress the pressing of the upstream side of the fuel flow against the fiber layer 61. And the joining portion 71b can suppress separation of the fiber layer 61 toward the fuel flow downstream side. The fibre layer 61 provides sealing only by contact with the flat faces 52b, 53b on the end faces. Therefore, a stable seal can be obtained without depending on the adhesive thickness. As a result, reliable fixing and sealing of the fiber layer 61 can be achieved. This structure can reduce the cost.
As shown in fig. 2, the engagement portions 22a, 51a provide a housing coupling portion. The housing coupling portion is formed so that the moisture condenser 32 can be kept coupled to the housing 6 even in a state where the filter 31 is removed from the housing 6. The replacement work includes a stage of releasing the coupling mechanism 23 and a stage of removing the cup 22 from the lid body 21. The operation of separating the lid body 21 and the cup body 22 in the coupling mechanism 23 is a turning operation. The connection between the water trap 32 and the cup 22 by the case connection part can be released by an operation different from the rotation operation. The housing coupling portion is brought into a released state by an axial operation of pulling the water trap 32 in the axial direction or an axial operation of slightly obliquely pulling the water trap while elastically deforming the resin material. Therefore, the coupled state of the housing coupling portion is not released by the operation of the coupling mechanism 23.
Further, the replacement work includes a stage of pulling out the filter 31 from the inside of the bowl 22, a stage of pulling out the water trap 32 from the inside of the bowl 22, and a stage of performing replacement and reassembly. When the filter 31 is pulled out in the axial direction, the housing coupling portion maintains the engaged state, and the coupling state between the water trap 32 and the bowl 22 is maintained. Therefore, even if the filter 31 is pulled out from the cup 22, the moisture condenser 32 remains in the cup 22. Thereby facilitating individual replacement of the filter 31. Further, the interior of the cup 22 is a dirty side area DS, and the upstream and downstream of the fiber layer 61 are also dirty side areas DS. Therefore, even if a new filter 31 is inserted after the connecting pipe 46 is pulled out, it is possible to suppress the foreign matter from entering the cleaning side region CS.
The connecting pipe 46 and the cylindrical portion 52a are a connecting portion that mechanically connects the filter 31 and the moisture condenser 32. Also, the linking pipe 46 and the cylindrical portion 52a are also fluid linking portions that provide fluid linking of the fuel passages to allow the fuel to flow through the fiber layers 61. The housing connection portion is formed so as to be able to maintain a connected state with the housing 6 even in a state where the connection of the fluid connection portion is released.
< production method >
A method of manufacturing a fuel filter device 2, comprising: a step of forming the housing 6; a step of disposing a filter unit 7 in the housing 6; and a step of closing the case 6. A method of manufacturing a filter unit 7, comprising: a step of assembling the filter 31; assembling the water-component collector 32; and a step of connecting the filter 31 and the water content collector 32.
A method of replacing a filter unit 7, comprising: a step of opening the case 6; a step of taking out the old filter unit 7; a step of arranging a new filter unit 7; and a step of closing the case 6. When the filter 31 is replaced alone, it increases: disassembling the old filter unit 7 into a filter 31 and a water content collector 32; and a step of manufacturing the new filter unit 7 by connecting the old water content collector 32 to the new filter 31. The disassembling process may include a stage of separating the filter 31 from the moisture condenser 32 while maintaining the coupled state of the moisture condenser 32 and the bowl 22. The disassembling process may be performed in the case 6 simultaneously with the opening process of the case 6. The joining process may be performed in the housing 6 while maintaining the joined state between the water trap 32 and the cup 22. The coupling step may be performed simultaneously with the closing step of the case 6.
A method of making a moisture trap 32, comprising: a forming step of forming the frame 51; a mounting step of mounting the fiber layer 61 on the frame 51; and a fixing process of fixing the fiber layer 61 to the frame 51. The forming process may include a step of molding the frame 51 with a resin material. The mounting process may be provided by a winding process that winds the material 62 along the frame 51. The mounting process may also be provided by the process of mounting frame 51 in a fibrous layer 61 of rolled material 62. In the present embodiment, the mounting step is provided by a winding step.
The mounting process includes a step of forming a seal between the fiber layer 61 and the frame 51 so that the fuel passes through the fiber layer 61. The seal is formed by pressing the end faces of the cylindrical fiber layers 61 against the flat faces 52b, 53 b. The seal is formed by pressing the longitudinal end faces of the material 62 against the flat faces 52b, 53b in the winding process. In the winding process, the material 62 is wound around the frame 51 while pressing the longitudinal end faces against the flat surfaces 52b, 53 b.
The winding step is a step of winding the material 62 around the frame 51. The winding process starts with winding on the rib 55 a. Material 62 is wound starting at end 63. When the end 64 is positioned at the predetermined position as shown, the winding process is ended.
The winding step is a step of winding the material 62 so that at least two layers or more are partially overlapped. The winding process comprises a first stage of winding the material 62 on the frame 51 only once. Thereby, a first turn of material 62 is formed. The winding step further includes a second step of additionally winding the material 62 on the frame 51 by one turn. Thereby forming a second loop of material 62. The winding process may further include a third step of additionally winding the material 62 on the frame 51 by one turn. Thereby, a third turn of material 62 is formed. As a result, the fiber layer 61 is formed.
The winding process, including the initial stage of positioning the material 62 on the top of the rib 55 a. In the initial stage, the end 63 is positioned between the first rib 55a and the last rib 55 b. In the initial stage, the material 62 is further positioned on the tip of the rib 55 a. In an initial stage, the material 62 is configured to pass over the rib 55 a. In an initial stage, material 62 may also be disposed over second rib 55. After the initial stage, the first, second and third stages are performed.
The winding process has a step of providing the last layer at least one intermediate layer apart from the frame 51. The process is provided by the third stage. The intermediate layer is provided by a first layer and a second layer.
The fixing step is to fix the fiber layer 61 to the frame 51 by forming a plurality of joints 71. The fixing process is intermittently performed in the winding process. The fixing process includes a plurality of stages for forming each of the plurality of joint portions 71. The securing process may include an initial stage for forming the initial joint 71a after the material 62 is positioned over the rib 55 a. The fixing process may further include an intermediate stage for forming the engaging portion 71a after the material 62 is positioned over the second and subsequent ribs 55 a.
The intermediate stage may be performed by sequentially forming the plurality of engaging portions 71a after positioning the material 62 on the plurality of ribs 55. The intermediate stage may be performed by repeating the single stage of forming one joint 71 on a plurality of ribs 55 after positioning the material 62 on one rib 55. In addition, the intermediate stage may be divided into a plurality of partial stages to be executed. In one partial stage, after the material 62 is arranged on a set of a plurality of ribs 55, for example, three ribs 55, a plurality of joints 71a are formed on the plurality of ribs 55. In the remaining portion stages, after the material 62 is arranged on the remaining set of ribs 55, for example, three ribs 55, a plurality of joint portions 71a are formed on the ribs 55.
Fig. 5 shows the first rib 55 a. A support portion 56 is formed at the tip of the rib 55 a. Before melting, the support portion 56 is slightly larger. The rib 55a has a volume capable of supplying the single-layer material 62 with the fixing molten resin.
Fig. 6 shows a state where the material 62 is positioned at the tip of the rib 55 a. In the winding process, the material 62 is positioned on the rib 55 a.
The fixing step includes a step of melting a part of the rib 55 a. The fixing step further includes a step of pressing the material 62. A part of the rib 55a is melted by being pressed against the high temperature member 57. Material 62 is compressed by being pressed by member 57. A part of the rib 55a can be melted by high energy supplied from the outside, for example, by laser irradiation, ultrasonic irradiation, electromagnetic wave irradiation, supply of hot air, or the like. A part of the rib 55a is deformed from the shape shown in fig. 6 in the melting stage. This stage is a supply stage of supplying the flowable material between the frame 51 and the material 62. The material is capable of imparting a degree of fluidity to the material 62.
The fixing step includes a step of positioning the fibers of the material 62 in the molten resin material. At this stage, the molten resin material penetrates and diffuses into the fiber layer. And, a part of the fibers enters into the molten resin material. This stage is a stage of intermixing the flowable material with the material 62.
The fixing step further includes a step of resolidifying the melted resin material. This stage is a stage of reducing the fluidity of the flowable material. The fluidity of the material decreases to a low level to which the material 62 is fixed to the frame 51.
Fig. 7 shows an example of the engaging portion 71. The joint 71 is a re-cured resin block. The joint 71 allows the fibers of the material 62 to enter the inside of the resin block. The shape of the engaging portion 71 is different from the shape of the rib 55 a. The shape of the rib 55a changes into an irregular block shape of the engaging portion 71. The surface of the joint portion 71 has an irregular surface accompanying the flow. The shape of the joint portion 71 may also be referred to as a bar or a column extending radially outward from the distal end of the support portion 56. Further, the material 62 may be slightly deformed to be dented by shrinkage at the time of resolidification of the joint portion 71 or by pressure applied from the outside to melt the rib 55 a. For example, the thickness of material 62 may be slightly reduced around joint 71.
As described above, in the first stage of the winding process, the innermost layer of the material 62 is disposed on the frame 51. Through the fixing step, a plurality of joint portions 71a are formed. This fixing process provides an adjoining joining step of joining the first layer to the frame 51 only in the radial direction. As a result, the innermost layer, i.e., the most upstream layer, of the material 62 is firmly fixed to the frame 51. Next, the winding process proceeds to the first stage, the second stage, and the third stage. With each advance of the stages of the winding process, the material 62 is arranged in a stack on the last rib 55 b.
Fig. 8 shows the last rib 55 b. A support portion 56 is formed at the tip of the rib 55 b. The rib 55b has a volume capable of supplying the three-layer material 62 with the fixing molten resin. The frame 51 corresponds to the number of layers of material 62 left thereon, or the thickness of the layers of fibers left thereon. When the material 62 of the third layer is positioned on the winding-completed rib 55b, the last partial stage of the fixing process is performed. In the final partial phase, the last rib 55b is melted and solidified again.
Fig. 9 shows an example of the engaging portion 71b on the winding-ended rib 55 b. In the fixing step, the rib 55b is melted to be bonded to at least the outermost layer of the material 62 forming the plurality of layers. The rib 55b is melted for bonding with the plurality of layers. The rib 55b is melted for bonding with all the layers. The joining portion 71b fixes the fiber layer 61 formed of a plurality of layers. The joint portion 71b can also be said to sew the fiber layer 61. The three-layer material 62 is greatly compressed by the member 57 to form the recess 66. This process provides a through-bonding process of bonding the last layer in the radial direction to the frame 51 through the intermediate layer.
A plurality of support portions 56 are provided in the axial direction on one rib 55. For example, the first rib 55a is provided with a plurality of support portions 56 in the axial direction. For example, the last rib 55b is provided with a plurality of support portions 56 in the axial direction. Therefore, a plurality of engaging portions 71a are formed on the rib 55a in the axial direction. And a plurality of final engagement portions 71b are formed on the rib 55 b. These plural last joining portions 71b fix the end portion 64 of the material 62, at which the winding is finished, to the frame 51. Since the end portion 64 is located on the most downstream side, the joint portion 71b fixes the entire thickness direction of the fiber layer 61 to the frame 51.
Fig. 10 shows a modification of the engaging portion 71 b. When the joint portion 71b is formed from the rib 55b, the thick three-layer material 63 is laminated around the rib 55 b. The joint 71b may not extend completely through the three-layer material 62.
< action >
Returning to fig. 2, the flow of fuel is indicated by arrows. The fuel supplied from the inlet 11 passes through the filter 31 after passing through the moisture condenser 32, and flows out from the outlet 12. The water droplets flowing out of the water content agglutinator 32 settle by their own weight and sink into the cup body 22. On the other hand, the fuel flows upward inside the bowl 22 and flows into the filter 31. The fuel flowing through the filter 31 reaches the outlet 12.
Water that sinks into the cup 22 settles to the bottom of the cup 22. In the figure, the water droplet WD and the water surface WL are schematically shown, wherein the water surface WL is the boundary between water and fuel. When the float 27 floats as the water surface WL rises, the water level sensor 26 outputs a detection signal. The detection signal alerts the operator. When the operator releases the drain plug 25, water is drained.
The filter 31 is imparted with a capability of removing solid foreign matter of a desired size in the fuel filter device 2. The filter 31 is designed to remove fine solid foreign matters so that the high-pressure pump and the like can maintain performance for a long time. On the other hand, the fiber layer 61 provided in the moisture condenser 32 cannot remove the above-mentioned expected solid foreign matter. This is because the fiber layer 61 has larger pores than the filter 31. The fiber layer 61 is designed to capture and aggregate water.
The fuel flows from the inner surface to the outer surface of the fiber layer 61. The joint portion 71a positions the inner peripheral surface of the fiber layer 61 at a predetermined position against the pressure of the fuel. The engagement portion 71b positions the outer peripheral surface of the fiber layer 61, for example, the end portion 64, at a predetermined position against the pressure of the fuel. Therefore, even if the fuel flows through the inside of the fiber layer 61, the fiber layer 61 can be prevented from being broken or decomposed.
The water contained in the fuel is captured by the fiber layer 61, and is aggregated into large water droplets. The water droplets are released again into the fuel from the outer surface of the fiber layer 61.
< effects >
According to the above-described embodiments, a plurality of advantages can be provided by a plurality of characteristic structures each independently available. The fiber layer 61 may provide the moisture condenser 32 with a thick condensation layer, and the fuel filter device 2. The fiber layer 61 is provided by a cylindrical roll body in which the band-like material 62 is wound two or more times. Thus, the thick fiber layer 61 can be formed from the ribbon-shaped material 62 which is easy to handle. As a result, the moisture condenser 32 having a thick condensed layer which is easy to manufacture, the filter unit 7 including the moisture condenser 32, and the fuel filter device 2 can be provided.
The fiber layer 61 is fixed to the frame 51 by a plurality of joints 71. The plurality of engagement portions 71 may provide reliable fixation. The plurality of joining portions 71 are arranged in a dispersed manner. The plurality of joints 71 are formed integrally with the fibers of the fiber layer 61. Thus, a reliable fixation can be formed.
A plurality of engaging portions 71, which include: a joint portion 71a that fixes the fiber layer 61 to the frame 51 at the inner peripheral surface of the fiber layer 61; and an engaging portion 71b that fixes the fiber layer 61 to the frame 51 at the outer peripheral surface of the fiber layer 61. The joint portion 71b provides a through joint portion. The through joint joins the material forming the last layer to the frame 51 through the intermediate layer. The through joints fix the position of the last layer while maintaining the thick fiber layers 61. Therefore, breakage of the fiber layer 61 due to the flow of the fuel can be suppressed.
The fiber layer 61 is fixed to the frame 51 at both the inner and outer peripheral surfaces thereof. The joint portion 71a can suppress the pressing from the inner peripheral surface of the fiber layer 61. The joint portion 71b can suppress separation from the outer peripheral surface of the fiber layer 61. In other words, the joint portion 71a suppresses the pressing of the fiber layer 61 on the fuel flow upstream side. And the joining portion 71b suppresses separation of the fiber layer 61 toward the fuel flow downstream side. Thus, the water content collector 32, which has a small number of components but can fix a thick condensed layer, the filter unit 7 including the water content collector 32, and the fuel filter device 2 can be provided.
According to the method of making the moisture collector 32, the strip of material is wound to at least partially overlap two or more layers. The last layer is arranged to separate at least one intermediate layer from the frame 51. In the bonding process, the material forming the last layer is bonded to the frame 51 through the intermediate layer. According to this method, the fiber layer 61 can be manufactured by a winding process. Also, the fiber layer 61 can be reliably fixed to the frame through the joining process. In the joining process, the fiber layer 61 is fixed to the frame 51 while maintaining the position of the last layer. Thus, the thick fiber layer 61 is maintained.
Second embodiment
This embodiment is a modification of the above embodiment. In the above embodiment, the water content collector 32 is provided in the dirty side region DS. Alternatively, the water content collector may be disposed in the cleaning side region CS.
As shown in fig. 11 and 12, the fuel filter device 2 has a filter 231 for removing solid foreign matter. The filter 231 defines and divides the inside of the housing 6 into a dirty side area DS and a clean side area CS. The filter 231 has a cylindrical filter medium in a pleated shape. The filter 231 has a sealing member such as an O-ring for preventing direct communication between the dirty side section DS and the clean side section CS.
The water trap 232 is disposed in the clean side region CS. In other words, the moisture condenser 232 is disposed downstream of the filter 231. The water trap 232 is disposed radially inside the filter 231. The water agglomerator 232 has a frame 51 and a fibrous layer 61 secured to the frame 51. The fiber layer 61 is fixed to the frame 51 by a plurality of joints 71. The fiber layer 61 provides a moisture-collecting layer. The water trap 232 is connected to the cup 22 by the engaging portions 22a, 51 a. In the present embodiment, the engaging portions 22a, 51a can also facilitate reuse of the water segregator 232.
In the present embodiment, the fuel flows in the radial direction from the outer peripheral surface to the inner peripheral surface of the tubular fiber layer 61. Since the fiber layer 61 is supported by the frame 51 on the inner side, the pressure generated along with the flow of the fuel acts to compress the fiber layer 61. On the other hand, the plurality of joining portions 71 extending from the frame 51 in the thickness direction of the fiber layer 61 function to maintain the thickness of the fiber layer 61. Therefore, in the present embodiment, the thick fiber layer 61 can be maintained.
The fuel filter device 2 has a moisture separation layer 233. The moisture separation layer 233 is disposed downstream of the moisture coalescer 232. The moisture separation layer 233 is disposed between the moisture coalescer 232 and the outlet 12. Between the moisture coalescer 232 and the moisture separation layer 233, a cylindrical cavity for settling water droplets is defined. The moisture separation layer 233 suppresses passage of water droplets, and promotes sedimentation of the water droplets. Moisture separating layer 233 is provided by a wire mesh having properties that may be referred to as water repellency, or hydrophobicity.
The moisture separation layer 233 is connected to the moisture condenser 232 by a connection mechanism 234. The attachment mechanism 234 is provided by a snap mechanism. The coupling mechanism 234 makes it possible to separately take out the filter 231 while maintaining the state in which the moisture separation layer 233 is coupled to the moisture coalescer 232. Therefore, the connection mechanism 234 can facilitate reuse of the moisture separation layer 233.
Third embodiment
This embodiment is a modification of the above embodiment. In the above embodiment, the moisture separation layer 233 is joined to the moisture coalescer 232. Alternatively, the moisture separation layer may also be coupled to the filter 231.
As shown in fig. 13, the moisture separation layer 333 is connected to the filter 231 by a connection mechanism 334. According to this structure, reuse of the water segregator 232 can be promoted. On the other hand, replacement of the filter 231 and the moisture separation layer 333 can be facilitated.
Fourth embodiment
This embodiment is a modification of the above embodiment. In the above embodiment, the moisture separation layer 233 is joined to the filter 231 or the moisture coalescer 232. Alternatively, the moisture separating layer may be separate.
As shown in fig. 14, moisture separation layer 433 has no joining mechanism. In this structure, the moisture separating layer 433 remains on the moisture trap 232 due to its own weight. However, the operator can easily remove the moisture separating layer 433 from the moisture coalescer 232. Therefore, the selection of replacement and reuse of the moisture separation layer 433 can be decided by the operator.
Fifth embodiment
This embodiment is a modification of the above embodiment. In the above embodiment, the material 62 is wound around the outside of the frame 51. Alternatively, the material 62 may also be wound on the inside of the frame 51.
As shown in fig. 15, the moisture condenser 532 has a frame 51. The moisture agglomerator 532 may be used as the moisture agglomerator 32, 232 in the previous embodiment. The frame 51 has a plurality of ribs 55 projecting radially inward. The frame 51 is disposed radially outward of the fiber layer 61. The plurality of support portions 56 are adjacent to the outer peripheral surface of the fiber layer 61.
The band-shaped material 62 is wound from the inside in an imaginary cylindrical cavity defined by the plurality of ribs 55. In the manufacturing method, the band-shaped material 62 is arranged in the internal cavity of the frame 51 in order from the end 63. End 64 is positioned beyond end 63 to be positioned in a more convolutely overlapping position. The band-shaped materials 62 overlap from the radially outer side to the radially inner side. In the present embodiment, the band-shaped material 62 is also sewn in the manufacturing method. In the present embodiment, the thick fiber layer 61 may be formed by the band-shaped material 62 wound in an overlapping manner.
The fiber layer 61 is fixed to the frame 51 by a plurality of joints 71. The fiber layer 61 is fixed to the first rib 55 and the support portion 56 by the joint portion 71 a. The joint 71a fixes one layer corresponding to one piece of the material 62. In other words, the joint portion 71a fixes the outermost layer. Another view is that the joint 71a is fixed to the layer most upstream in the fuel flow. The moisture collector 532 has a plurality of engaging portions 71a for fixing the first layer. These plural engaging portions 71a are arranged in a circumferentially dispersed manner.
The fiber layer 61 is fixed to the last rib 55 by the joint portion 71 b. The joining portion 71b fixes a plurality of layers corresponding to the plurality of materials 62. In other words, the joint portion 71b fixes the innermost layer. Another view is that the joint 71b is fixed to the layer furthest downstream in the fuel flow. The moisture collector 532 has a plurality of engaging portions 71b for fixing the last layer. These plural engaging portions 71b are arranged in a dispersed manner in the circumferential direction.
The fiber layer 61 is fixed to the ribs 55 by the joints 71 c. The joint portion 71c fixes the plurality of layers. The number of layers fixed by the joint portion 71c is between the number of layers fixed by the joint portion 71a and the number of layers fixed by the joint portion 71 b. In the illustrated example, the joint portion 71b is fixed by two layers. In other words, the joint portion 71c is fixed to a layer in the middle of the fuel flow. The moisture trap 532 has a plurality of engaging portions 71 c. These plural engaging portions 71c are arranged in a circumferentially dispersed manner. The plurality of engaging portions 71c are also referred to as intermediate engaging portions. The plurality of joining portions 71c reinforce the thick fiber layer 61 in the inside thereof.
The plurality of joining portions 71a securely fix the fiber layer 61 to the frame 51 on the radially outer side of the fiber layer 61. The plurality of joining portions 71a suppress pressing from the radially outer side to the radially inner side of the fiber layer 61. The plurality of engaging portions 71b are radially inward of the fiber layer 61, and reliably fix the fiber layer 61 to the frame 51. The plurality of joining portions 71b can suppress the decomposition toward the inner peripheral surface of the fiber layer 61, in other words, the radial direction inner side of the lowermost layer.
In the present embodiment, the thick fiber layer 61 may be formed of a tape-like material 62 that is easy to handle. In the present embodiment, the thick fiber layer 61 can also be reliably fixed to the frame 51 by the plurality of joint portions 71. Also, the plurality of joining portions 71a can suppress the pressing of the fiber layer 61 from the fuel flow upstream side. The plurality of joining portions 71b can suppress separation of the fiber layer 61 toward the fuel flow downstream side.
Other embodiments
The inventive content of the description is not limited to the embodiments illustrated. The summary includes the illustrated embodiments and variations thereof based on those skilled in the art. For example, the inventive content is not limited to the combinations of components and/or elements disclosed in the embodiments. The inventive content can be implemented in various combinations. The invention contents may have an additional portion that can be added to the embodiment. The summary of the invention also includes embodiments in which components and/or elements are omitted in the embodiments. The summary of the invention also includes substitutions and combinations of elements and/or components between one embodiment and another embodiment. The technical scope of the disclosure is not limited to the description of the embodiments. The technical scope of the present invention is defined by the claims, and all changes that have the same meaning and range as the claims are also understood to be included.
In the above embodiment, the positive pressure system in which the fuel filter device 2 is provided downstream of the low-pressure pump is exemplified. Alternatively, a negative pressure system in which the fuel filter device 2 is disposed upstream of the low pressure pump may be applied. In the above embodiment, the filter 31 has the honeycomb type element 42. Instead, various types of filter media such as a chrysanthemum type filter media and a vortex type filter media can be used.
In the above embodiment, the case 6 may be divided into two parts, i.e., the lid 21 and the cup 22. Alternatively, the housing 6 may be configured to be divided into three portions. Further, only the member corresponding to the lid may be separated. In either structure, the filter unit 7 is replaceably housed in the housing 6.
In the above embodiment, the moisture agglomerator includes the star frame 51 with the radial ribs 55. Alternatively, the moisture condenser may use a frame having various shapes such as a cage type, a spiral type, and the like. In addition, the frame 51 may have various surface shapes such as a concentric stepped surface, a plurality of protrusions, and the like, instead of the flat surfaces 52b, 53b, in order to ensure reliable contact with both end surfaces of the fiber layer 61. In the above embodiment, the outer peripheral surface of the fiber layer 61 is exposed on the outer surface in the radial direction of the water content collector. Alternatively, a net-like, columnar protective member may be provided further outside the outer peripheral surface of the fiber layer 61. Further, in the above embodiment, the rib 55 is melted by the one-layer material 62 or the three-layer material. Alternatively, needles for piercing the material 62 may be provided on the ribs 55a, 55 b. The material 62 may be secured by a needle.
In the above embodiment, the fiber layer 61 is formed by winding the tape-like material 62 several times. Alternatively, the number of windings of the tape-like material 62 may be set to more than one turn in order to obtain the desired thickness of the fibre layers 61.
In the above embodiment, the joint portion 71 is formed by melting the resin material forming the frame 51. Alternatively, when the fibers forming the fiber layer 61 are meltable, the joint 71 may be formed by melting the fiber layer 61. Further, the joint portion 71 may be formed by supplying a fluid adhesive between the frame 51 and the fiber layer 61 and curing the adhesive. Even in this case, by the plurality of engaging portions 71, it is possible to provide reliable fixation that can withstand the fuel flow, the pressure difference.
In the above embodiment, the engaging portions 71a are provided between the first layer of the belt-like material 62 and the plurality of ribs 55, and the engaging portions 71b are provided between the third layer of the belt-like material 62 and the ribs 55 b. Alternatively, only the first joint portion 71a and the last joint portion 71b may be provided. Further, only a part of the plurality of engaging portions 71a may be provided. A part of the plurality of joints 71a may be a joint passing through a plurality of layers, similar to the joint 71 b.
In the above embodiment, the sealing is provided by bringing both end faces of the fiber layer 61 into contact with the flat faces 52b, 53 b. Alternatively, the frame 51 may be bonded to the fiber layer 61 to provide a seal. For example, an adhesive may be disposed between the frame 51 and the fiber layer 61. For example, a welded portion may be provided between the frame 51 and the fiber layer 61, and the resin material forming the frame 51 may be melted and resolidified.
In the above embodiment, the coupling portions provided by the engaging portions 22a, 51a are engaging mechanisms. Alternatively, a coupling mechanism using a screw may be provided. Alternatively, the water content collector 32 and the cup 22 may be permanently joined. For example, the frame 51 of the moisture agglomerator 32 is welded or bonded to the cup 22. In the above embodiment, the coupling portion provided by the coupling tube 46 and the cylindrical portion 52a is a fluid coupling having a sealing property, and the fluid coupling is provided by the insertion relationship between the tube and the tube. Alternatively, a sealing member such as an O-ring or a lip seal may be provided. Further, the screw connection may be used together. Alternatively, it may be provided by axial pressing between the end faces or by press-fitting between both members.

Claims (20)

1. A moisture agglomerator, comprising:
a frame (51) that allows fuel to flow in a radial direction;
a fiber layer (61) which is a cylindrical fiber layer that is attached to the frame and that aggregates moisture in the fuel, and which includes a roll of a band-shaped material (62) that is arranged in two or more turns so as to overlap two or more layers in the radial direction; and
a plurality of joints (71) securing the fibrous layers to the frame; wherein
The plurality of joining sections (71) are arranged in a dispersed manner on the cylindrical outer peripheral surface of the fiber layer (61).
2. A moisture agglomerator, comprising:
a frame (51) that allows fuel to flow in a radial direction;
a fiber layer (61) which is a cylindrical fiber layer that is attached to the frame and aggregates moisture in the fuel, and which includes a roll body of a band-shaped material (62) that is arranged so as to at least partially overlap two or more layers in the radial direction; and
a plurality of joints (71) securing the fibrous layers to the frame; wherein the content of the first and second substances,
the plurality of joints have through joints (71b) that join the material forming the last layer, which is arranged apart from the frame by at least one intermediate layer, to the frame through the intermediate layer.
3. The moisture agglomerator of claim 2, wherein the material is configured in two or more turns so as to overlap two or more layers in the radial direction.
4. The moisture agglomerator of claim 2, wherein a plurality of the junctions further have,
an abutting joint portion (71a) that joins the material forming a first layer in the radial direction from the frame to the frame.
5. A water coalescer according to claim 4,
the material having one end (63) and another end (64) in the length direction;
said abutment joint (71a) joining said material to said frame in the vicinity of said one end (63);
the through-joint (71b) joins the material to the frame in the vicinity of the other end (64).
6. A water trap according to any of claims 1-5,
the frame has a plurality of support portions (56) that are disposed radially inside or radially outside the fiber layer and adjacent to the inner or outer circumferential surface of the fiber layer;
the plurality of engagement portions are provided on the plurality of support portions, respectively.
7. A water trap according to any one of claims 1-5, wherein a plurality of said junctions are arranged circumferentially and axially apart from each other.
8. A water trap according to any of claims 1-5,
the frame has a plane (52b, 53b) opposite to both end faces of the fiber layer,
the fibrous layer has two end faces that are in contact with only the plane.
9. A water collector according to claim 1 or 2, which is housed in a housing (6) forming a fuel passage together with a filter removing solid foreign matters from the fuel to collect the water in the fuel,
the moisture condenser includes a housing coupling portion (51a) formed to maintain a coupled state with the housing even in a state where the filter is removed from the housing.
10. The moisture agglomerator of claim 9, comprising:
a frame (51) that allows fuel to flow in a radial direction; and
a fiber layer (61) attached to the frame to aggregate moisture in the fuel; wherein
The housing coupling portion is provided on the frame.
11. The moisture coalescer according to claim 9, further comprising a fluid junction (52a) providing a junction of fuel channels for flow of fuel into the moisture coalescer;
the housing connecting portion is formed so as to be able to maintain a connected state with the housing even in a state where the connection in the fluid connecting portion is released.
12. The moisture agglomerator of claim 9, wherein the housing has a lid and a cup separably joined by a joining mechanism (23);
the shell connecting part is connected with the cup body.
13. A water trap according to claim 12, wherein the housing coupling portion releases the coupled state with the cup body by an operation different from an operation of separating the lid body and the cup body on the coupling mechanism.
14. A fuel filtration device, comprising:
a water coalescer (32, 232, 532) according to any of claims 1-5;
a filter that removes solid foreign matter from the fuel; and
a housing (6) defining a fuel passage and housing the moisture trap and the filter.
15. The fuel filtration device of claim 14, further comprising a moisture separation layer (233, 333, 433) disposed downstream of the moisture trap to prevent passage of water droplets.
16. A method for manufacturing a water condenser,
the moisture agglomerator includes: a frame (51) that allows fuel to flow in a radial direction; and a cylindrical fiber layer for aggregating moisture in the fuel;
the manufacturing method of the water collector comprises the following steps:
a winding step of winding a belt-like material (62) in which moisture in fuel is condensed, into a roll body in which at least two layers are partially overlapped, on the inside or outside of the frame; and
a bonding step of bonding the fiber layer to the frame; wherein
The winding step includes a step of disposing a last layer from the frame with at least one intermediate layer interposed therebetween;
the bonding process has a step of bonding the material forming the last layer to the frame through the intermediate layer.
17. A method of making a water collector according to claim 16, wherein said bonding step includes:
an abutting joining step of joining only the first layer in the radial direction to the frame; and
the radially last layer is bonded to the frame through the intermediate layer throughout the bonding step.
18. A method of making a water agglomerator according to claim 16 or 17, further comprising,
forming a flat surface (52b, 53b) on the frame, the flat surface facing both end surfaces of the fiber layer;
in the winding step, the material is wound while bringing a longitudinal end surface extending in the longitudinal direction into contact with the flat surface.
19. A fuel filtration device, comprising:
the moisture agglomerator of claim 9, the housing, and the filter.
20. The fuel filtration device of claim 19, further comprising a moisture separation layer (233, 333, 433) disposed downstream of the moisture trap to inhibit passage of water droplets.
CN201780041715.3A 2016-07-05 2017-06-09 Moisture collector, fuel filter device, and method for manufacturing moisture collector Active CN109416006B (en)

Applications Claiming Priority (5)

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JP2016133710A JP6658361B2 (en) 2016-07-05 2016-07-05 Water coagulator, fuel filter device, and method of manufacturing water coagulator
JP2016-133711 2016-07-05
JP2016133711A JP2018003758A (en) 2016-07-05 2016-07-05 Water condenser and fuel filter device
JP2016-133710 2016-07-05
PCT/JP2017/021413 WO2018008327A1 (en) 2016-07-05 2017-06-09 Water flocculator, fuel filter device, and method for manufacturing water flocculator

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