WO2013149533A1 - 一种空滤器及其制备工艺 - Google Patents

一种空滤器及其制备工艺 Download PDF

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Publication number
WO2013149533A1
WO2013149533A1 PCT/CN2013/072273 CN2013072273W WO2013149533A1 WO 2013149533 A1 WO2013149533 A1 WO 2013149533A1 CN 2013072273 W CN2013072273 W CN 2013072273W WO 2013149533 A1 WO2013149533 A1 WO 2013149533A1
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WIPO (PCT)
Prior art keywords
density
air filter
parts
tpe
filter element
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Application number
PCT/CN2013/072273
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English (en)
French (fr)
Inventor
朱崇明
Original Assignee
福建华昆特种汽车配件有限公司
福州华昆赛车配件技研有限公司
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Application filed by 福建华昆特种汽车配件有限公司, 福州华昆赛车配件技研有限公司 filed Critical 福建华昆特种汽车配件有限公司
Publication of WO2013149533A1 publication Critical patent/WO2013149533A1/zh

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Classifications

    • 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
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • F02M35/02408—Manufacturing filter elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0002—Casings; Housings; Frame constructions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/10—Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
    • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
    • 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
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • F02M35/02441—Materials or structure of filter elements, e.g. foams
    • F02M35/0245—Pleated, folded, corrugated filter elements, e.g. made of paper
    • 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
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • F02M35/02475—Air cleaners using filters, e.g. moistened characterised by the shape of the filter element
    • F02M35/02491—Flat filter elements, e.g. rectangular

Definitions

  • the present invention relates to the field of filters, and more particularly to an air filter and a process for its preparation. Background technique
  • the air filter is a device for removing particulate impurities in the air, including an air filter fixing frame and a filter element.
  • air filters There are two main types of air filters available:
  • the fixing frame is made of hard outer frame such as PP or PA and rubber side band.
  • the material of the filter element is paper.
  • the air filter is formed by the injection molding process between the fixing frame and the filter element.
  • the air filter has a low ventilation, and the flexibility of the fixing frame material is very poor, and a gap between the fixing frame and the filter element is likely to occur during use, resulting in poor sealing, and the fixing frame of the material can only Disposable, difficult to recycle, can not be degraded, does not meet the requirements of low cost and environmental protection;
  • the material of the fixing frame is PU
  • the material of the filter element is non-woven fabric
  • the air filter is formed between the fixing frame and the filter element by the potting process.
  • the air filter has low production efficiency and high process control difficulty.
  • the individual products must be dried in the production process, the energy consumption is large, and the surface is prone to defects such as pores, and the appearance is not beautiful. Summary of the invention
  • the technical problem to be solved by the present invention is to provide an air filter having good sealing property, recyclable degradation, and flat appearance, and a preparation process thereof.
  • one technical solution adopted by the present invention is:
  • An air filter comprising a fixing frame and a filter element, wherein a peripheral edge of the filter element is embedded in a frame of the fixing frame, the fixing frame is made of a TPE, and the filter element comprises two layers of iron mesh and is sandwiched between two
  • the non-woven fabric between the layers of iron mesh, the fixing frame and the filter element are integrally formed by an insert molding process.
  • the nonwoven fabric is a pleated nonwoven fabric coated with an air filter oil.
  • the production formula of the TPE comprises the following components by weight:
  • thermoplastic styrene butadiene rubber with a density of 0.93g/cm 3 ;
  • the density is 1.0g/cm 3 .
  • the TPE is obtained by the following steps:
  • Step 1 Ingredients: Mix the following parts by weight:
  • thermoplastic styrene butadiene rubber with a density of 0.93g/cm 3 ;
  • the density is 1.0g/cm 3 .
  • Step 2 Extrusion granulation
  • the mixed materials are placed in a twin-screw extrusion granulator.
  • the insert molding process comprises the following steps:
  • Step 1 Preparing the material: The TPE is piped to the feeding port of the vertical injection molding machine, and the filter core is placed in a mold for molding the air filter fixing frame, and the peripheral edge of the filter element is located in the frame cavity of the mold;
  • Step 2 heating and melting: controlling the heating temperature of the heating cylinder of the vertical injection molding machine is 120 ° C ⁇ 180 ° C, melt plasticizing TPE;
  • Step 3 Injection molding: The molten TPE is injected at an injection pressure of 20 to 100 kg/cm 3 Injection into the mold described in step 1;
  • Step 4 Cooling: After the mold is cooled, open the mold and take out the injection molded parts to obtain the air filter with the fixed frame and the filter element integrally formed.
  • the air filter of the invention adopts a fixing frame of a thermoplastic elastomer TPE material and a filter element of a non-woven material, and the fixing frame and the filter element are integrally formed by an insert molding process, so that the fixing frame and the filter element can be tightly combined and are not easily separated, and the sealing effect is good.
  • the service life of the air filter is improved; the process control of the insert molding process is difficult, the production efficiency of the single product is more than 10 times higher than that of the glue filling process, and the appearance defects of the injection molded product are small, so the production efficiency is greatly improved.
  • the energy consumption is greatly reduced, and the appearance of the product is flat and beautiful. Because the TPE is environmentally friendly and non-toxic and can be recycled, the fixed frame can be reused many times, which reduces the production cost, and is easy to degrade even if it is degraded, greatly reducing environmental pollution. .
  • a preparation process of an air filter comprising the following steps:
  • Step 1 Prepare the filter element, including the following steps:
  • Step 2 Insert molding, including the following steps:
  • TPE is piped to the feed port of the vertical injection molding machine, and the filter element is placed in a mold for molding the air filter fixing frame, and the peripheral edge of the filter element is located in the frame cavity of the mold;
  • heating and melting controlling the heating temperature of the heating cylinder of the vertical injection molding machine is 120 ° C: ⁇ 180 ° C, the TPE is melt plasticized;
  • G injection molding: the molten TPE is injected into the mold described in step E at an injection pressure of 20 to 100 kg/cm 3 ;
  • Cooling After the mold is cooled, open the mold and take out the injection molded parts to obtain the air filter with the fixed frame and the filter element integrally formed;
  • Step 3 Post-forming processing, including the following steps:
  • Step 1 Ingredients: Mix the following parts by weight:
  • thermoplastic styrene butadiene rubber with a density of 0.93g/cm 3 ;
  • the density is 1.0g/cm 3 .
  • Step 2 Extrusion granulation: The mixed materials are placed in a twin-screw extrusion granulator and extruded at 180 to 210 ° C for granulation.
  • the step 3 further comprises a pad printing and packaging step.
  • the air filter preparation process of the invention is a preparation process which is specially designed for the insert frame of the TPE material and the filter element of the non-woven material. Since the fixing frame of the TPE material has good elasticity, and the insert molding process can make the fixing frame and the filter element integrally formed and be more closely combined, the air filter preparation process of the invention can prepare the air filter with superior sealing performance.
  • the forming process of the fixed frame is also the assembly process of the fixed frame and the filter element, and it is no longer necessary to separately produce the fixed frame and the filter element before performing the two
  • the assembly process greatly shortens the production cycle of the air filter, and the production efficiency of a single product is 10 times higher than that of the glue filling process.
  • the TPE injection molding product has few appearance defects, so the air filter preparation process of the invention can greatly improve the production efficiency, greatly reduce the energy consumption, and the appearance of the air filter is flat and beautiful.
  • Fig. 1 is a perspective view showing an air filter of the present invention.
  • Figure 2 is a schematic cross-sectional view showing the air filter of the present invention.
  • Fig. 3 is a flow chart showing the process of preparing the air filter of the present invention.
  • the air filter of the present invention includes a fixing frame 1 and a filter element 2 , and a peripheral edge of the filter element 2 is embedded in a frame of the fixing frame 1 , and the fixing frame 1 is made of a TPE.
  • the filter element 2 comprises two layers of iron mesh and a non-woven fabric sandwiched between two layers of iron mesh, and the fixing frame 1 and the filter element 2 are integrally formed by an insert molding process.
  • the nonwoven fabric is a pleated nonwoven fabric coated with an air filter.
  • the application of air filter oil can ensure the air filter's ability to capture dust while ensuring ventilation.
  • the pleated design increases the surface area of the filter element, thus increasing the air filter ventilation.
  • Example 1 the production formula of the TPE comprises the following components by weight: 15 parts of ethylene propylene diene rubber, density of 0.95 g / cm 3 ;
  • thermoplastic styrene butadiene rubber with a density of 0.93g/cm 3 ;
  • the density is 1.0g/cm 3 .
  • the TPE prepared according to the above formula has an air filter fixing frame which not only has a flat appearance, but also has sufficient strength and good flexibility, and can be kept tight with a non-woven filter element in a high-frequency vibration environment. The fit does not separate, thus greatly improving the sealing performance of the air filter.
  • Step 1 Ingredients: Mix the raw materials of each component according to the production formula of TPE; Step 2. Extrusion granulation: Put the mixed materials into the twin-screw extrusion granulator
  • the TPE pellets obtained through the above steps have better injection molding properties.
  • the insert molding process includes the following steps:
  • Step 1 Preparing the material: The TPE is piped to the feeding port of the vertical injection molding machine, and the filter core is placed in a mold for molding the air filter fixing frame, and the peripheral edge of the filter element is located in the frame cavity of the mold;
  • Step 2 heating and melting: controlling the heating temperature of the heating cylinder of the vertical injection molding machine is 120 ° C ⁇ 180 ° C, melt plasticizing TPE;
  • Step 3 injection molding: the molten TPE is injected into the mold described in step 1 at an injection pressure of 20 to 100 kg/cm 3 ;
  • Step 4 Cooling: After the mold is cooled, open the mold and take out the injection molded parts to obtain the air filter with the fixed frame and the filter element integrally formed.
  • the air filter of the invention adopts a fixing frame of a thermoplastic elastomer TPE material and a filter core of a non-woven material, and the fixing frame and the filter element are integrally formed by an insert molding process, so that the fixing frame and the filter element can be tightly combined and are not easily separated, and the sealing effect is obtained.
  • the service life of the air filter is improved; the process control of the insert molding process is difficult, the production efficiency of a single product is more than 10 times higher than that of the glue filling process, and the appearance defects of the injection molded product are small, so the production efficiency is greatly improved.
  • the energy consumption is greatly reduced, and the appearance of the product is flat and beautiful. Because the TPE is environmentally friendly and non-toxic and can be recycled, the fixed frame can be reused many times, which reduces the production cost, and is easy to degrade even if it is degraded, greatly reducing environmental pollution. .
  • the preparation method of the air filter of the present invention comprises the following steps: Step 1. Preparing a filter element, comprising the following steps:
  • Non-woven fabric coated with air filter oil can effectively ensure the ability to capture dust while ensuring ventilation.
  • the pleated design increases the surface area of the filter element, thus increasing the ventilation of the air filter.
  • Step 2 Insert molding, including the following steps:
  • TPE is piped to the feed port of the vertical injection molding machine, and the filter element is placed in a mold for molding the air filter fixing frame, and the peripheral edge of the filter element is located in the frame cavity of the mold;
  • heating and melting controlling the heating temperature of the heating cylinder of the vertical injection molding machine is 120 ° C: ⁇ 180 ° C, melt plasticizing TPE;
  • injection molding the molten TPE is injected into the mold described in step E at an injection pressure of 20 to 100 kg/cm 3 ;
  • Cooling After the mold is cooled, open the mold and take out the injection molded parts to obtain the air filter with the fixed frame and the filter element integrally formed;
  • Step 3 Post-forming processing, including the following steps: I. Trimming: Remove a small amount of flash and flash from injection molding.
  • the TPE is produced by the following steps:
  • Step 1 Ingredients: Mix the following parts by weight:
  • thermoplastic styrene butadiene rubber with a density of 0.93g/cm 3 ;
  • the density is 1.0g/cm 3 .
  • Step 2 Extrusion granulation: The mixed materials are placed in a twin-screw extrusion granulator and extruded at 180 to 210 ° C for granulation.
  • the TPE prepared according to the above formula and preparation method has an air filter fixing frame which not only has a flat appearance, but also has sufficient strength and good flexibility, and can be used in a high-frequency vibration environment and a non-woven material.
  • the filter element remains tightly fitted without separation, thus greatly improving the sealing performance of the air filter.
  • the step 3 further includes a pad printing and packaging step. That is, the trademark and the item number are printed on the trimmed product, and the product is packaged in a plastic bag, a color box, a box or a sticker according to the packaging requirements.
  • the air filter preparation process of the invention is a preparation process which is specially designed for the insert frame of the TPE material and the filter element of the non-woven material. Since the fixing frame of the TPE material has good elasticity, and the insert molding process can make the fixing frame and the filter element integrally formed and be more closely combined, the air filter preparation process of the invention can prepare the air filter with superior sealing performance.
  • the forming process of the fixed frame is also the assembly process of the fixed frame and the filter element, and it is no longer necessary to separately produce the fixed frame and the filter element before performing the two
  • the assembly process greatly shortens the production cycle of the air filter, and the production efficiency of a single product is 10 times higher than that of the glue filling process.
  • the TPE injection molding product has few appearance defects, so the air filter preparation process of the invention can greatly improve the production efficiency, greatly reduce the energy consumption, and the appearance of the air filter is flat and beautiful.
  • the air filter of the present invention is particularly suitable for use in an automobile engine because it has a large aeration amount, a good sealing property, and a good filtering effect on dust impurities in a gas entering the engine, thereby effectively improving the combustion efficiency and power of the engine.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Manufacturing & Machinery (AREA)
  • Filtering Materials (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

一种空滤器，包括固定框（1）和滤芯（2），所述滤芯（2）的四周边缘嵌设于所述固定框（1）的框体内，所述固定框（1）的材质为TPE，所述滤芯（2）的材质为无纺布，所述固定框（1）和滤芯（2）通过嵌件成型工艺一体成型。还包括一种空滤器的制备方法，包括制备滤芯步骤、嵌件成型步骤和成型后处理步骤。采用上述空滤器及其制备方法，密封性好、通气量大，可以提高发动机的燃烧效率并提升动力。

Description

一种空滤器及其制备工艺 技术领域
本发明涉及过滤器领域， 具体地说是一种空滤器及其制备工艺。 背景技术
空滤器， 即空气滤清器， 是用于清除空气中的微粒杂质的装置， 包 括空滤器固定框和滤芯。 现有的空滤器， 主要有以下两种：
1、 固定框的材质为 PP或 PA等硬质外框和橡胶边带， 滤芯的材质 为纸， 固定框和滤芯之间通过注塑工艺形成空滤器。 这种空滤器通气量 低， 由于固定框材质的柔韧性很差， 在使用过程中很容易出现固定框和 滤芯之间产生缝隙， 从而造成密封不良的情况， 且这种材质的固定框只 能一次性使用， 艮难回收利用， 也无法降解， 不符合低成本和环保的要 求；
2、 固定框的材质为 PU, 滤芯的材质为无纺布， 固定框和滤芯之间 通过灌胶工艺形成空滤器。这种空滤器的生产效率低，工艺控制难度高， 单个产品在生产过程中必须烘干，能耗大，且表面容易出现气孔等缺陷， 外观不美观。 发明内容
为了克服上述现有技术的不足， 本发明所要解决的技术问题是提供 一种密封性好、 可回收降解、 外观平整的空滤器及其制备工艺。
为了解决上述技术问题， 本发明釆用的一个技术方案为：
一种空滤器， 包括固定框和滤芯， 所述滤芯的四周边缘嵌设于所述 固定框的框体内， 所述固定框的材质为 TPE, 所述滤芯包括两层铁网和 夹设于两层铁网之间的无纺布， 所述固定框和滤芯通过嵌件成型工艺一 体成型。 其中， 所述无纺布为涂覆有空滤油的折褶式无纺布。
其中， 所述 TPE的生产配方包括以下重量份的组分:
三元乙丙橡胶 15份， 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份， 密度为 0.93g/cm3;
橡胶油 40份， 密度为 0.92g/cm3;
聚丙婦 13份， 密度为 0.90g/cm3;
碳酸钙 12份， 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3。
其中， 所述 TPE由以下步骤制得：
步骤 1、 配料： 将以下重量份的各组分充分混合:
三元乙丙橡胶 15份， 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份， 密度为 0.93g/cm3;
橡胶油 40份， 密度为 0.92g/cmj;
丙烯 13份， 密度为 0.90g/cm3;
碳酸钙 12份， 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3。
步骤 2、 挤出造粒 将混合好的物料放入双螺杆挤出造粒机在
180〜210°C下挤出造粒。
其中， 所述嵌件成型工艺包括以下步骤：
步骤 1、 备料： 将 TPE通过管道输送到立式注塑机的进料口， 将滤 芯置入用于成型空滤器固定框的模具内， 滤芯的四周边缘位于所述模具 的框体型腔内；
步骤 2、 加热熔融： 控制立式注塑机的加热筒的加热温度为 120°C 〜180°C , 将 TPE熔融塑化；
步骤 3、 注塑成型： 将熔融后的 TPE以 20〜100kg/cm3的注塑压力注 射入步骤 1所述的模具中；
步骤 4、 冷却： 待模具冷却后， 打开模具， 取出注塑件， 即可得到 固定框和滤芯一体成型的空滤器。
本发明空滤器釆用热塑性弹性体 TPE材质的固定框和无纺布材质 的滤芯， 且固定框和滤芯通过嵌件成型工艺一体成型， 因此固定框和滤 芯可以紧密结合且不易分离， 密封效果好， 提高了空滤器的使用寿命； 而嵌件成型工艺的工艺控制难度低， 单个产品的生产效率较灌胶工艺提 升 10倍以上， 且注塑成型的产品外观缺陷少， 因此生产效率大为提高， 耗能大为降低，产品外观平整美观；由于 TPE环保无毒且可以循环使用， 因此固定框可多次重复利用， 降低了生产成本， 即使 ^艮废也易于降解， 大大减少了对环境的污染。
为了解决上述技术问题， 本发明釆用的另一个技术方案为： 一种空滤器的制备工艺， 包括以下步骤：
步骤 1、 制备滤芯， 包括以下步骤：
A、 上油： 将空滤油均匀的喷涂在无纺布上；
B、 分切： 釆用红外线光电纠偏的分切机将步骤 1 所得的无纺布按 照产品要求的尺寸进行分切；
C、 打折： 将分切好的无纺布夹设于两层铁网之间， 并按照产品要 求的折高进行打折， 控制精度为 ± 0.2mm;
D、 裁切： 按照产品要求的折数， 对打折好的无纺布和铁网进行裁 切， 得到滤芯；
步骤 2、 嵌件成型， 包括以下步骤：
E、 备料： 将 TPE通过管道输送到立式注塑机的进料口， 将滤芯置 入用于成型空滤器固定框的模具内， 滤芯的四周边缘位于所述模具的框 体型腔内；
F、加热熔融：控制立式注塑机的加热筒的加热温度为 120°C：〜 180°C , 将 TPE熔融塑化； G、 注塑成型： 将熔融后的 TPE以 20〜100kg/cm3的注塑压力注射入 步骤 E所述的模具中；
H、 冷却： 待模具冷却后， 打开模具， 取出注塑件， 即可得到固定 框和滤芯一体成型的空滤器；
步骤 3、 成型后处理， 包括以下步骤：
I、 修边： 将注塑产生的少量飞边及溢料去除掉。
7、 根据权利要求 6 所述的空滤器的制备工艺， 其特征在于： 所述 TPE由以下步骤制得：
步骤 1、 配料： 将以下重量份的各组分充分混合：
三元乙丙橡胶 15份, 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份, 密度为 0.93g/cm3;
橡胶油 40份, 密度为 0.92g/cm3;
聚丙婦 13份, 密度为 0.90g/cm3;
碳酸钙 12份, 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3。
步骤 2、 挤出造粒： 将混合好的物料放入双螺杆挤出造粒机在 180〜210°C下挤出造粒。
其中， 所述步骤 3还包括移印和包装步骤。
本发明的空滤器制备工艺，是专门针对 TPE材质的固定框和无纺布 材质的滤芯而釆用的以嵌件成型工艺为核心的制备工艺。由于 TPE材质 的固定框具有良好的弹性， 且嵌件成型工艺可以使固定框和滤芯一体成 型而结合得更为紧密， 因此釆用本发明的空滤器制备工艺可以制备出密 封性能优越的空滤器， 并提高了空滤器的使用寿命； 由于嵌件成型工艺 的工艺控制难度低， 固定框的成型过程也是固定框和滤芯的装配过程， 无需再分别生产出固定框和滤芯后再进行两者的装配工序， 因此大大缩 短了空滤器的生产周期， 单个产品的生产效率较灌胶工艺提升 10倍以 上， 且 TPE注塑成型的产品外观缺陷少， 因此釆用本发明的空滤器制备 工艺可以使生产效率大为提高，耗能大为降低， 空滤器的外观平整美观。 附图说明
图 1所示为本发明的空滤器的立体图。
图 2所示为本发明的空滤器的横截面示意图。
图 3所示为本发明的空滤器制备工艺的工艺流程图。
标号说明：
1、 固定框 2、 滤芯 具体实施方式
为详细说明本发明的技术内容、 构造特征、 所实现目的及效果， 以 下结合实施例详予说明。
实施例 1
参照图 1所示， 本发明的空滤器包括固定框 1和滤芯 2, 所述滤芯 2 的四周边缘嵌设于所述固定框 1 的框体内， 所述固定框 1 的材质为 TPE, 所述滤芯 2包括两层铁网和夹设于两层铁网之间的无纺布， 所述 固定框 1和滤芯 2通过嵌件成型工艺一体成型。
在实施例 1中， 参照图 2所示， 所述无纺布为涂覆有空滤油的折褶 式无纺布。 涂覆空滤油可以在保证通气量的同时， 又能够有效的保证空 滤器对粉尘的捕捉能力； 而折褶式的设计， 加大了滤芯的表面积， 因此 提高了空滤器的通气量。
在实施例 1中， 所述 TPE的生产配方包括以下重量份的组分： 三元乙丙橡胶 15份， 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份， 密度为 0.93g/cm3;
橡胶油 40份， 密度为 0.92g/cm3;
聚丙烯 13份， 密度为 0.90g/cm3; 碳酸钙 12份， 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3。
按照上述配方制备而得的 TPE, 所制得的空滤器固定框不仅具有平 整的外观， 而且具备足够的强度和良好的柔韧性， 能够在高频震动环境 下与无纺布材质的滤芯保持紧密的贴合而不会分离， 因此大大提高了空 滤器的密封性能。
进一步的， 上述 TPE由以下步骤制得：
步骤 1、 配料： 按照 TPE的生产配方将各个组分原料充分混合； 步骤 2、 挤出造粒： 将混合好的物料放入双螺杆挤出造粒机在
180〜210°C下挤出造粒。
经上述步骤制得的 TPE粒料， 其注塑成型性能更好。
在实施例 1中， 所述嵌件成型工艺包括以下步骤：
步骤 1、 备料： 将 TPE通过管道输送到立式注塑机的进料口， 将滤 芯置入用于成型空滤器固定框的模具内， 滤芯的四周边缘位于所述模具 的框体型腔内；
步骤 2、 加热熔融： 控制立式注塑机的加热筒的加热温度为 120°C 〜180°C , 将 TPE熔融塑化；
步骤 3、 注塑成型： 将熔融后的 TPE以 20〜100kg/cm3的注塑压力注 射入步骤 1所述的模具中；
步骤 4、 冷却： 待模具冷却后， 打开模具， 取出注塑件， 即可得到 固定框和滤芯一体成型的空滤器。
本发明的空滤器釆用热塑性弹性体 TPE材质的固定框和无纺布材 质的滤芯， 且固定框和滤芯通过嵌件成型工艺一体成型， 因此固定框和 滤芯可以紧密结合且不易分离，密封效果好，提高了空滤器的使用寿命； 而嵌件成型工艺的工艺控制难度低， 单个产品的生产效率较灌胶工艺提 升 10倍以上， 且注塑成型的产品外观缺陷少， 因此生产效率大为提高， 耗能大为降低，产品外观平整美观；由于 TPE环保无毒且可以循环使用， 因此固定框可多次重复利用， 降低了生产成本， 即使 ^艮废也易于降解， 大大减少了对环境的污染。
实施例 2
参照图 2所示， 本发明的空滤器的制备方法， 包括以下步骤： 步骤 1、 制备滤芯， 包括以下步骤：
A、 上油： 将空滤油均匀的喷涂在无纺布上；
涂覆了空滤油的无纺布可以在保证通气量的同时， 又能够有效的保 证对粉尘的捕捉能力；
B、 分切： 釆用红外线光电纠偏的分切机将步骤 1 所得的无纺布按 照产品要求的尺寸进行分切；
C、 打折： 将分切好的无纺布夹设于两层铁网之间， 并按照产品要 求的折高进行打折， 控制精度为 ± 0.2mm;
折褶式的设计，加大了滤芯的表面积， 因此提高了空滤器的通气量。
D、 裁切： 按照产品要求的折数， 对打折好的无纺布和铁网进行裁 切， 得到滤芯；
步骤 2、 嵌件成型， 包括以下步骤：
E、 备料： 将 TPE通过管道输送到立式注塑机的进料口， 将滤芯置 入用于成型空滤器固定框的模具内， 滤芯的四周边缘位于所述模具的框 体型腔内；
F、加热熔融：控制立式注塑机的加热筒的加热温度为 120°C：〜 180°C , 将 TPE熔融塑化；
G、 注塑成型： 将熔融后的 TPE以 20〜100kg/cm3的注塑压力注射入 步骤 E所述的模具中；
H、 冷却： 待模具冷却后， 打开模具， 取出注塑件， 即可得到固定 框和滤芯一体成型的空滤器；
步骤 3、 成型后处理， 包括以下步骤： I、 修边： 将注塑产生的少量飞边及溢料去除掉。
在实施例 2中， 所述 TPE由以下步骤制得：
步骤 1、 配料： 将以下重量份的各组分充分混合:
三元乙丙橡胶 15份, 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份, 密度为 0.93g/cm3;
橡胶油 40份, 密度为 0.92g/cm3;
聚丙婦 13份, 密度为 0.90g/cm3;
碳酸钙 12份, 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3。
步骤 2、 挤出造粒： 将混合好的物料放入双螺杆挤出造粒机在 180〜210°C下挤出造粒。
按上述配方和制备方法所制得的 TPE, 所制得的空滤器固定框不仅 具有平整的外观， 而且具备足够的强度和良好的柔韧性， 能够在高频震 动环境下与无纺布材质的滤芯保持紧密的贴合而不会分离， 因此大大提 高了空滤器的密封性能。
在实施例 2中， 所述步骤 3还包括移印和包装步骤。 即把商标和货 号移印在经过修边处理后的产品上， 并把产品按照包装要求用塑料袋、 彩盒、 外箱或贴纸等包装起来。
本发明的空滤器制备工艺，是专门针对 TPE材质的固定框和无纺布 材质的滤芯而釆用的以嵌件成型工艺为核心的制备工艺。由于 TPE材质 的固定框具有良好的弹性， 且嵌件成型工艺可以使固定框和滤芯一体成 型而结合得更为紧密， 因此釆用本发明的空滤器制备工艺可以制备出密 封性能优越的空滤器， 并提高了空滤器的使用寿命； 由于嵌件成型工艺 的工艺控制难度低， 固定框的成型过程也是固定框和滤芯的装配过程， 无需再分别生产出固定框和滤芯后再进行两者的装配工序， 因此大大缩 短了空滤器的生产周期， 单个产品的生产效率较灌胶工艺提升 10倍以 上， 且 TPE注塑成型的产品外观缺陷少， 因此釆用本发明的空滤器制备 工艺可以使生产效率大为提高，耗能大为降低， 空滤器的外观平整美观。
本发明的空滤器， 特别适用于汽车发动机， 因其通气量大、 密封性 好、 对进入发动机内的气体中的粉尘杂质的过滤效果好， 因此能有效提 高发动机的燃烧效率和动力。
以上所述仅为本发明的实施例， 并非因此限制本发明的专利范围， 凡是利用本发明说明书内容所作的等效结构或等效流程变换， 或直接或 间接运用在其他相关的技术领域， 均同理包括在本发明的专利保护范围 内。

Claims

权 利 要 求 书
1、 一种空滤器， 包括固定框和滤芯， 所述滤芯的四周边缘嵌设于 所述固定框的框体内， 其特征在于： 所述固定框的材质为 TPE, 所述滤 芯包括两层铁网和夹设于两层铁网之间的无纺布， 所述固定框和滤芯通 过嵌件成型工艺一体成型。
2、 根据权利要求 1 所述的空滤器， 其特征在于： 所述无纺布为涂 覆有空滤油的折褶式无纺布。
3、 根据权利要求 1所述的空滤器， 其特征在于： 所述 TPE的生产 配方包括以下重量份的组分：
三元乙丙橡胶 15份, 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份, 密度为 0.93g/cm3;
橡胶油 40份, 密度为 0.92g/cm3;
聚丙婦 13份, 密度为 0.90g/cm3;
碳酸钙 12份, 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3。
4、 根据权利要求 3所述的空滤器， 其特征在于： 所述 TPE由以下 步骤制得：
步骤 1、 配料： 将以下重量份的各组分充分混合：
三元乙丙橡胶 15份， 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份， 密度为 0.93g/cm3;
橡胶油 40份, 密度为 0.92g/cm3;
聚丙婦 13份, 密度为 0.90g/cm3;
碳酸钙 12份, 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3;
步骤 2、 挤出造粒 将混合好的物料放入双螺杆挤出造粒机在 180〜210°C下挤出造粒。
5、 根据权利要求 1 所述的空滤器， 其特征在于： 所述嵌件成型工 艺包括以下步骤：
步骤 1、 备料： 将 TPE通过管道输送到立式注塑机的进料口， 将滤 芯置入用于成型空滤器固定框的模具内， 滤芯的四周边缘位于所述模具 的框体型腔内；
步骤 2、 加热熔融： 控制立式注塑机的加热筒的加热温度为 120°C 〜180°C , 将 TPE熔融塑化；
步骤 3、 注塑成型： 将熔融后的 TPE以 20〜100kg/cm3的注塑压力注 射入步骤 1所述的模具中；
步骤 4、 冷却： 待模具冷却后， 打开模具， 取出注塑件， 即可得到 固定框和滤芯一体成型的空滤器。
6、 一种空滤器的制备工艺， 其特征在于， 包括以下步骤： 步骤 1、 制备滤芯， 包括以下步骤：
A、 上油： 将空滤油均匀的喷涂在无纺布上；
B、 分切： 釆用红外线光电纠偏的分切机将步骤 1 所得的无纺布按 照产品要求的尺寸进行分切；
C、 打折： 将分切好的无纺布夹设于两层铁网之间， 并按照产品要 求的折高进行打折， 控制精度为 ± 0.2mm;
D、 裁切： 按照产品要求的折数， 对打折好的无纺布和铁网进行裁 切， 得到滤芯；
步骤 2、 嵌件成型， 包括以下步骤：
E、 备料： 将 TPE通过管道输送到立式注塑机的进料口， 将滤芯置 入用于成型空滤器固定框的模具内， 滤芯的四周边缘位于所述模具的框 体型腔内；
F、加热熔融：控制立式注塑机的加热筒的加热温度为 120°C：〜 180°C , 将 TPE熔融塑化；
G、 注塑成型： 将熔融后的 TPE以 20〜100kg/cm3的注塑压力注射入 步骤 E所述的模具中；
H、 冷却： 待模具冷却后， 打开模具， 取出注塑件， 即可得到固定 框和滤芯一体成型的空滤器；
步骤 3、 成型后处理， 包括以下步骤：
I、 修边： 将注塑产生的少量飞边及溢料去除掉。
7、 根据权利要求 6 所述的空滤器的制备工艺， 其特征在于： 所述 TPE由以下步骤制得：
步骤 1、 配料： 将以下重量份的各组分充分混合：
三元乙丙橡胶 15份, 密度为 0.95g/cm3;
热塑性丁苯橡胶 13份, 密度为 0.93g/cm3;
橡胶油 40份, 密度为 0.92g/cm3;
聚丙婦 13份, 密度为 0.90g/cm3;
碳酸钙 12份, 密度为 2.5g/cm3;
色母 2份， 密度为 1.6g/cm3;
其他助剂 5份， 密度为 1.0g/cm3;
步骤 2、 挤出造粒： 将混合好的物料放入双螺杆挤出造粒机在 180〜210°C下挤出造粒。
8、 根据权利要求 6 所述的空滤器的制备工艺， 其特征在于： 所述 步骤 3还包括移印和包装步骤。
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KR20030091411A (ko) * 2002-05-27 2003-12-03 (주)엠알 에어필터
KR100774443B1 (ko) * 2006-07-21 2007-11-08 (주)굿에어텍 에어필터의 플렉시블 스트립 제조용 열가소성 탄성중합체조성물

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CN106042246A (zh) * 2016-07-14 2016-10-26 宁波市恒辉盛业过滤科技有限公司 一种塑料滤芯热成型机
CN106042246B (zh) * 2016-07-14 2018-08-17 宁波市恒辉盛业过滤科技有限公司 一种塑料滤芯热成型机

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