The disclosure of Japanese Patent Application No. 2003-327092 filed on Sep. 19, 2003 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
1. Field of the Invention
The present invention relates to a filter unit. More specifically, it relates to a filter unit obtained through a simplified manufacturing process.
2. Description of the Related Art
A known filter unit for removing foreign matter in fuel is provided upstream or downstream of a fuel pump in a motor vehicle. With strong demands for reduction in the weight and cost of each motor vehicle part or component, various measures have also been taken for such fuel filter units.
As one example of such a cost and weight reduced filter unit, the applicant has proposed a filter unit indicated in FIGS. 16 to 18, which includes a filter element that is able to be manufactured without adhesive, and therefore in a simplified manufacturing process (see Japanese Laid Opened Patent Application No. 2002-282626).
Referring to FIGS. 16 to 18, a filter element 1 has a three-layer structure including a coarse layer 1b formed of non-woven fabric and serving as a passage portion through which fuel just passes, a fine layer 1a formed of non-woven fabric and serving as a filtering portion for removing foreign matter in fuel, and another coarse layer 1b formed of non-woven fabric and serving as said passage portion. The filter element 1 is folded (or two pieces of the filter element 1 are placed on the top of other) such that a V-shaped filter 2 having an opening 3 in one side is formed, and a filter assembly 5 is obtained by rolling the V-shaped filter 2 around a core 4 as shown in
In this case, however, the opposite surfaces of the coarse layer 1b must be bonded by thermal welding, or the like, before rolled around the core 4. The portion of the V-shaped filter 2 shown in the left side in
Thermal welding is performed using an iron 6. The iron 6 has a forked tip including heating portions 6a at the inner sides facing each other and non-heating portions 6b at the outer sides. When welding the filter element 1, the iron 6 is made to sandwich the upper end of one internal portion of the V-shaped filter 2 and the upper end of another portion of the V-shaped filter 2 facing that portion, and the iron 6 is then moved circularly about the core 4 as indicated by an arrow R in
Subsequently, the filter element 5 is fit into a case 8 having a fuel inlet 9 and a fuel outlet 10, whereby a fuel filter unit A is obtained. Fuel flows through the fuel inlet 9 into the case 8 and passes through the coarse layer 1b at the opening 3 in the upper side of the filter element 5 and the fine layer 1a in which foreign matter is removed. After filtered at the fine layer 1a, the fuel passes through the coarse later 1b in the other side and flows out via the fuel outlet 10.
In this fuel filter unit A, however, the outer surface of the filter element 5 needs to be bonded to the inner surface of the case 8 to prevent unfiltered fuel from passing through the fuel filter unit A.
Meanwhile, referring to
The use of the adhesive 12 however requires at least one applying process in the manufacturing procedure and additional material cost for the adhesive 12, thereby increasing the total manufacturing cost accordingly. Also, care must be taken to ensure a sufficient bonding (sealing) quality since adhesive usually hardens depending on the temperature and humidity or through chemical reaction between base material and hardening agent. Furthermore, in recent years, polyacetal resin has been increasingly used as material for such a case owing to its relatively low cost and high swellability. However, polyacetal resin involves a problem that its adhesive applicability is low, and therefore the filter assembly can only be fixed with low adhesiveness.
In view of the above problems, the invention has been made to provide a filter unit which is able to be manufactured by fixing a filter assembly into a case without adhesive, thus achieving simplified manufacturing process and reduced cost.
To accomplish the above object, a first aspect of the invention relates to a filter unit for removing foreign matter in flowing body which includes a filter assembly and a case for containing the filter assembly. The filter assembly include (i) a filter element two surfaces of which are attached so that an internal space is formed between them, the filter element being rolled or folded into a specific shape, and (ii) an annular member through which the flowing body flows into or out of the filter assembly. One end of the annular member is placed within the internal space of the filter element, while the other end of the annular member is placed outside of the same internal space. The case has a case inlet through which the flowing body flows into the case and a case outlet through which the flowing body flows out from the case. Either the case inlet or the case outlet is in communication with the other end of the annular member of the filter assembly.
According to the above structure, the filter assembly is able to be fixed to the case simply by connecting the other end of the annular member to the case inlet or the case outlet irrespective of the state of abutment between the outer surface of the filter assembly and the internal surface of the case. Accordingly, the need of adhesive is eliminated and installation of the filter assembly into the case is simplified, thus reducing the production cost.
A second aspect of the invention relates to a filter unit for removing foreign matter in flowing body, which includes a filter assembly and a case for containing the filter assembly. The filter assembly includes (i) two filter elements attached so that an internal space is formed between the two surfaces of the filter element, the filter elements being together rolled or folded into a specific shape, and (ii) an annular member through which the flowing body flows into or out of the filter assembly. One end of the annular member is placed within the internal space between the filter elements, while the other end of the annular member is placed outside of the same internal space. The case has a case inlet through which the flowing body flows into the case and a case outlet through which the flowing body flows out from the case, either the case inlet or the case outlet being in communication with the other end of the annular member of the filter assembly.
According to this structure, the same advantages and effects as the first aspect of the invention are able to be obtained.
The foregoing and/or further objects, features and advantages of the invention will become more apparent from the following description of preferred embodiment with reference to the accompanying drawings, in which like numerals are used to represent like elements and wherein:
Exemplary embodiments of the invention will be described with reference to the accompanying drawings. First of all, it is to be noted that while the invention has been embodied as a flitter device provided downstream of a fuel pump in a motor vehicle in each exemplary embodiment the invention is not limited to such use in a motor vehicle.
A first exemplary embodiment will hereinafter be described. Referring to
The filter element 20 is folded so that two surfaces thereof are attached. To obtain such a form of the filter element 20, one filter element 20 may be folded at the center to lay one side on the other as in this embodiment, or two filter elements 20 may instead be layered on each other, for example. Thus, fuel is made to flow through the coarse layer 22, the fine layer 21, and another coarse layer 22.
Also if non-woven fabric made of polyester, polypropylene, rayon, acetate, or the like, is used as material for the filter element 20, it would become easier to bond the filter element 20 by thermal welding, or the like.
In this structure, fuel passes through one of the coarse layers 22, the low density layer 24, the high density layer 25, and the other of the coarse layers 22. While the fine layer 21 include two sub-layers in this example, it may include more than two sub-layers arranged in such an order that the filter density increases along with the fuel flow direction. Accordingly, such a multi-layered filter element may also be used to form the filter element 20. Hereinafter, a filter assembly 35 refers to a filter assembly constituted by the filter element 20 and an annular member 26, while a fuel filter unit A refers to a fuel filter unit including the filter assembly 35 and other necessary components.
In the meantime, it is conceivable that, when the two surfaces of the filter element 20 are attached as aforementioned, the space for allowing fuel to flow inside the 20 may be insufficient. To counter this, in this exemplary embodiment, convex and concave dimples 23 are formed on the opposite internal surfaces in the filter element 20 (see
In the first exemplary embodiment, referring to
In the first exemplary embodiment, the filter element 20 formed of three layers and having an elongated rectangular shape, shown in
The annular member 26 is made of resin and has an upper opening 27 and a lower opening 28. A plurality of side holes 29 for facilitating the flow of fuel are formed substantially in the lower side of the annular member.
The annular member 26 is fit into the filter element 20 along the folded portion 32 in such a way that the side holes 29 are located in the filter element 20 while the upper portion of the filter element 20 projects upward from the upper end of the filter element 20. The two attached surfaces of the filter element 20 are then firmly bonded along the remaining three sides by thermal welding, or the like, and the filter element 20 and the annular member 26 are firmly bonded together at their contact portions in the same manner.
As a result, a space 31 is formed in the filter element 20 which leads to the outside via the lower opening 28, the side holes 29, and the upper opening 27. It is understood that there is substantially no clearance at the space 31 while the drawings show some. According to this structure, fuel passes through the coarse layers 22 on both sides. To facilitate the flow of fuel towards the space 31, the side holes 29 may be made face towards the space 31 or the opening area of the side hole(s) 29 facing the space 31 may be made larger than others.
The filter element 20 is then rolled around the annular member 26 as a core to provide the filter assembly 35 shown in
Having the foregoing structure, the filter assembly 35 works both in a case in which fuel enters the filter assembly 35 from the peripheral portion of the filter element 20 and flows out via the upper opening 27 of the annular member 26, and in a case in which fuel enters the filter assembly 35 from the upper opening 27 of the annular member 26 and flows out via the peripheral portion of the filter element 20
While the filter assembly 35 has been formed by rolling the filter element 20 around the annular member 26, the filter element 20 may instead be rolled about one end portion of the filter element 20 (rightmost end portion in
Next, a second exemplary embodiment of the invention will be described with reference to FIGS. 7 to 9. The filter element 20 having three layers (see
The annular member 26 shown in FIGS. 4 to 6 is also used in this embodiment. The annular member 26 is inserted into the center portion of the filter element 20 folded as aforementioned, perpendicularly with respect to the folded portion 32 such that the side holes 29 are located in the filter element 20 while the upper portion of the filter element 20 projects upward from the filter element 20. The two surfaces of the filter element 20 are then firmly bonded along the remaining three sides by thermal welding, or the like, and the filter element 20 and the annular member 26 are firmly bonded together at their contact portions in the same manner.
Accordingly, left and right spaces 31 are formed in the filter element 20 each leading to the outside via the lower opening 28, the side holes 29, and the upper opening 27. It is understood that there is substantially no clearance at each space 31 while the drawing shows some. According to this structure, fuel passes through the coarse layers 22 on both sides. To facilitate the flow of fuel towards the space 31, as in the first exemplary embodiment, the side holes 29 may be made face towards the space 31 or the opening area of the side hole(s) 29 facing the space 31 may be made larger than others.
Then, referring to
Having the foregoing structure, the filter assembly 35 works both in a case in which fuel enters the filter assembly 35 from the peripheral portion of the filter element 20 and flows out via the upper opening 27 of the annular member 26, and in a case in which fuel enters the filter assembly 35 from the upper opening 27 of the annular member 26 and flows out through the peripheral portion of the filter element 20
In the second exemplary embodiment, too, the non-woven fabric shown in
Next, a third exemplary embodiment will be described with reference to FIGS. 10 to 12. The filter element 20 shown in
In the third exemplary embodiment, referring to
The annular member 26 is fit into the filter element 20 such that the vertical pipe 26a is projected upwards through the opening 33 formed at the center of the upper piece of the filter element 20 and the lateral pipe 26b extends in parallel to the lateral direction of the annular member 26. Then, the upper and lower pieces of the filter element 20 are firmly bonded along all sides by thermal welding, or the like, and the vertical pipe 26a is firmly bonded to the inner periphery of the opening 33 in the same manner.
As a result, a space 31 is formed in the filter element 20 which leads to the outside via the lower opening 28 and the side holes 20 of the annular member 26. Also in this exemplary embodiment, to facilitate the flow of fuel towards the space 31, the side holes 29 may be made face towards the space 31 or the opening area of the side hole(s) 29 facing the space 31 may be made larger than others.
Then, the right and left portions of the filter element 20 are folded several times such that each fold line is in parallel to the axis of the annular member 26 and each folded surface of the filter element 20 extends in the right-left direction substantially symmetrically about the annular member 26. The filter element 20 is then fastened by a band, or the like, to be retained in the folded form.
In the third exemplary embodiment, too, the non-woven fabric shown in FIG. 2 in which the fine layer includes two or more sub-layers may be used as the filter element 20. Also, the filter paper having the dimples 23 shown in
In this case, too, the annular member 26 shown in
As a result, a space 31 is formed in the end portion of the filter element 20 which leads to the outside via the side holes 29, the lower opening 28, and the upper opening 27 of the annular member 26. Also in this exemplary embodiment, to facilitate the flow of fuel towards the space 31, the side holes 29 may be made face towards the space 31 or the opening area of the side hole(s) 29 facing the space 31 may be made larger than others.
Then, the filter element 20 is folded several times from one end thereof such that each fold line is in parallel to the axis of the lateral pipe 26b and the folded surfaces of the filter element 20 are lined up in the vertical direction under the annular member 26. The filter element 20 is then fastened by a band, or the like, to be retained in the folded form.
In this case, too, the non-woven fabric shown in
The filter assembly 35 is installed in the case 40 in the following procedure, for example. The annular member 26 of the filter assembly 35 is inserted into the upper pipe portion 42 of the cap 41 from the bottom side, and the annular member 26 and the upper pipe portion 42 are bonded at their contact portions. Then, the cap 41 to which the filter assembly 35 has been fixed as above is then placed on the case 40 so as to cover the upper opening of the case 40, and the upper end of the case 40 and the bottom surface of the cap 41 are bonded by thermal welding, or the like. Thus, a space 48 for facilitating the flow of fuel is formed between the output surface of the filter assembly 35 and the inner surface of the case 40.
While in the above example the case 40 and the cap 41 have been described as separate components, they may together be regarded as the case. Meanwhile, having the foregoing structure, the fuel filter unit A works both in a case in which fuel enters 40 from the upper pipe portion 42 and flows out via the annular member 26, the filter element 20, and the lower pipe portion 43, and in a case in which the fuel flows in reverse.
Another form of the fuel filter unit A is shown in
The flange 47 is placed on the case 40 to cover the upper opening of the case 40, and the cap 41, which has been formed to have a concave shape in section in this example, is then placed on the top of the flange 47. Subsequently, the bottom surface of the flange 47 and the upper end of the case 40 are bonded by thermal welding, or the like, and so are the top surface of the flange 47 and the lower end of the cap 41.
Accordingly, since the filter assembly 35 is fixed to the case 40 via the flange 47, the annular member 26 and the upper pipe portion 42 are not necessarily positioned in line with each other, therefore the upper pipe portion 42 is able to be easily formed at a desired position with respect to the cap 41, increasing its design freedom. While in the above example the case 40 and the cap 41 have been described as separate components, they may together be regarded as the case.
The fuel pump 51 is connected to an opening 54 of the plate 53, the rim of which projects downward. The flange 47 to which the filter assembly 35 has been fixed as mentioned above is then sandwiched at its circumference between the upper end of the case 52 and the lower end of the cap 41 and the cap 41 having the upper pipe portion 42 is placed on the top of the fuel tank 50.
According to this structure, fuel pumped up from the fuel tank 50 by the fuel pump 51 is made to flow through the opening 54 into the fuel filter unit A located downstream of the fuel pump 51. After filtered by the fuel filter unit A, the fuel then flows out from the tank 50 via the upper opening 27 and the upper pipe portion 42. While the fuel filter unit A is installed in the fuel tank 50 in this example, it may instead be provided outside of the fuel tank 50. In the foregoing structure, the filter unit A according to the invention has been applied to a gasoline engine in which the filter unit A is provided downstream of the fuel pump 51, the filter unit A may instead be used in, for example, a diesel engine and provided upstream of a fuel tank, as shown in
Also, motor vehicle application does not limit at all the scope of the invention, but the invention may be embodied as a filter unit for other use. Namely, while the invention has been described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the preferred embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements other than described above. In addition, while the various elements of the preferred embodiments are shown in various combinations and configurations, which are exemplary, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.
Number | Date | Country | Kind |
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2003-327092 | Sep 2003 | JP | national |