FILTER ELEMENT, INTERIOR AIR FILTER AND PRODUCTION METHOD

Abstract

A filter element has a fold pack with a filter material folded in a zigzag shape. The fold pack has lateral fold profiles and an end fold section disposed at a head side of the fold pack. Lateral strips are attached to the lateral fold profiles of the fold pack. A seal section angularly projects at an angle away from the end fold section at the head side of the fold pack. The seal section is provided with at least one incision or cutout configured to receive a corresponding filter housing contour. A filter assembly with such a filter element is provided. The filter housing has a housing part with a filter housing contour provided with at least one engagement element. The at least one incision or cutout of the seal section receives the at least one engagement element of the filter housing contour.

Claims

1. A filter element comprising: a fold pack comprising a filter material folded in a zigzag shape, the fold pack comprising lateral fold profiles and an end fold section disposed at a head side of the fold pack; lateral strips attached to the lateral fold profiles of the fold pack; a first seal section angularly projecting at an angle away from the end fold section at the head side of the fold pack; wherein the first seal section comprises at least one first incision or cutout, configured to receive a corresponding first filter housing contour.

2. The filter element according to claim 1, further comprising a head strip attached to the end fold section, wherein the head strip comprises the first seal section.

3. The filter element according to claim 1, wherein the first seal section is formed by the end fold section projecting past the head side.

4. The filter element according to claim 1, further comprising a second seal section projecting laterally at an angle away from a first one of the lateral strips.

5. The filter element according to claim 4, wherein the second seal section comprises at least one second incision or cutout configured to receive a corresponding second filter housing contour.

6. The filter element according to claim 4, wherein the second seal section is a section of the first one of the lateral strips and projects laterally past a width and/or past a height of the fold pack.

7. The filter element according to claim 1, wherein the first seal section is a flat material strip and the at least one first incision or cutout is a notch, a hole and/or a stamped-out portion in the flat material strip.

8. The filter element according to claim 1, further comprising a head strip attached to the fold pack at the head side, wherein the first seal section is a section of the head strip and projects laterally past a length and/or past a height of the fold pack.

9. The filter element according to claim 1, wherein the first seal section is a section of the end fold section and projects laterally past a length and/or past a height of the fold pack.

10. The filter element according to claim 1, wherein the first seal section is comprised of formed of the filter material.

11. The filter element according to claim 1, wherein the angle at which the first seal section angularly projects away from the end fold section is variable.

12. A filter assembly comprising: a filter housing comprising a first housing part with a filter housing contour comprising at least one engagement element; a filter element configured to be received at least partially in the filter housing, the filter element comprising: a fold pack comprising a filter material folded in a zigzag shape, the fold pack comprising lateral fold profiles and an end fold section disposed at a head side of the fold pack; lateral strips attached to the lateral fold profiles of the fold pack; a seal section angularly projecting at an angle away from the end fold section at the head side of the fold pack; wherein the seal section comprises at least one incision or cutout configured to receive the at least one engagement element of the filter housing contour.

13. The filter assembly according to claim 12, wherein the first housing part comprises a first seal ridge against which the seal section is fastened.

14. The filter assembly according to claim 13, wherein the filter housing comprises a second housing part with a second seal ridge, wherein the seal section is sealingly clamped between the first and the second seal ridges.

15. The filter assembly according to claim 12, wherein the at least one engagement element comprises a hook.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] FIG. 1 shows a schematic illustration of a general motor vehicle with an interior air filter.

[0046] FIG. 2 shows a perspective illustration of a filter material.

[0047] FIG. 3 shows a schematic view of a filter element according to an embodiment.

[0048] FIG. 4 shows a perspective view of a first embodiment of a filter assembly in an exploded illustration.

[0049] FIG. 5 shows a perspective view of the first embodiment in an assembled state and in a vertical section view.

[0050] FIG. 6 shows a section view of the first embodiment and detail views.

[0051] FIG. 7 shows a perspective view of a second embodiment of a filter assembly in an exploded illustration.

[0052] FIG. 8 shows a side view with a rim-side vertical section view of FIG. 7.

PREFERRED EMBODIMENTS

[0053] FIG. 1 shows a motor vehicle 100 with an air conditioning device comprising a filter assembly 10. For example, the air conditioning device can be designed as a heating/air conditioning device. The air conditioning device or the filter assembly 10 takes up external air 11 and guides filtered air 12 to a cabin 13 (also referred to as passenger compartment) of the motor vehicle 100. The filtration is realized by means of a filter element 1 embodied as an interior air filter.

[0054] FIG. 2 shows a folded filter material 3 in isolation and can be referred to in the illustrated form as a fold pack 2. The filter material 3 is, for example, a filter nonwoven, filter fabric, laid filter, or filter felt, in particular a needle felt. In particular, the filter material 3 can be produced by a meltblown method. The filter material 3 can comprise natural fibers such as cotton or synthetic fibers, for example, of polyester, polyphenyl sulfide, or polytetrafluoroethylene. The fibers can be oriented during processing in, at a slant to and/or transversely to the machine direction M. Also, the fibers can be stretched in a spatial direction. The filter material 3 can be designed as a one-layer or multi-layer configuration.

[0055] For forming the fold pack 2, the filter material 3 comprises folds 6 which typically extend transversely to the machine direction M. The folded filter material 3 is also referred to as pleating. The folds 6 can be produced by means of folding along sharp fold edges 7, 8 (also referred to as fold tips) or by a corrugated configuration of the filter material 3. In FIG. 2, one can see top fold edges 7 and bottom-side fold edges 8 in the orientation of FIG. 2. A respective fold 6 can be defined by two neighboring fold sections 5 which are connected to each other by a corresponding fold edge 8. Folding is designed as zigzag folding. Thus, a zigzag-shaped fold profile 4, 9 at the sides of the fold pack 2 results.

[0056] Folding in which the folds 6 have a varying height H is possible also. Moreover, the fold distance C between the folds 6 or neighboring fold edges 7, 8 of identical fold orientation can vary. The filter material 3 can be designed to be self-supporting, i.e., the folds 6 are shape-stable for an intended flow in filtration operation.

[0057] The filter material 3 is delimited in machine direction M by end fold sections 5A, 5B. Transverse thereto, the filter material 3 is delimited by lateral fold end edges (also referred to as fold profiles 4, 9). “Fold end edge” means the lateral edge of the filter material 3 at the side of the fold pack 2 which extends between neighboring fold edges 7, 8 of a respective fold 6.

[0058] The filter material 3, in the plan view, i.e., in the plane E of its flat extension, can have a rectangular shape. However, also a triangular, pentagonal or polygonal, round or oval shape is conceivable.

[0059] In the illustration of FIG. 2, a length L of the fold pack 2 along the machine direction M and transverse to the fold edges 7, 8 is indicated. Along the fold edges 7, 8 and transverse to the machine direction M, a width B of the fold pack 2 is usually indicated. As a radial direction, a direction in the plane E is understood here and an axial direction is perpendicularly arranged thereto, i.e., substantially along the flow direction.

[0060] For producing a filter element, for example, an interior air filter element, a circumferential frame element is attached to the fold pack 2 illustrated in FIG. 2. In FIG. 3, the illustrated fold pack 2 of FIG. 2 is indicated with top-side fold edges 7. Lateral strips 14, 15 are attached to the fold profiles 4, 9. The lateral strips 14, 15 each have an L-profile with a section 14A, 15A, which is, for example, glued to the fold profiles 4, 9, and a laterally projecting leg 14B, 15B. The laterally projecting lateral strip sections or legs 14B, 15B serve as seal sections for lateral sealing in relation to the housing surfaces. The vertical legs 14A, 15A in the orientation of FIG. 2 correspond to the height H of the fold pack 2.

[0061] At the head side, in the orientation of FIG. 3 pointing forwardly to the right, the fold pack 2 is closed off by the head strip 16. The head strip 16 comprises again a section or leg 16A, which corresponds to the height H of the fold pack 2, and a laterally and angularly projecting leg 16B as seal section. At the head section of the fold pack 2 positioned opposite the head strip 16, which in the orientation of FIG. 3 is indicated at the top to the left, the end fold section 5A has a projecting leg 5C as seal section extending past the height H and the length L of the fold pack 2. The leg 5C is separated from the end fold section 5A by a fold edge.

[0062] While the lateral strips with the sections 14A, 15A attached to the fold profiles 4, 9 and the angled seal sections 14B, 15B are relatively stable, the head-side strips or seal sections 5C, 16B have a reduced stability originating from the fold pack 2. The fold edge serves substantially as stabilization and the seal section 5C, 16B projects past it from the respective end fold 5A or the head strip section 16A. In order to obtain an improved positioning and fastening or support of the angularly projecting seal section 5C, 16B, the seal sections 5C, 16C are provided with stamped-out portions 17, 18.

[0063] In this context, two respective holes 18 are provided in the seal section 5C, 16B, respectively, and a central notch 17. Corresponding engagement elements of a housing can engage these incisions 17 or cutouts 18. On the one hand, in this way an improved positioning and fastening of the entire filter element is obtained and, on the other hand, in the manner of a lock-and-key principle the use of unsuitable filter elements with contours or incisions/cutouts that are not matching can be prevented. In this way, the operational safety, for example, of the motor vehicle in which a corresponding filter element 1 is to be used, can be increased. Further embodiments, not explicitly mentioned, have at the head strip side either angularly projecting seal sections 16B as part of the head strip 16 or appropriately configured end fold sections 5C.

[0064] In FIGS. 4, 5, and 6, a first embodiment of a filter assembly 10 is illustrated. In this context, FIG. 4 shows a perspective view in an exploded illustration with a filter housing of two housing parts 19, 20 and a filter element 1 that can be received therein. FIG. 5 shows the filter assembly or filter device 10 in the assembled state, and FIG. 6 shows section views.

[0065] One can see in FIGS. 4 and 5 a filter housing 25 to be assembled of two housing parts 19, 20. The filter housing 25 is constructed frame-shaped and suitable to receive a cuboid filter element 1. The filter element 1 has in this context a fold pack 2, lateral strips visible in FIG. 4 of which only the leading one 14B is identified with a reference character, and two head strips 16 (16A, 16B), wherein angularly projecting sections which are radially folded over are present as seal sections 16B. The seal sections 16B have each three notches 17 that have a quadrangular shape.

[0066] The seal sections 16B are manufactured in this context of filter material and implemented as tabs or strips. The bottom housing part 20 in the orientation of FIG. 4 comprises at the head strip side of the filter element 1 two seal ridges 22 and, on each side, holders 21 oppositely positioned to the respective seal ridge 22. The top housing part 19 has also two seal ridges 24 provided for the head strip sides and comprising engagement elements 23 formed by inwardly oriented projections.

[0067] In the assembled state, as illustrated in FIG. 6, the top seal ridges 24 are guided between the bottom seal ridge 22 and the holders 21. The holders 21 correspond with the engagement elements 23 of the top seal ridge 24 so that the engagement elements (projections) 23 engage the cutouts 17 of the seal section 16B implemented as stamped-out portions. In FIG. 6 at the bottom to the left, a detail illustration is shown in which the section extends through a region in which the seal ridge 24 respectively its radially inwardly oriented projections cannot be directly seen. One can see in the section view of FIG. 6, at the bottom to the left, that the head strip section 16B functioning as seal section is clamped and seals between the seal ridge 22 of the bottom housing part 20 and the seal ridge 24 of the top housing part 19, at least in the bottom region.

[0068] Moreover, the engagement of the engagement elements (projections) 23 of the top seal strip 24, as illustrated in FIG. 6 at the bottom to the right, in the corresponding contours of the stamped-out portion 17 leads to a horizontal displacement securing action, in the orientation of FIG. 6, of the seal section 16B. In addition, it is prevented that a wrong installation position of the filter element within the housing occurs. In the illustration of FIG. 6, a rectangular incision or a stamped-out portion 17 has been carried out from an outer edge 28 of the seal section 16B. In the illustration of FIG. 4, one can see that three such cutouts or incisions 17 at the respective seal section 16B are provided, respectively. In the installed state, the seal section 16B is substantially folded over such that it extends along the flow direction S. In this context, the width of the seal section 16B can be adjusted to the housing construction, respectively.

[0069] FIGS. 7 and 8 show a second embodiment of a filter assembly with seal sections extending circumferentially about a fold pack 2. FIG. 7 shows a perspective exploded view and FIG. 8 a side view with a rim-side vertical section view. In the embodiment according to FIGS. 7 and 8, the filter element 1 has a square footprint and the fold pack 2 is provided with lateral and head strips. The lateral strips 14, 15 have a lateral angularly projecting section as seal section 14B, 15B, likewise the head strips 16B, 16C. The tabs or strips 14B, 15B, 16B, 16C functioning as seal sections are provided with holes 18 which can be attached to engagement elements of the housing part 19 embodied as hooks 26.

[0070] The housing part 19 has a frame, circumferentially extending about the outer contour of the filter element, with outwardly oriented hooks 26. In FIG. 8, one can see in the installed state how the respective seal section 14B, 16B is folded over about the housing edge and from the exterior is fastened on the hooks 26 by means of the holes 18. In this context, the respective hook 26 pushes through the hole of the seal section 16B, 16C, 14B, 15B. Not all hooks and openings are provided with reference characters.

[0071] In the variant of FIGS. 7 and 8, the housing rim also serves as seal ridge from the interior against the lateral strip and head strip sections 16A secured by attachment by means of the hooks 26 and from the exterior against the seal sections 16B (compare FIG. 8, bottom right). In this way, a good sealing action without additional seal means is effected at the rim side.

[0072] By corresponding contours by incisions or cutouts at the seal section of the filter element, on the one hand, and of the housing receiving the filter element, on the other hand, in particular at the head strip side, a good sealing action, positioning, and stabilization of the filter element is obtained. Even though in the description certain geometries of corresponding contours of the incisions or cutouts and engagement elements have been explained, they can be adapted to the respective installation situation. Preferably, at least two such incisions/cutouts are provided per side of the filter element at the head strip side.

REFERENCE CHARACTERS

[0073] 1 filter element/interior air filter

[0074] 2 fold pack

[0075] 3 filter material

[0076] 4, 9 fold profile

[0077] 5 fold section

[0078] 5A, 5B end fold section

[0079] 5C seal section

[0080] 6 folding

[0081] 7, 8 fold edge

[0082] 9 fold profile

[0083] 10 filter device/filter assembly

[0084] 11 raw air

[0085] 12 filtered air

[0086] 13 cabin

[0087] 14 (14A, 14B) lateral strip

[0088] 15 (15A, 15B) lateral strip

[0089] 14B, 15B seal section

[0090] 16 (16A, 16B) head strip

[0091] 16C seal section

[0092] 17 incision

[0093] 18 cutout (hole)

[0094] 19, 20 housing part

[0095] 21 holder

[0096] 22 seal ridge

[0097] 23 engagement element

[0098] 24 seal ridge

[0099] 25 housing

[0100] 26 hook

[0101] 27 housing separation

[0102] 28 edge

[0103] 100 vehicle

[0104] b projection

[0105] B width

[0106] C fold distance

[0107] E plane

[0108] H height

[0109] L length

[0110] M machine direction

[0111] S flow direction