DE102018116098A1 - Method for producing a filter element and filter element - Google Patents

Abstract

Method for producing a filter element (1) for filtering a fluid, in which a curable bonding material (23) in the uncured state is introduced between a filter medium (12) and a frame device (2) surrounding the filter medium (12), wherein the non-cured bonding material (23) is held in shape at least partially by means of a casting shell (9) .Filter element (1) for filtering a fluid comprising: a filter medium (12) having an expansion (H) in a flow direction the filter medium (12) circulating frame means (2), and a connecting structure (23 ') between the filter medium (12) and the frame means (2), wherein the connecting structure (23') the edge of the filter medium (12) over the entire extent (H ) and at least partially exposed on the inflow side (16) and / or outflow side (17).

Description

Technical area

The present invention relates to a method of manufacturing a filter element for filtering a fluid and a filter element produced by such a method.

State of the art

The DE 102012007625 A1 describes a filter device with a filter body and a filter frame enclosing the filter frame. The edge region of the filter body is connected via a hardened connection medium with the filter frame. The filter frame is formed circumferentially.

The US 2003/0177745 A1 describes a filter device for an air cleaner, which has a frame with four side beams and four corner elements. The carriers each have an outer plate and two webs for forming a chamber in which a respective peripheral portion of a filter element is received. Between the peripheral portion of the filter element and the carriers an adhesive material is introduced to secure the filter element to the carriers.

Against this background, it is the object of the present invention to provide an improved method for producing a filter element and an improved filter element.

Disclosure of the invention

Accordingly, a method for producing a filter element for filtering a fluid is proposed in which between a filter medium and the filter medium circulating frame means a curable bonding material is introduced in the uncured state, wherein the uncured bonding material is at least partially held by means of a casting shell in the form ,

The filter element produced by the method may be particularly suitable for filtering air. The filter element is in particular an air filter element. For example, the filter element may be suitable for filtering the indoor air or combustion air in motor vehicles.

The filter medium used in the method has in particular an extension in a flow direction. The expansion corresponds, for example, to a thickness or height of the filter medium. The outer shape formed by the filter medium then has, for example, a cuboid shape with a height, a width and a depth. The thickness or height corresponds, for example, to the expansion in the direction of flow.

The filter medium has in particular a bellows. The bellows has in particular a folded or pleated filter medium, in particular a zigzag folded filter medium. The expansion of the filter medium in the flow direction corresponds in the case of a bellows in particular a folding height of folds of the bellows.

The filter medium may also be a flat, unfolded filter medium. The expansion of the filter medium in the flow direction corresponds in the case of a flat, unfolded filter medium in particular a thickness of the flat filter medium.

The filter medium has in particular an inflow side or raw side, on which the unfiltered fluid enters the filter medium. Furthermore, the filter medium has a downstream side or a clean side, at which the filtered fluid emerges from the filter medium.

In the filter element produced by the method, the frame device surrounds the filter medium at the edge, in particular it runs around an edge of the filter medium which connects the inflow side and the outflow side.

The curable bonding material in the uncured state is in particular a liquid, viscous and / or foamed bonding material. Liquid, viscous and / or foamed connecting material is to be understood here as meaning that the connecting material is preferably liquid, viscous and / or foamed only during processing, in particular during introduction between the filter medium and the frame device and before or during curing. The curable bonding material may increase in volume upon insertion between the filter medium and the frame means, e.g. B. by foaming, and can solidify by curing, so that it is no longer liquid, viscous and / or foamed after curing.

The uncured connection material is held in shape at least partially with the aid of a casting shell, in particular with the aid of a surface of a casting shell. In particular, the casting shell forms a contour or boundary surface which prevents the liquid, viscous and / or foamed bonding material from spreading on introduction between the filter medium and the frame means surrounding the filter medium. In addition, the uncured bonding material may become entangled between the filter medium and the filter media when introduced Frame device also held by means of the frame means, the filter medium and / or a comb structure in the form and are prevented by these in each case partially or completely to a spread.

The casting shell can be a one-piece casting shell. In embodiments, the casting shell can also have an upper shell and a lower shell, wherein the upper shell can be arranged on the lower shell in such a way that a cavity or receiving portion for receiving the filter medium during manufacture is formed between them. In embodiments in which the casting shell has an upper shell and a lower shell, the uncured bonding material is introduced between the filter medium and the frame surrounding the filter medium, that it with the help of the lower shell, in particular by a surface of the lower shell, and with the aid of the upper shell , in particular by a surface of the upper shell is held in shape. It can be said that the bonding material is poured in.

Due to the introduction of the curable bonding material between the filter medium and the frame means such that it is held in shape at least partially by means of the casting shell, it is possible to use a simple and inexpensive manufactured frame means, in particular a prefabricated frame means, for stabilizing the filter medium. For example, the frame device can be produced by means of an injection molding tool. Furthermore, the frame means can be manufactured individually, in particular separately from the process of attaching the frame means to the filter medium. Thereby, attaching the frame means to the filter medium can be easily and inexpensively performed. In particular, the attachment of the frame means to the filter medium may be accomplished by means of a simple and inexpensive casting shell rather than a costly injection molding tool. As a result, manufacturing costs can be saved.

• - Anordnen der Rahmeneinrichtung in der Gießschale,
• - Anordnen des Filtermediums innerhalb der Rahmeneinrichtung in der Gießschale,
• - Einbringen des aushärtbaren Verbindungsmaterials im nicht ausgehärteten Zustand zwischen das Filtermedium und die Rahmeneinrichtung, und/oder
• - Aushärten des Verbindungsmaterials zum Ausbilden einer Verbindungsstruktur zwischen dem Filtermedium und der Rahmeneinrichtung.

In embodiments, the method comprises at least one of the steps:

• Arranging the frame means in the pouring tray,
• Arranging the filter medium within the frame means in the pouring tray,
• - Introducing the curable bonding material in the uncured state between the filter medium and the frame means, and / or
• - curing the bonding material to form a connection structure between the filter medium and the frame means.

In embodiments, all of the aforementioned steps are performed.

Arranging the frame means in the pouring tray may include inserting the frame means into the pouring tray. Arranging the filter medium in the casting shell may include inserting the filter medium, for example with the fluid inflow side or the fluid outflow side downwards, into the casting shell. In embodiments in which the casting shell has an upper shell and a lower shell, arranging the frame means in the casting shell may include inserting the framework into the lower shell of the casting shell, and placing the filter medium in the casting shell may insert the filter medium within the framework into the casting shell Have lower shell of the casting shell. In this case, the method may further include disposing the upper shell on the lower shell such that the filter medium and the frame means are received in the cavity between the lower shell and the upper shell. The arrangement of the upper shell can take place, for example, after the introduction of the curable bonding material in the uncured state between the filter medium and the frame device.

The curable bonding material is cured after insertion between the filter medium and the frame means to form a connection structure between the filter medium and the frame means. The curing can be carried out, for example, by crosslinking the curable bonding material, in particular a two-component material. The curing may, for example, an increase in volume of the connecting material, so that the bonding material is pressed during curing against the frame means and the filter medium. The bonding structure formed by the curing is a physical connection structure which is in fluid-tight contact, in particular in a non-detachable fluid-tight connection, with the frame means on one side and with the filter medium on the other side. In particular, in addition to a sealing function for fluid-tight sealing between the frame device and the filter medium, the connecting structure has a mechanical holding function for fastening the frame device to the filter medium.

In embodiments, the curable bonding material is introduced in the uncured state around the filter medium circulating, in particular cast.

Due to the introduction or pouring of the curable bonding material in the uncured state around the filter medium circulating, the connecting structure can be formed circumferentially around the filter medium, so that the filter medium is circumferentially sealed fluid-tight and the frame device is stably fixed to the filter medium.

In particular, the curable bonding material in the non-cured state is circulated around the filter medium in such a way that it forms a circumferential sealing structure between the frame device and the filter medium in the cured state of the bonding material. The sealing structure in particular provides a fluid-tight seal between the filter medium and the frame means.

In embodiments, the curable bonding material is introduced into a space between the filter medium and the frame device such that the gap is filled in the cured state of the bonding material, in particular completely circumferential.

In particular, in the method, the filter medium is arranged within the frame device in such a way that the space, in particular circumferential, is formed between the filter medium and the frame device.

In the introduction of the curable bonding material, in particular, an introduced amount of uncured connecting material is dimensioned such that the intermediate space between the filter medium and the frame device is filled, in particular completely filled, by the curing of the connecting structure formed thereby. The curing of the connecting material may in particular lead to an increase in volume. Therefore, when introducing the curable bonding material in the uncured state, the gap may be partially filled and completely filled by the curing.

Due to said sizing of the charged amount of curable bonding material, the bonding material may press on the filter medium and the frame means upon curing. Thereby, the frame means can be stably and fluid tightly attached to the filter medium.

In embodiments, the filter medium comprises a bellows having convolutions with a folding height, and the curable bonding material is introduced between the bellows and the frame means such that the bonding material in the cured state covers the bellows edgewise over the entire folding height.

The expansion of the filter medium in the flow direction corresponds in the case of a bellows in particular the folding height of the folds of the bellows.

Due to the introduction of the curable bonding material such that the bonding material in the cured state covers the bellows on the edge over the entire folding height, the bellows can be sealed fluid-tight over its entire folding height and mechanically stabilized. Preferably, the folding profiles are covered by the hardened bonding material, whereby laterally a fluid-tight covering by means of the bonding material or a connecting structure formed therefrom is provided.

In embodiments, the curable bonding material comprises a plastic material, in particular PUR foam.

The curable bonding material may be a plastic material comprising polyurethane (PUR). The curable bonding material, for. As polyurethane material, in particular, may have at least two components. When mixing the at least two components they react chemically with each other, so that the compound material foams and a foam, for. As polyurethane foam forms. Further, the polyurethane material cross-links during mixing of the at least two components. During foaming, the crosslinking of the liquid bonding material may occur or begin. When crosslinking, the bonding material solidifies in particular such that it is no longer liquid. The curable bonding material is introduced or poured in particular in the liquid, viscous and / or foamed state between the frame device and the filter medium. The finished cross-linked connection material preferably forms a solid, in particular low and / or non-deformable, connection structure between the frame device and the filter medium.

Due to the curable bonding material, which has a polyurethane material, in particular PUR foam, the connecting material can fill the space between the filter medium and the frame particularly well. In particular, too Surface irregularities of the contact surfaces with the filter medium and / or with the frame device of the PUR foam are compensated. In particular, the PUR foam can partially penetrate into the filter medium, so that the contact between PUR foam and the filter medium is particularly fluid-tight. Thus, with a connecting material, which is a polyurethane material, in particular PUR foam, the frame means are connected to the filter medium particularly fluid-tight and mechanically stable.

In embodiments, the frame means comprises at least one frame member opposite a side of the filter medium having a recess or opening, and the curable bonding material is introduced so as to extend into the recess or opening.

The recess or opening may be, for example, a recess or a passage opening. The recess or opening communicates with the space between the filter medium and the frame means. The curable bonding material is thus introduced into the space between the filter medium and the frame means, in particular its introduced amount is such that it fills the gap and extends into the recess or opening. In this respect, a particularly good adhesion between the connecting material and the frame device can be achieved.

In embodiments in which the recess or opening is a through-hole, this through-hole connects the space between the filter medium and the frame means to an outside of the frame means. In this example, the curable bonding material is introduced into the space between the filter medium and the frame means such that it fills the gap, extends through the recess or opening and protrudes beyond the outside of the frame means and there has a protruding portion, in particular an undercut, forms.

Due to the introduction of the curable bonding material so that it extends into the recess or opening, in particular such that it forms an undercut, an even more stable attachment of the frame means to the filter medium can be achieved by means of the bonding material.

In embodiments, the frame device is produced in an injection molding process, in particular as a one-piece frame device.

Due to the manufacture of the frame means in an injection molding process, the frame means can be made particularly simple and inexpensive. In particular, the frame means can be produced by means of a simple injection molding tool. The injection mold for producing the frame device is in particular simpler than an injection mold, which is required for the production of a cream device by means of an extrusion coating of a filter medium.

In embodiments, the filter medium comprises a bellows and the method comprises fixing convolutions of the bellows, in particular by means of a band attached to or at marginal folding profiles, a band attached to or at folding edges and / or a comb structure engaging in the folds.

By fixing the folds of the bellows, the folds can be held in position prior to or during insertion (s) and / or curing (s) of the bonding material.

The fixing of the folds of the bellows can be carried out before arranging the bellows in the casting shell and / or after arranging the bellows in the casting shell.

The attached on or at marginal folding profiles tape and / or attached to or at folding edges band may be a band, for example made of nonwoven, a rigid or flexible plastic, paper or cardboard and / or from a filter material. The fixing of the folds by means of the attached on or at marginal folding profiles tape and / or attached to or at folding edges tape may have a sticking of the tape or on the corresponding folding profiles or folding edges, in particular before placing the bellows in the casting shell.

The fixing of the folds by means of a comb structure engaging in the folds can be effected by arranging the bellows on or on the comb structure and / or by arranging the comb structure on or on the bellows. For example, the bellows can be arranged on or on the comb structure arranged in the casting shell and / or the comb structure can be arranged on or on the bellows arranged in the casting shell. In particular, the comb structure may have two comb elements, for example a lower comb and an upper comb. In this case, the fixing of the folds by means of the comb structure may include arranging the bellows on the lower comb so that the lower comb engages the folds from below, and arranging the upper comb or on the bellows, so that the upper comb engages from above into the folds of the bellows.

• - ein Filtermedium, welches eine Ausdehnung in einer Durchströmrichtung aufweist,
• - eine um das Filtermedium umlaufende Rahmeneinrichtung, und
• - eine Verbindungsstruktur zwischen dem Filtermedium und der Rahmeneinrichtung, wobei die Verbindungsstruktur das Filtermedium randseitig über die gesamte Ausdehnung bedeckt und anströmseitig und/oder abströmseitig zumindest teilweise freiliegt.

According to a further aspect, a filter element for filtering a fluid, in particular produced according to a method described above or below, is provided. The filter element has:

• a filter medium which has an extension in a flow direction,
• - A circulating around the filter medium frame means, and
• a connecting structure between the filter medium and the frame device, wherein the connecting structure covers the filter medium on the edge over the entire extent and at least partially exposed on the inflow side and / or outflow side.

The flow direction points from a fluid inflow side to a fluid outflow side of the filter medium. In particular, a height of the connecting structure in the direction of the flow direction is greater than or equal to, in particular greater than or equal to, the extent of the filter medium in the flow direction.

Because the connecting structure covers the filter medium on the edge over the entire extent, the filter medium is sealed fluid-tight over its entire height in the direction of flow and mechanically stabilized. As a result, during assembly of the filter element in a device, for. B. in a motor vehicle, the inflow side or raw side of the filter medium from the downstream or clean side of the filter medium are very well separated.

An exposed portion of the connection structure makes it possible to manufacture the same with the aid of a low-cost method in which hardenable connection material is introduced, in particular cast, into a gap between the frame device and the filter medium.

In embodiments, the filter media includes a pleated crotch and corresponds to the extent of the filter media of a convolution height of the pleats.

In particular, the connecting structure covers the bellows on the edge over the entire folding height and is at least partially exposed on the inflow side and / or outflow side. Because the connecting structure covers the bellows on the edge over the entire folding height, the bellows is sealed fluid-tight over its entire height and mechanically stabilized. As a result, during assembly of the filter element in a device, for. B. in a motor vehicle, the inflow side or raw side of the bellows are separated very well from the downstream or clean side of the bellows. In particular, the connection structure forms a circumferential sealing structure between the frame device and the filter medium.

In embodiments, the filter medium is held within the frame means, in particular exclusively, by means of the connection structure.

The fact that the filter medium is held within the frame means exclusively by means of the connection structure, can be dispensed with further holding devices for the filter medium.

In embodiments, the connection structure is completely free on the outflow side and on the upstream side.

Due to the fact that the connection structure is completely exposed circumferentially on the outflow side and on the upstream side, the filter element can be produced in a simple and cost-effective manner. In particular, the connection structure between the filter medium and the frame means can be easily created by introducing the bonding material between the filter medium and the frame means.

In embodiments, the frame means comprises at least one frame member opposite a side of the filter medium having a recess or opening into which the connection structure extends.

The recess or opening may be a recess or a through hole. In embodiments in which the recess or opening is a passage opening, the connection structure extends through the passage opening and forms a section projecting beyond an outer side of the frame device, a so-called undercut.

Characterized in that the connecting structure extends into the recess or opening, in particular forms an undercut, the frame means is fixed to the filter medium stable.

In embodiments, the connection structure is formed of a cast-in PUR material, in particular a PUR foam.

In embodiments, the frame means comprises frame members which, with the aid of the connection structure, encircle on the sides of Filter medium are attached and have parallel to an inflow or outflow side of the filter medium extending laterally projecting frame parts.

In particular, the laterally projecting frame parts extending parallel to an inflow or outflow side of the filter medium may be provided for mounting the filter element in a device. The laterally projecting frame parts may, for example, have openings for attachment, in particular by means of screws.

Other advantages and features described with respect to the method apply to the filter element accordingly.

Further possible implementations of the invention also include not explicitly mentioned combinations of features or exemplary embodiments described above or below with respect to the embodiments. The skilled person will also add individual aspects as improvements or additions to the respective basic form of the invention.

Further advantageous embodiments and aspects of the invention are the subject of the dependent claims and the embodiments of the invention described below. Furthermore, the invention will be explained in more detail by means of preferred embodiments with reference to the attached figures.

list of figures

• 1: ein Ablaufdiagramm für ein Verfahren zum Herstellen eines Filterelements gemäß einer Ausführungsform;
• 2: eine schematische perspektivische Ansicht einer Ausführungsform einer Gießschale;
• 3: eine schematische Teilschnittansicht der Gießschale gemäß 2;
• 4: eine schematische perspektivische Ansicht einer Ausführungsform eines Filterelements;
• 5: eine schematische perspektivische Ansicht des Filterelements gemäß 4;
• 6: eine Draufsicht des Filterelements gemäß 4;
• 7: eine Querschnittsansicht des Filterelements entlang einer Linie A-A in 6; und
• 8: eine Querschnittsansicht des Filterelements entlang einer Linie B-B in 6.

It shows:

• 1 FIG. 3 is a flowchart for a method of manufacturing a filter element according to an embodiment; FIG.
• 2 a schematic perspective view of an embodiment of a casting shell;
• 3 a schematic partial sectional view of the casting shell according to 2 ;
• 4 a schematic perspective view of an embodiment of a filter element;
• 5 a schematic perspective view of the filter element according to 4 ;
• 6 : a plan view of the filter element according to 4 ;
• 7 FIG. 3 is a cross-sectional view of the filter element along a line AA in FIG 6 ; and
• 8th FIG. 4 is a cross-sectional view of the filter element taken along a line BB in FIG 6 ,

In the figures, identical or functionally identical elements, unless otherwise indicated, have been given the same reference numerals.

Embodiment (s) of the invention

The 1 shows a flowchart for a method of manufacturing a filter element 1 according to one embodiment. In this embodiment, for producing the filter element 1 a casting bowl 9 as they are in the 2 and 3 shown is used. It shows 2 a schematic perspective view of the casting shell 9 and 3 a schematic partial sectional view of the casting shell 9 in the closed state.

With the help of in 1 The method shown, for example, a filter element 1 as it is in the 4 to 8th shown in different views. Show 4 and 5 in each case a schematic perspective view of the filter element 1 and 6 shows a plan view of the filter element 1 , The 7 and 8th each show a cross-sectional view of the filter element 1 corresponding along a line AA or a line BB in 6 ,

In the first step S1 of the method becomes a frame device 2 provided. The frame device 2 was produced in particular in an injection molding process. The frame device 2 points, as in the 4 to 8th shown two frame elements 3 each with four through holes 4 and two more frame elements 5 on. The frame elements 3 and 5 form a closed edge. The frame elements 5 can, as in the 4 to 8th shown a lower height than the frame members 3 to have. The frame elements 5 but can also be the same height as the frame elements 3 to have. Furthermore, the frame device 2 from the frame elements 3 and 5 laterally projecting frame parts 6 on, which for example by means of angle elements 7 on the frame elements 3 are supported. The laterally projecting frame parts 6 extend parallel to an inflow side 16 and a downstream side 17 a filter medium 12 , The laterally projecting frame parts 6 have four openings 8th for attachment in a device, for example in a motor vehicle.

The provided framework 2 becomes in the first process step S1 in a pouring bowl 9 arranged. The casting bowl 9 can a casting shell according to the in the 2 and 3 shown casting shell 9 which is a lower shell 10 and a top shell 11 having. The lower shell 10 can on the upper shell 11 be arranged as in 3 shown so that between the lower shell 10 and the upper shell 11 a receiving section 26 to the Picking up the frame device 2 and the bellows 12 is formed. Arranging the frame device 2 in the casting bowl 9 takes place in particular by being on an inner surface 27 the lower shell 10 is arranged. In another embodiment, a casting shell can also be in one piece, in particular a simple casting shell similar to that in FIG 2 shown lower shell 10 , his.

At the second step S2 of the process becomes the filter medium 12 within the framework 2 in the casting bowl 9 arranged. The filter medium 12 is a bellows in the example. However, in other embodiments, the filter medium may have a different shape, for example, it may be a flat filter medium without convolutions.

The bellows 12 is like in the 4 to 8th shown from zigzag folds 13 with a folding height H educated. In the 4 to 8th are just some examples of some convolutions 13 provided with reference numerals. The folds 13 have edge folding profiles 14 and folding edges 15 on which one together around the bellows 12 form peripheral edge. The bellows 12 has the inflow side 16 and the downstream side 17 on, like in the 4 to 6 shown. However, it may also be the designated 16 side of the downstream side and the side designated 17 on the upstream side.

The bellows 12 becomes such within the framework 2 in the casting bowl 9 arranged that between the bellows 12 and the frame device 2 a circumferential gap 18 is formed. The space thus formed 18 in particular by the folding profiles 14 and the folding edges 15 the bellows 12 on the one hand and through the frame elements 3 and 5 the frame device 2 on the other hand limited.

The method may be before and / or after placing the bellows 12 in the casting bowl 9 an optional step S3 Fixing the folds 13 respectively. This step S3 Fixing the folds 13 can also be omitted. In the embodiment described here, the method has a step S3 Fixing the folds 13 with the help of one in the folds 13 engaging comb structure 19 on. The comb structure 19 points, as in the 2 and 3 shown a lower crest 20 and an upper ridge 21 on. The lower crest 20 and the upper ridge 21 each have a plurality of comb teeth 22 on. In the 2 are exemplary only some of the comb teeth 22 provided with reference numerals.

For fixing the folds 13 is before or after arranging the frame device 2 in the lower shell 10 , the lower crest 20 in the lower shell 10 arranged. For example, the lower comb 20 within the framework 2 in the lower shell 10 arranged, or it will be the lower ridge first 20 in the lower shell 10 arranged and then the frame device 2 so in the lower shell 10 arranged that they are the lower crest 20 circulates. Arranging the bellows 12 within the framework 2 in the casting bowl 9 then takes place such that the bellows 12 on the lower ridge 20 is arranged so that the comb teeth 22 of the lower ridge 20 from below into the folds 13 intervention. For fixing the folds 13 is further after placing the bellows 12 on the lower ridge 20 the upper ridge 21 on the bellows 12 arranged. This is the upper ridge 21 so on the bellows 12 arranged that the comb teeth 22 of the upper ridge 21 from above into the folds 13 intervention. In this way can / can the bellows 12 , especially the folds 13 to be held in position.

In the fourth step S4 of the process becomes a curable bonding material 23 in the uncured state between the bellows 12 and the framework 2 brought in. In particular, the curable bonding material becomes 23 in liquid or foamed form in the circumferential gap 18 between the bellows 12 and the frame device 2 which are both in the lower shell 10 are arranged, introduced or poured. This is the curable bonding material 23 from the inner surface 27 the lower shell 10 , from the frame elements 3 and 5 , the framework device 2 and of the comb structure 19 fixed bellows 12 or the comb structure 19 kept in shape. In particular, the curable bonding material becomes 23 from the inner surface 27 the lower shell 10 , the frame elements 3 and 5 and the comb structure 19 prevented from spreading. In the 4 to 8th which the filter element produced by the method 1 show is the curable bonding material 23 as a connection structure 23 ' shown in the cured state.

As in the 6 to 8th shown, the curable bonding material 23 for example, between the bellows 12 and the framework 2 be introduced that it partially, in particular in a small edge region, in the folding bellows 12 spreads out into the bellows 12 still fluid-tight seal. 7 shows an example of a filter element produced in this way 1 in which the connection structure 23 ' at the folding profiles 14 with a penetration length e in the bellows 12 extends into it. Similarly, the connection structure may be 23 ' at the fold edges 15 in the bellows 12 extend through a predetermined penetration length, as in the 6 and 8th you can see. This can be achieved in the manufacturing process in that the upper crest 21 the comb structure 19 a smaller dimension than the lower comb 20 and the connecting material 23 when introducing with the help of the comb structure 19 is kept in shape. As in the 2 and 3 shown, the top comb can 21 a length L1 and a width B1 which are each assigned shorter than a length L2 and a width B2 of the lower ridge 20 , This can be done with the help of the lower comb 20 and the upper ridge 21 fixed bellows 12 so in the comb structure 19 be placed over the top of the ridge 21 protrudes laterally. As a result, the curable bonding material 23 at the folding profiles 14 and the folding edges 15 the bellows 12 partly in the folding bellows 12 be introduced into, as in the 6 to 8th for the finished filter element 1 shown.

After introduction of the liquid or foamed compound material 23 in the lower shell 10 becomes the mold 9 with the help of the upper shell 11 closed, with the bellows 12 and the framework 2 in the receiving section 26 the casting bowl 9 be recorded. In particular, the folds 13 the bellows 12 between the lower ridge 20 and the upper ridge 21 fixed.

In the described embodiment, the curable bonding material 23 a flexible plastic material, in particular a polyurethane material, which consists of at least two components. After mixing the at least two components they react chemically with each other, so that the connecting material 23 foams under volume increase (PUR foam). Furthermore, the connecting material crosslinks 23 in the chemical reaction of the at least two components, so that it solidifies.

The liquid or foaming started connecting material 23 foams when introduced into the gap 18 (further) and increases its volume. As a result, it is circumferentially laterally to the bellows 12 , in particular the folding profiles 14 and the folding edges 15 , and to the framework 2 , in particular the frame elements 3 and 5 , pressed. This will be the connecting material 23 very good with the bellows 12 and with the frame device 2 brought into contact and a fluid-tight connection between the bellows 12 and the frame device 2 reached. Furthermore, the connecting material 23 doing so from the inner surface 27 the lower shell 10 and an inner surface 28 the upper shell 11 held in shape and prevented from spreading.

There will be such an amount of curable bonding material 23 in the uncured state in the intermediate space 18 between the bellows 12 and the frame device 2 introduced or poured in that the gap 18 in the cured state by the foaming of the connecting material 23 , in particular completely circumferential, is filled in and the connection structure 23 ' in the cured state, the bellows 12 on the edge over the entire folding height H covered. In particular, the connection structure covers 23 ' the folding profiles 14 and the folding edges 15 over the entire folding height H , This allows the bellows 12 about his total folding height H fluid-tight with the help of the connection structure 23 ' sealed and mechanically stabilized.

The amount of introduced bonding material 23 in the uncured state is further dimensioned so that it by the foaming through the through holes 4 the frame elements 3 is pushed through and outsides 24 the frame elements 3 protrudes. In 4 is exemplary only the outside 24 one of the two frame elements 3 provided with a reference numeral. That over the outsides 24 the two frame elements 3 protruding connecting material 23 there forms undercuts in the cured state 25 the connection structure 23 ' as in the 4 to 7 shown. Is exemplary in the 4 to 7 only one of the several undercuts 25 of the filter element 1 provided with a reference numeral. By forming the undercuts 25 can the frame element 2 particularly stable on the bellows 12 be attached.

In the fifth step S5 of the process becomes the bonding material 23 cured to form the connection structure 23 ' between the bellows 12 and the frame device 2 , By the chemical reaction of the at least two components of the bonding material 23 which is a polyurethane material, the joining material begins 23 to network. Crosslinking solidifies the bonding material 23 and forms the connection structure 23 ' , The connection structure 23 ' creates a fluid-tight and mechanically bearing connection between the bellows 12 and the frame device 2 , The connection structure 23 ' is, for example, a solid, in particular less and / or non-deformable structure or layer.

The filter element 1 may be an air filter, a cabin filter or the like. The filter element 1 may also be configured to filter working fluid such as water, oil, urea solution or fuel, especially diesel fuel, kerosene or gasoline. The filter element 1 can be used in motor vehicles, trucks, construction machinery, watercraft, rail vehicles, aircraft or in building services.

Although pleated filter media are shown as bellows in the embodiments, the filter media may also be flat or unfolded. Conceivable, for example, a three-dimensional expansion having media edge have a height or thickness.

LIST OF REFERENCE NUMBERS

1

filter element

2

frame means

3

frame element

4

Through opening

5

frame element

6

frame part

7

angle element

8th

opening

9

casting shell

10

subshell

11

Front Cover

12

bellow

13

folds

14

folding profile

15

folding edge

16

inflow

17

outflow

18

gap

19

comb structure

20

lower crest

21

upper ridge

22

comb teeth

23

connecting material

23 '

connecting structure

24

outside

25

undercut

26

receiving portion

27

palm

28

palm

B1

width

B2

width

e

penetration

H

fold height

L1

length

L2

length

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QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102012007625 A1 [0002]
• US 2003/0177745 A1 [0003]

Claims (16)

Method for producing a filter element (1) for filtering a fluid, in which a curable bonding material (23) in the uncured state is introduced between a filter medium (12) and a frame device (2) surrounding the filter medium (12), wherein the uncured connection material (23) is held in shape at least partially by means of a casting shell (9). Method according to Claim 1 , with at least one of the steps: - arranging (S1) the frame device (2) in the casting shell (9), - arranging (S2) the filter medium (12) within the frame device (2) in the casting shell (9), - introducing ( S3) of the curable bonding material (23) in the uncured state between the filter medium (12) and the frame device (2), and / or - curing (S5) the bonding material (23) to form a connecting structure (23 ') between the filter medium ( 12) and the frame device (2). Method according to Claim 1 or 2 , wherein the curable bonding material (23) in the uncured state around the filter medium (12) circumferentially introduced, in particular cast, (S3). Method according to one of Claims 1 to 3 in which the curable bonding material (23) is introduced into a space (18) between the filter medium (12) and the frame (2) (S3) such that the gap (18) in the cured state of the bonding material (23, 23 ') , in particular completely circumferential, is filled. Method according to Claim 3 or 4 wherein the filter medium (12) comprises a bellows having convolutions (13) with a folding height (H), and the curable bonding material (23) is interposed between the bellows (12) and the frame means (2) (S3), that the connecting material (23, 23 ') in the cured state covers the bellows (12) at the edge over the entire folding height (H). Method according to one of Claims 1 to 5 , wherein the curable bonding material (23) comprises a plastic material, in particular PUR foam. Method according to one of Claims 1 to 6 wherein the frame means (2) comprises at least one frame member (3) having a recess or opening (4) opposite one side of the filter medium (12), and the hardenable bonding material (23) is inserted (S3) into the Recess or opening (4) extends. Method according to one of Claims 1 to 7 , wherein the frame means (2) in an injection molding process, in particular as a one-piece frame means (2), is manufactured. Method according to one of Claims 1 to 8th in that the filter medium (12) comprises a bellows and the method further comprises: - fixing (S4) folds (13) of the bellows (12), in particular by means of a band attached to or at marginal folding profiles (14), on or at fold edges (15) attached belt and / or in the folds (13) engaging comb structure (19). Filter element (1) for filtering a fluid, in particular produced by a method according to one of Claims 1 to 9 , comprising: - a filter medium (12) having an extension (H) in a flow direction, - a frame device (2) revolving around the filter medium (12), and - a connection structure (23 ') between the filter medium (12) and the frame device (2), wherein the connecting structure (23 ') the filter medium (12) on the edge over the entire extent (H) covered and at least partially exposed on the inflow side (16) and / or outflow side (17). Filter element (1) after Claim 10 in that the filter medium (12) comprises a bellows with folds (13) and the extent (H) corresponds to a folding height (H) of the folds (13). Filter element (1) after Claim 10 or 11 , wherein the filter medium (12) within the frame means (2), in particular exclusively, by means of the connecting structure (23 ') is held. Filter element (1) according to one of Claims 10 to 12 , Wherein the connecting structure (23 ') on the outflow side (17) and the inflow side (16) circumferentially completely exposed. Filter element (1) according to one of Claims 10 to 13 wherein the frame means (2) comprises at least one frame member (3) opposite a side of the filter medium (12) and having a recess or opening (4) into which the connection structure (23 ') extends. Filter element (1) according to one of Claims 10 to 14 , wherein the connecting structure (23 ') from a cast PUR material, in particular a polyurethane foam, is formed. Filter element (1) according to one of Claims 10 to 15 wherein the frame means (2) frame members (3, 5), which by means of the connecting structure (23 ') circumferentially on sides (14, 15) of the filter medium (12) are fixed, and parallel to an inflow side (16) or outflow side (17) of the filter medium (12) extending laterally projecting frame parts (6).

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