Abstract:
An air filter-shaping mold includes an upper and a lower mold base combined together. The upper and the lower mold base are respectively formed with plural curved separating plates. A filter material having the same shape as the separating plates is placed on the separating plates of the lower mold base for carrying out forming of an air filter, able to save labor and time in making molds and cost on material, to position the filter material precisely, to elevate production efficiency and to stabilize quality of products.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates to an air filter shaping mold, particularly to one having excellent efficiency in processing, provided with less components and able to form an air filter with one round of processing.  
         [0003]     2. Description of the Prior Art  
         [0004]     A conventional air filter shaping mold, as shown in  FIG. 1 , includes an upper, an intermediate and a lower mold base  11 ,  12  and  13  combined together. The upper and the lower mold base  11 ,  13  respectively and correspondingly have plural projecting separating plates  111 ,  131  provided spaced apart equidistantly and interposing each other, and the intermediate mold base  12  is formed with a through cavity  121  in the center. After combined together, the intermediate mold base  12  is firmly sandwiched between the upper and the lower mold base  11 ,  13 , and the projecting separation plates  111 ,  131  of the upper and the lower mold base  11 ,  13  are positioned in the cavity  121  of the intermediate mold base  12 .  
         [0005]     To integrally form an air filter  14  by means of the conventional shaping mold  10 , the intermediate mold base  12  is first assembled closely on the lower mold base  13 , and then a plane filter cotton sheet  141  is placed on the upper side of the lower mold base  13 . Next, the upper mold base  11  is closely compressed on the intermediate and the lower mold base  12 ,  13 , and simultaneously, the projecting separating plates  111 ,  131  of the upper and the lower mold base  11  and  13  are arranged interposing each other to compress the filter cotton sheet  141  into continuous curves spaced apart equidistantly. Subsequently, raw material of rubber is poured into the cavity  121  of the intermediate mold base  12  by an injection device through the pouring passage  15  and the pouring gate  16  of the upper mold base  11  to form a gelatin frame  142  covering up the outer circumferential edge of the filter cotton sheet  141 . Lastly, the upper, the intermediate and the lower mold base  11 ,  12 ,  13  are orderly separated from one another and the finished product of an air filter  14  is removed out and then the intermediate mold base  12  is again assembled on the lower mold base  13 , thus obtaining an integrally formed air filter.  
         [0006]     Although the conventional air filter-shaping mold  10  can integrally form an air filter  14 , yet the forming process is too complicated and inconvenient, and substantially the finished products are imperfect in quality. The reasons for these drawbacks are described below.  
         [0007]     1. To integrally form an air filter, it is necessary to use the upper, the intermediate and the lower mold base  11 ,  12  and  13  at the same time, wasting much labor and time in making molds and much cost on material. Besides, in a forming process, precision of combination of the three mold bases must be taken into consideration, because it may greatly influence the external appearance of finished products.  
         [0008]     2. In a forming process, the filter cotton sheet  141  is directly made into continuous curves by the projecting separation plates  111 ,  131  of the upper and the lower mold base  11  and  13 . Nevertheless, the upper and the lower mold base  11 ,  13  are fixed on the injection device which has no auxiliary apparatus for fixedly positioning the filter cotton sheet  141 ; therefore the filter cotton sheet  141  may deflect and shift sideways when the upper mold base  11  is closely assembled on the lower mold base  13 . If the filter cotton sheet  141  is excessively deflected, its outer end  143  may shrink inward and fail to be bonded with the frame  142 , possible to render the entire filter cotton sheet  141  inclined on one side and hence influence the quality of products.  
       SUMMARY OF THE INVENTION  
       [0009]     The objective of the invention is to offer an air filter-shaping mold composed of an upper and a lower mold base. The lower mold base is formed with a plurality of projecting separating plates, and a filter material of a preset shape is positioned on these separating plates for carrying out forming of an air filter, saving labor and time in making molds and cost on material, positioning the filter material precisely and stabilizing quality of products. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0010]     This invention will be better understood by referring to the accompanying drawings, wherein:  
         [0011]      FIG. 1  is a partial exploded perspective view of a conventional air filter-shaping mold:  
         [0012]      FIG. 2  is a cross-sectional view of the conventional air filter-shaping mold having its three mold bases combined together:  
         [0013]      FIG. 3  is a cross-sectional view of the conventional air filter-shaping mold having its three mold bases opened and separated:  
         [0014]      FIG. 4  is an exploded perspective view of a first preferred embodiment of an air filter-shaping mold in the present invention:  
         [0015]      FIG. 5  is a partial perspective view of the first preferred embodiment of the upper mold base of the air filter-shaping mold in the present invention:  
         [0016]      FIG. 6  is a partial exploded and cross-sectional view of the first preferred embodiment of the air filter-shaping mold in the present invention:  
         [0017]      FIG. 7  is a cross-sectional view of the first preferred embodiment of the air filter-shaping mold in the present invention, showing two mold bases combined together:  
         [0018]      FIG. 8  is a cross-sectional view of the first preferred embodiment of the air filter-shaping mold in the present invention, showing the two mold bases combined together and poured therein with raw material of rubber:  
         [0019]      FIG. 9  is an exploded and cross-sectional view of the first preferred embodiment of the air filter-shaping mold in the present invention, showing the two mold bases opened and separated after an air filter is formed:  
         [0020]      FIG. 10  is a perspective view of the air filter formed by the air filter-shaping mold of the first preferred embodiment in the present invention: and  
         [0021]      FIG. 11  is a partial cross-sectional view of a second preferred embodiment of an air filter-shaping mold in the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0022]     A first preferred embodiment of an air filter-shaping mold in the present invention, as shown in  FIGS. 4, 5  and  6 , includes an upper mold base  20  and a lower mold base  30  combined together.  
         [0023]     The upper mold base  20  is a rectangular body having its lower side bored with an upper cavity  21  of a preset depth. The cavity  21  has its bottom side formed with a plurality of triangular separating plates  211  protruding downward and spaced apart equidistantly, and between every two separating plates  211  is formed a triangular upper accommodating groove  212 . An annular groove  213  of a preset width is formed between all the separating plates  211  and the circumferential edge of the upper cavity  21  and has plural through pouring holes  214  bored at preset locations in an upper surface and communicating to the topside of the upper mold base  20 . The upper mold base  20  further has its upper surface bored with plural pouring passages  215  communicating with one another and with the pouring holes  214  to pour raw material therein and guide it to get into and fill up the annular groove  213  through the pouring holes  214 , with some pouring gates  214  positioned close to the four corners of the annular groove  213 . Besides, the upper mold base  21  has four combining hole  216  respectively provided at four corners of the bottom.  
         [0024]     The lower mold base  30  to be assembled with the bottom side of the upper mold base  20  is bored in the upper side with a lower cavity  31  having its bottom formed with a plurality of triangular separating plates  311  protruding upward and spaced apart equidistantly, and between every two separating plates  311  is formed a triangular lower accommodating groove  312 . Thus, when the upper and the lower mold base  20 ,  30  are combined together, the separating plates  211 ,  311  of the upper and the lower mold base  20  and  30  can be interposed with one another and positioned in the accommodating grooves  312 ,  212  of the lower and the upper mold base  30 ,  20 . In addition, an annular groove  313  of a preset width is formed between all the separating plates  311  and the circumferential edge of the lower cavity  31 . The annular groove  313  of the lower cavity  31  is formed with an arc-shaped surface and matches with the annular groove  213  of the upper cavity  21 . The lower mold base  30  further has four combining studs  314  respectively fixed at four corners of the upper surface to be respectively inserted in the four combining holes  216  of the upper mold base  20 .  
         [0025]     To carry out forming of an air, as shown in  FIGS. 6 and 7 , the air filter shaping mold is installed on an injecting device in advance, and a filter material  41  formed in advance with continuous saw teeth is deposited on the separating plates  311  of the lower cavity  31 , and then the upper and the lower mold base  20 ,  30  are combined together. At this time, the separating plates  211  in the upper cavity  21  and the separating plates  311  in the lower cavity  31  are interposed with one another to clamp and compress the filter material  40 . Then, as shown in  FIG. 8 , raw material of rubber is poured into the annular grooves  213 ,  313  of the upper and the lower cavity  21 ,  31  through the pouring passages  215  and the pouring holes  214  by the injection device, and the raw material of rubber is then covered on and bonded with part of the circumferential edge of the filter material  41  to form the outer frame  42  of an air filter  40 . After finishing pouring the raw material into the annular grooves  213 ,  313  and forming the frame  42  of an air filter, the upper and the lower mold base  20 ,  30  are opened and separated, and the finished product of an air filter  40  is removed out, thus finishing forming integrally an air filter  40  having a great strength and stable quality, as shown in  FIGS. 9 and 10 .  
         [0026]     The filter material  41  in the first preferred embodiment is composed of a filter fabric  411  and metallic gauze  412 . The filter fabric  411  is a non-woven fabric or cotton cloth having function of air filtering, and the metallic gauze  412  is covered on the surfaces of the filter fabric  411  so as to strengthen the whole structure of the filter material  41 . In addition, the filter material  41  can be metallic gauze made of stainless steel or a filter fabric or the like to meet different demands of customers. Furthermore, the annular groove  313  of the lower cavity  31  of the lower mold base  30  is formed with an arc-shaped surface; thus, after the frame  42  of an air filter  40  is formed, its upper edge can be formed with a current guiding surface  421  of a preset radian, which is able to smoothly guide air to move downward and pass through the filter material to be filtered, able to decrease reflected current of air and increase quantity of air sucked into the engine for use, as shown in  FIG. 9 .  
         [0027]     A second preferred embodiment of an air filter shaping mold in the present invention, as shown in FIG.  11 , includes an upper and a lower mold base  20 ,  30  combined together. The upper and the lower mold base  20 , and  30  are respectively formed inside with a plurality of pillar-shaped separating plates  211   a ,  311   a  having their ends respectively formed with an arc-shaped surface, and between every two pillar-shaped separating plates  211   a ,  311   a  is formed a pillar-shaped groove  212   a ,  312   a . And a filter material  41   a  is formed with continuous curves to match with the pillar-shaped separating plates  211   a ,  311   a . Although the shapes of the separating plates and the accommodating grooves in the second preferred embodiment are different from those in the first preferred embodiment, yet these two kinds of air filter shaping molds have equal effect in forming of a high-quality air filter.  
         [0028]     To sum up, this invention has the following advantages.  
         [0029]     1. The air filter shaping mold in the invention can form an air filter with one round of processing only by employing an upper and a lower mold base, having fewer components than the conventional air filter shaping mold and hence able to save cost on molds and material.  
         [0030]     2. The air filter shaping mold in the invention only includes an upper and a lower mold base; therefore in the forming process of an air filter, these two mold bases can be combined or opened and separated quickly and conveniently, greatly elevating production efficiency.  
         [0031]     3. The filter material is formed in advance with continuous curves to match with the curved separating plates in the upper and the lower cavity; therefore the filter material can be quickly and stably positioned in the cavities to prevent it from deflecting and shifting sideways when the two mold bases are combined together, able to make the filter material and the frame bonded together precisely to enhance quality of products.  
         [0032]     While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications that may fall within the spirit and scope of the invention.