CA2910857A1 - Manufacture of multi-layer filters - Google Patents
Manufacture of multi-layer filters Download PDFInfo
- Publication number
- CA2910857A1 CA2910857A1 CA2910857A CA2910857A CA2910857A1 CA 2910857 A1 CA2910857 A1 CA 2910857A1 CA 2910857 A CA2910857 A CA 2910857A CA 2910857 A CA2910857 A CA 2910857A CA 2910857 A1 CA2910857 A1 CA 2910857A1
- Authority
- CA
- Canada
- Prior art keywords
- roller
- stack
- powered
- sewn
- powered roller
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/0001—Making filtering elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
- B01D2275/10—Multiple layers
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Filtering Materials (AREA)
- Treatment Of Fiber Materials (AREA)
Abstract
A device for the assembly of multi-layer filters comprises a plurality of roll holding means permitting rolls of filter material to unroll in parallel. A first powered roller is provided to gather a plurality of webs of filter material from the rolls in a multi-layer stack. A second powered roller downstream of the first powered roller to pull the stack from the first roller, under tension. An opposed pair of sewing machines is positioned between the first and second powered rollers, to sew the stacks of webs along side edges. The sewing machines are provided with trimming blades to trim the outside margins of the sewn stacks. A third powered roller downstream of said second roller pulls the sewn stack away from the second roller under tension.
The third powered roller is provided with measuring and cutting means to measure desired lengths of the sewn stack, and cut the stack into desired lengths.
The third powered roller is provided with measuring and cutting means to measure desired lengths of the sewn stack, and cut the stack into desired lengths.
Description
MANUFACTURE OF MULTI-LAYER FILTERS
The invention relates to a method and apparatus for the production of multi-layer filters.
The problem addressed by the present invention is how to attach multi-layers of types of material used to make premium air filters so that up to 12 or more layers could be sandwiched together and formed into rectangles for assembly into filters.
A faster and more efficient method would be essential to provide a commercially viable filter.
The present invention describes a novel way of constructing a multi-layered article of cloth material. The inventor was investigating a way of securing various layers of material so that they were aligned in a rectangular shape so that the layers could then be attached to a frame made of rigid plastic. The cloth layers had to be secured to one another so as to act as a unit once attached to the frame.
The previous method for construction included; measuring and cutting each rectangle of material individually; then manually aligning each layer with the one below and running a bead of glue along each of the four sides. Then adding the next layer in the same fashion until all the layers were secured at their edges. This method was very time consuming. In search of a more efficient way to secure the layers, the inventor tried sewing them on a standard sewing machine, but found that keeping the layers aligned and flat was not feasible. This invention describes the novel way we found to secure the edges and maintain the flat seam using automated sewing techniques. We constructed a machine that joins multiple layers in a continuous automatic sewing process. The machine features two sewing machines facing each other (right and left feeds).
The layers are fed into the machines automatic feed rollers from rolls (of material) mounted in front of the sewing machines. The distance between the sewing heads can be adjusted to whatever the required width of the rectangle. (any excess material is cut off by blades mounted on each machine.) Automatic feed rollers mounted after the sewing machines pull the material layers through the sewing process so as to keep the layer flat while being sewn. The second operation on the same machine pulls the band of layers (now secured on two sides) through a second set of feed rollers that have a metering device that stop the band of layers at a desired length. Then a rotating saw blade specially designed to cut cloth and mounted on a track automatically slides across the end of the multi-layer band and severs it from the continuous band producing the desired article. Namely a rectangle of multi-layers fabric that is fully secured and can be handled easily and is fit to proceed to the next part of the construction process for the desired product (a specialty air filter).
This process and machine represent a large increase in efficiency and speed of construction of a multi-layered article of cloth or any sewable product.
In a broad aspect, the present invention provides a device for the assembly of multi-layer filters comprising: i) a plurality of roll holding means permitting rolls of filter material to unroll in parallel; ii) a first powered roller to gather a plurality of webs of filter material from said rolls in a multi-layer stack; iii) a second powered roller downstream of said first powered roller to pull said stack from said first roller, under tension; iv) an opposed pair of sewing machines between said first and second powered rollers, to sew said stacks of webs along side edges, said sewing machines being provided with trimming blades to trim the outside margins of said sewn stacks;
and v) a third powered roller downstream of said second roller, to pull the sewn stack away from the second roller under tension, said third powered roller being provided with measuring and cutting means to measure desired lengths of said sewn stack, and cut said stack into said desired lengths.
In drawings that illustrate the present invention by way of example:
Figure 1 is a side, partially schematic view of a device of the present invention, for implementing the method of the present invention.
Referring to the drawing, it will be seen that the present invention provides a device capable of holding a multitude of fabric rolls, parallel to each other, so that they can be unwound together by feeding the fabric from each into a roller 1 that grips the layers of fabric, and pulls them toward an oppose pair of sewing machines 2.
The invention relates to a method and apparatus for the production of multi-layer filters.
The problem addressed by the present invention is how to attach multi-layers of types of material used to make premium air filters so that up to 12 or more layers could be sandwiched together and formed into rectangles for assembly into filters.
A faster and more efficient method would be essential to provide a commercially viable filter.
The present invention describes a novel way of constructing a multi-layered article of cloth material. The inventor was investigating a way of securing various layers of material so that they were aligned in a rectangular shape so that the layers could then be attached to a frame made of rigid plastic. The cloth layers had to be secured to one another so as to act as a unit once attached to the frame.
The previous method for construction included; measuring and cutting each rectangle of material individually; then manually aligning each layer with the one below and running a bead of glue along each of the four sides. Then adding the next layer in the same fashion until all the layers were secured at their edges. This method was very time consuming. In search of a more efficient way to secure the layers, the inventor tried sewing them on a standard sewing machine, but found that keeping the layers aligned and flat was not feasible. This invention describes the novel way we found to secure the edges and maintain the flat seam using automated sewing techniques. We constructed a machine that joins multiple layers in a continuous automatic sewing process. The machine features two sewing machines facing each other (right and left feeds).
The layers are fed into the machines automatic feed rollers from rolls (of material) mounted in front of the sewing machines. The distance between the sewing heads can be adjusted to whatever the required width of the rectangle. (any excess material is cut off by blades mounted on each machine.) Automatic feed rollers mounted after the sewing machines pull the material layers through the sewing process so as to keep the layer flat while being sewn. The second operation on the same machine pulls the band of layers (now secured on two sides) through a second set of feed rollers that have a metering device that stop the band of layers at a desired length. Then a rotating saw blade specially designed to cut cloth and mounted on a track automatically slides across the end of the multi-layer band and severs it from the continuous band producing the desired article. Namely a rectangle of multi-layers fabric that is fully secured and can be handled easily and is fit to proceed to the next part of the construction process for the desired product (a specialty air filter).
This process and machine represent a large increase in efficiency and speed of construction of a multi-layered article of cloth or any sewable product.
In a broad aspect, the present invention provides a device for the assembly of multi-layer filters comprising: i) a plurality of roll holding means permitting rolls of filter material to unroll in parallel; ii) a first powered roller to gather a plurality of webs of filter material from said rolls in a multi-layer stack; iii) a second powered roller downstream of said first powered roller to pull said stack from said first roller, under tension; iv) an opposed pair of sewing machines between said first and second powered rollers, to sew said stacks of webs along side edges, said sewing machines being provided with trimming blades to trim the outside margins of said sewn stacks;
and v) a third powered roller downstream of said second roller, to pull the sewn stack away from the second roller under tension, said third powered roller being provided with measuring and cutting means to measure desired lengths of said sewn stack, and cut said stack into said desired lengths.
In drawings that illustrate the present invention by way of example:
Figure 1 is a side, partially schematic view of a device of the present invention, for implementing the method of the present invention.
Referring to the drawing, it will be seen that the present invention provides a device capable of holding a multitude of fabric rolls, parallel to each other, so that they can be unwound together by feeding the fabric from each into a roller 1 that grips the layers of fabric, and pulls them toward an oppose pair of sewing machines 2.
- 2 -The sewing machines 2 are positioned at the side margins of the fabric layers, and can be adjusted closer together, or further apart, as desired. Each sewing machine head is also provided with a trimming blade, so that as the fabric moves forward, and is sewn together by the sewing machines, it is also trimmed to a desired width.
The trimmed fabric then passes through a driven pair of puller rollers 3, which provide the force to pull the fabric through the sewing machine head. Then, the sewn fabric is pulled by a take-up roller 4, through a drive roller 5 that also functions to measure, by conventional means, the fabric as it is pulled through. At regular predetermined intervals, the measuring device signals a cut-off knife 6 or saw blade mounted on a track 7 adjacent the drive roller, to cut a work piece, which will consist of a predetermined length of multi-layer filter, sewn together along its side edges.
The two remaining edges can then be sewn, if desired, and the finished filter mounted in a frame for use.
As can be appreciated from Figure 1, the present invention can utilize any desired number of layers of fabric, and the fabric may be selected for particular filtering properties. For instance, fabric layers may include:
1) glass fiber 2) synthetic fiber
The trimmed fabric then passes through a driven pair of puller rollers 3, which provide the force to pull the fabric through the sewing machine head. Then, the sewn fabric is pulled by a take-up roller 4, through a drive roller 5 that also functions to measure, by conventional means, the fabric as it is pulled through. At regular predetermined intervals, the measuring device signals a cut-off knife 6 or saw blade mounted on a track 7 adjacent the drive roller, to cut a work piece, which will consist of a predetermined length of multi-layer filter, sewn together along its side edges.
The two remaining edges can then be sewn, if desired, and the finished filter mounted in a frame for use.
As can be appreciated from Figure 1, the present invention can utilize any desired number of layers of fabric, and the fabric may be selected for particular filtering properties. For instance, fabric layers may include:
1) glass fiber 2) synthetic fiber
3) natural fiber
4) activated carbon coated cloth
5) filter paper made from glass fibers
6) synthetic fibers treated with absorbent and so on. It will be understood that any combination of layers, as required or specified for a particular filtering application may be combined by the manufacturing method and device of the present invention.
Claims (2)
1. A device for the assembly of multi-layer filters comprising:
i) a plurality of roll holding means permitting rolls of filter material to unroll in parallel;
ii) a first powered roller to gather a plurality of webs of filter material from said rolls in a multi-layer stack;
iii) a second powered roller downstream of said first powered roller to pull said stack from said first roller, under tension;
iv) an opposed pair of sewing machines between said first and second powered rollers, to sew said stacks of webs along side edges, said sewing machines being provided with trimming blades to trim the outside margins of said sewn stacks;
and v) a third powered roller downstream of said second roller, to pull the sewn stack away from the second roller under tension, said third powered roller being provided with measuring and cutting means to measure desired lengths of said sewn stack, and cut said stack into said desired lengths.
i) a plurality of roll holding means permitting rolls of filter material to unroll in parallel;
ii) a first powered roller to gather a plurality of webs of filter material from said rolls in a multi-layer stack;
iii) a second powered roller downstream of said first powered roller to pull said stack from said first roller, under tension;
iv) an opposed pair of sewing machines between said first and second powered rollers, to sew said stacks of webs along side edges, said sewing machines being provided with trimming blades to trim the outside margins of said sewn stacks;
and v) a third powered roller downstream of said second roller, to pull the sewn stack away from the second roller under tension, said third powered roller being provided with measuring and cutting means to measure desired lengths of said sewn stack, and cut said stack into said desired lengths.
2. A device as claimed in claim 1, also comprising a take-up roller between said second and third powered rollers, to maintain tension in said stack while the cutting of said stack in desired lengths is performed.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2910857A CA2910857A1 (en) | 2014-10-30 | 2015-10-30 | Manufacture of multi-layer filters |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2869009A CA2869009A1 (en) | 2014-10-30 | 2014-10-30 | Manufacture of multi-layer filters |
| CA2,869,009 | 2014-10-30 | ||
| CA2910857A CA2910857A1 (en) | 2014-10-30 | 2015-10-30 | Manufacture of multi-layer filters |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2910857A1 true CA2910857A1 (en) | 2016-04-30 |
Family
ID=55809290
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2869009A Abandoned CA2869009A1 (en) | 2014-10-30 | 2014-10-30 | Manufacture of multi-layer filters |
| CA2910857A Abandoned CA2910857A1 (en) | 2014-10-30 | 2015-10-30 | Manufacture of multi-layer filters |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2869009A Abandoned CA2869009A1 (en) | 2014-10-30 | 2014-10-30 | Manufacture of multi-layer filters |
Country Status (1)
| Country | Link |
|---|---|
| CA (2) | CA2869009A1 (en) |
-
2014
- 2014-10-30 CA CA2869009A patent/CA2869009A1/en not_active Abandoned
-
2015
- 2015-10-30 CA CA2910857A patent/CA2910857A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| CA2869009A1 (en) | 2016-04-30 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |
Effective date: 20181030 |