CN101801497B - 船用燃气轮机过滤器的制造方法 - Google Patents
船用燃气轮机过滤器的制造方法 Download PDFInfo
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Abstract
提供一种用于制造袋式过滤器组件的方法。两个侧集管元件和两个端集管元件均具有一对纵向延伸的侧壁和一对纵向延伸的底壁,从而形成纵向延伸的通道,这两个侧集管元件和两个端集管元件在端部处接合而形成具有两个相对侧部和两个相对端部的矩形集管。每个所述相对侧部的底壁和侧壁以及每个所述相对端部的底壁和侧壁相邻,从而形成具有连续底壁和连续内侧壁和外侧壁的矩形集管,其内具有连续通道。袋式过滤器元件的上游外周部插入所述连续通道中,并在该连续通道中放置液态聚合材料。使所述液态聚合材料固化,从而形成与所述过滤器元件的上游外周部成一体的集管框架。
Description
本申请要求2008年4月10日提交的当前未决美国专利申请序列号12/100,699的优先权及其权益,该专利申请要求2007年7月31日提交的美国临时专利申请60/953,088的优先权及权益,将这些专利申请的全部内容结合于此。
技术领域
本发明总体涉及具有从集管(header)延伸的袋状过滤口袋的空气或气体过滤器组件。
背景技术
公知这种类型的空气和气体清洁过滤器组件,其中呈具有开口端的袋或口袋形式的多个伸长管状柔性口袋绕集管中的孔附连至集管。袋的结构使组件在使用时在空气压力作用下膨胀并沿气流方向离开集管向下游延伸。该膨胀和延伸对于给定集管面积提供增大的过滤面积。
在现有技术中,这些过滤器元件通常利用夹、铆钉、钳、紧固件、粘合剂等机械附连至集管,绕其中的孔机械附连至钢或塑料过滤器集管,或者卡在两部件式集管的部件之间。已发现这样的构造技术昂贵且是劳动密集型的。此外,被过滤的空气、气体或水常常在集管与过滤器袋的界面附近泄漏,从而大大降低过滤效率。
发明内容
本发明提供一种用于制造袋式过滤器组件的方法,该过滤器组件具有带有至少一个孔的集管,过滤器元件的入口外周部在该孔中与所述集管成一体。有利的是,所述集管具有一对相对的侧元件和一对端元件,形成在其下游侧具有连续通道的矩形集管,该连续通道用于接收袋式过滤介质的上游边缘。利用液态聚合材料——有利的是聚氨酯——填充其内放置有过滤介质的通道,使该液态聚合材料固化从而使过滤介质与集管成一体。这提供了牢固的锚固以及用于过滤介质的气密和水密安装。本发明可应用于这样的过滤器,其中将单独的袋式过滤器元件固定至集管或者有利的是在外边缘处利用接缝在其内形成相邻的袋式过滤器元件的连续片的过滤介质。本发明的方法提供其中伸长柔性袋元件的开口端与集管成一体的扩展区域型的过滤器组件。
附图说明
图1是根据本发明方法制造的过滤器面板组件的立体图;
图2是根据本发明方法构造的多个过滤器面板组件的立体图,示出了海洋环境下的应用;
图3是集管的分解图,示出了组装方法;
图4是组装后的集管的实施方式的立体图,示出了用于接收过滤介质的上游部分的连续通道;
图5A是过滤器面板组件的剖视分解图,示出了根据本发明一个实施方式的制造方法;以及
图5B是由本发明方法制造的完全组装的过滤器面板组件的剖视图。
具体实施方式
应当理解,本发明的应用不限于以下说明所提及的或图中示出的部件的构造及布局的细节。本发明能够具有其它实施方式并能够以各种方式实践或实施。而且,还应当理解,这里所用的措辞和术语用于说明之目的,而不应当视为限制。这里,“包含”、“包括”、或“具有”及其变型的使用旨在涵盖其后所列的条目及其等同物以及附加条目。除非另有限制,否则这里术语“连接”、“耦接”、“连通”及“安装”及其变型被广义地使用,并且涵盖直接及间接连接、耦接及安装。此外,术语“连接”和“耦接”及其变型并不限于物理或机械连接或耦接。
此外,且如以下段落中所述,图中所示的具体机械结构旨在例示本发明的实施方式,并且其它另选机械结构也是可行的。
图1示出根据本发明方法构造的过滤器面板组件100。过滤器面板组件100具有其内形成有多个袋的过滤介质102。有利的是,过滤介质102内具有由连续片的多孔过滤材料形成的多个袋,其中顶边缘和底边缘接合而形成袋,该袋在与集管的公共平面中具有袋之间的顶点。可通过向袋元件的相邻侧弯曲或弯折连续片的过滤材料并通过点焊或本领域公知的其它手段固定其边缘而制成。另选的是,可在与集管安装在一起之前单独制造过滤介质102的各个袋构件。这可通过将一片过滤材料切割成一定尺寸而实现。将切割出的过滤材料片对折叠并将重叠的侧边缘缝合或焊接在一起。有利的是,过滤介质102由硬麻布、稀松的棉麻织物或者诸如玻璃纤维或其它聚合材料的任何类多孔材料构成。在其中过滤器面板组件100用在海洋环境中的实施方式中,过滤介质102设计成凝结高浓度的液滴并移除颗粒材料。应当理解,通过本发明的制造步骤提供的过滤器面板组件可用于过滤任何气体或液体,包括但不限于空气和水。
相对的侧集管元件104和相对的端集管元件105在角部处接合而形成具有连续外表面的矩形集管。侧集管元件104和端集管元件105可具有任何长度,类似长度或不同长度,从而提供具有任何期望尺寸的矩形的或方形的集管。有利的是,介质罩条106在介质102中的过滤袋顶点附近横跨在相对的端集管元件105之间,在由集管元件104和105形成的集管平面内保持相邻袋之间的上游边缘。过滤介质102的外周部与集管元件104和105成一体。有利的是,集管元件104和105由聚合材料构成,并且更有利的是由单个挤出件切割成一定长度。在期望的实施方式中,过滤器面板组件100完全由可燃材料构成,使得该组件适于焚化。
图2示出多个过滤器面板组件200和300,它们适当串联布置,用于在海洋环境中使用。该多级系统包括多个第一除雾器108。除雾器108为具有高排放性能的惯性装置,用于从进气中移除水滴。进气从除雾器108经过至预过滤器300。预过滤器300具有其内形成有多个袋的过滤介质302。有利的是,过滤介质302由高渗透性低压降过滤材料构成,并设计成聚结高浓度的液滴。相对的侧集管元件104和相对的端集管元件105在角部处接合而形成矩形集管,该集管具有与其成一体的过滤介质302的入口部。有利的是,介质罩条106在过滤介质302中的过滤袋顶点附近横跨在相对的端集管元件105之间,在由集管元件104和105形成的集管平面内保持相邻袋之间的上游边缘。预过滤器300之后是高规格的过滤器200,该过滤器200具有其内形成有多个袋的过滤介质202。有利的是,过滤介质202具有比过滤介质302更高的效率,并且同样有利地设计成结合高聚集性的液滴。相对的侧集管元件104和相对的端集管元件105在角部处接合而形成矩形集管,该集管具有与其成一体的过滤介质202的入口部。有利的是,介质罩条106在过滤介质202中的过滤袋顶点附近横跨在相对的端集管元件105之间,在由集管元件104和105形成的集管平面内保持相邻袋302之间的上游边缘。除雾器110为具有高排放性能的惯性装置,用于从离开规格过滤器200的空气中移除水滴,从而为船用燃气轮机之类的装置提供进气。由于空气过滤系统中的变化尺寸要求,可将若干面板定位在一起并排成排,提供平行过滤。这可通过将两个以上过滤器面板组件200或300并排放置在一起而实现。可利用合适的密封剂密封侧集管元件104和/或相对的端集管元件105的相邻边缘,从而防止提供平行过滤的一排过滤器面板元件之间的空气泄漏。
图3示出集管的组装方法。使相对的侧集管元件104和相对的端集管元件105在角部处接合而形成具有连续外表面的矩形集管。有利的是,集管元件104和105由聚合材料构成,更有利的是由单个挤出件以近似45°斜切成一定长度。更有利的是,每个集管元件104和105具有纵向延伸的矩形腔(由图5A和图5B中所示的横构件115形成),适于闭合接收“L”形夹112的端部。集管的制造方法包括首先挤出连续长度的集管材料。接着,将挤出的集管材料以近似45°斜切成期望长度的侧元件104和侧元件105。然后,设置“L”形夹112,放置“L”形夹112的第一端部并牢固紧固至侧元件104或端元件105的矩形腔中,并放置“L”形夹112的另一端部并牢固紧固至侧元件104或端元件105中的另一个的腔中。该布局提高了将集管保持90°角部的倾向性并改善了其强度。
图4示出定位成接收过滤介质102的组装的集管。相对的侧集管元件104和相对的端集管元件105如图3中所示在角部处接合而形成具有连续外表面的矩形集管。该连续外表面具有内壁119和外壁121,形成通道116,该通道限制集管的下游侧以用于过滤介质安装目的。端集管元件105的内壁119有利地具有多个大致相等间隔的凹槽114,该凹槽用于接收加强杆、介质罩条和/或一部分过滤介质。
图5A示出袋式过滤器组件100的制造方法。通过图3中所示的方法使两个相对的侧集管元件104和两个相对的端集管元件105在角部处接合而形成矩形集管,该集管具有限制该集管的下游侧的连续通道116。通道116具有内壁119和外壁121以及包括横构件115的下壁。横构件115在每对纵向延伸的内壁119和外壁121之间大致平行于纵向延伸的底壁113纵向延伸,从而形成在通道116下方纵向延伸的腔。“L”形支架112插入并固定至相邻的侧集管元件104和端集管元件105的矩形腔中。紧邻横构件115将袋式过滤介质102的上游外周部插入集管的内侧壁119和外侧壁121之间的通道116中。紧邻大致相等间隔的凹槽114放置袋式过滤介质102的袋的顶点的外角部。介质罩条106有利地放置在袋式过滤介质102的袋的顶点附近并在端集管元件105的相对内侧壁119中的相对凹槽114之间延伸。介质罩条106是可选的,并设计有光滑倒圆的上游表面,从而通过降低气流阻力而减小横过过滤器组件的压降。此外,介质罩条106与加强杆118的相结合提高了集管中的袋保持布局的强度。紧邻每个顶点以及每个介质罩条106与过滤介质102的下游表面相邻地将加强杆118放置到凹槽114中。有利的是,加强杆118通过凹槽114延伸至通道116中。加强杆118可由金属材料构成,但有利的是由聚合物构成。接着,将液态聚合材料120放置到通道116中并使其固化。有利的是,聚合材料120为聚氨酯,但是可为固化时与过滤介质102、侧集管元件104和端集管元件105成一体的任何材料。例如,聚合材料120可以为热硬化性液态树脂或双组分树脂。例如,可使用散布在液态增塑剂中的聚氯乙烯树脂。
图5B示出通过本发明方法组装的完全组装起来的过滤器面板组件的剖视图。两个相对的侧集管元件104与相对的端集管元件105在角部处与“L”形支架112接合而形成矩形集管。限制集管的下游侧的连续通道116基本上已被填满聚合材料120并硬化,从而使侧集管元件104、相对的端集管元件105以及袋式过滤介质102的上游外周部成一体。横构件115示出为在每对纵向延伸的内壁119与外壁121之间大致平行于纵向延伸的底壁113纵向延伸,从而形成矩形腔。“L”形支架112固定至相邻的侧集管元件104和端集管元件105的矩形腔中。袋式过滤介质102的上游外周部在内侧壁119和外侧壁121之间与集管成一体。本发明的一体式设计防止空气泄漏并防止水在介质到集管的界面处绕过。袋式过滤介质102的袋的顶点的外角部紧邻每个凹槽114。介质罩条106在袋式过滤介质102的袋的顶点的上游侧附近,并在相对的凹槽114之间延伸。加强杆118紧邻每个介质罩条116与过滤介质102的下游表面相邻地延伸到凹槽114中。箭头示出待过滤的空气流或其它气体流的方向,并指示过滤器组件的上游侧。空气流致使袋如所示朝过滤介质的下游侧延伸。
未被支撑的过滤介质102可对着集管塌缩折叠起来,从而提供利于储存、处理和运输的大致平坦的包装。使用中,在将过滤器安装在合适的通风系统或空气调节系统中,使得过滤介质的袋的自由端沿远离集管的气流方向延伸时,气流的力使袋展开至其全长,展开至如图中所示大致笔直的水平位置。
尽管这里考虑其优选实施方式而示出并描述了本发明,然而本发明不限于这些具体实施方式。因而,这里示出并描述的本发明的形式应仅作为例示,在不脱离如所附权利要求中所阐述的本发明范围的情况下可选择其它实施方式。
Claims (11)
1.一种用于制造袋式过滤器组件的方法,该方法包括:
挤出一定长度的集管元件材料,所述集管元件材料具有一对纵向延伸的侧壁、在所述侧壁之间且与所述侧壁大致正交地延伸的纵向延伸的横构件、以及在所述横构件下方且与所述横构件大致平行地接合所述侧壁的下边缘的纵向延伸的底壁;
以近似45°将所述一定长度的集管元件材料斜切成集管端部和集管侧部;
将“L”形夹的一端部插入所述集管端部或所述集管侧部的每个端部中的腔内,所述腔由所述侧壁、所述底壁和所述横构件限定;
将所述“L”形夹的另一端部插入所述集管端部或所述集管侧部中的另一个中,以形成具有绕下游侧的连续通道的矩形集管,所述通道由所述横构件和所述侧壁限定;
将过滤器元件的上游外周部插入所述通道中,所述过滤器元件具有多个袋;
将液态聚合材料放置在所述通道中;以及
使所述液态聚合材料固化,从而形成与所述过滤器元件的所述上游外周部成一体的集管框架。
2.按照权利要求1所述的用于制造袋式过滤器组件的方法,其中,所述液态聚合材料为聚氨酯。
3.按照权利要求1所述的用于制造袋式过滤器组件的方法,该方法还包括从所述集管端部中的所述通道的内侧壁移除多部分材料的步骤,从而在该内侧壁中形成凹槽,所述凹槽大致相等地间隔开并在每个集管端部中相对地对准。
4.按照权利要求3所述的用于制造袋式过滤器组件的方法,其中,将过滤器元件的上游外周部插入所述通道中的所述步骤之后是将加强杆的每个端部放置在每一组相对地对准的所述凹槽中的步骤,所述加强杆在所述过滤介质中的每个所述袋的顶点处与所述过滤介质的下游表面相邻。
5.按照权利要求4所述的用于制造袋式过滤器组件的方法,其中,将加强杆的每个端部放置在每一组相对对准的凹槽中的所述步骤之后是在每个所述袋的顶点处将介质罩条放置在所述过滤介质的上游表面附近的步骤,所述介质罩条在相对内侧壁中的相对凹槽之间延伸。
6.一种用于制造船用燃气轮机过滤器的方法,该方法包括:
设置一对端集管元件和一对侧集管元件,所述端集管元件和所述侧集管元件均具有:纵向延伸的侧壁;纵向延伸的横构件,该横构件在所述侧壁之间且与所述侧壁大致正交地延伸,从而在所述集管元件的下游侧在所述横构件上方形成通道;以及纵向延伸的底壁,该底壁在所述横构件下方且与所述横构件大致平行地接合所述侧壁的下边缘,从而在所述底壁上方形成腔,具有所述底壁和所述横构件的所述集管元件的每个端部均为近似45°的角度;
将“L”形夹的一端部插入并固定至所述端集管元件或所述侧集管元件的每个端部中的所述腔中;
将所述“L”形夹的另一端部插入并固定至所述端集管元件或所述侧集管元件中的另一个中,从而形成矩形集管;
将过滤器元件的上游外周部插入所述通道中,所述过滤器元件具有多个袋;
将液态聚合材料放置在所述通道中;以及
使所述液态聚合材料固化,从而形成与所述过滤器元件的所述上游外周部成一体的集管。
7.按照权利要求6所述的方法,其中,所述液态聚合材料为聚氨酯。
8.按照权利要求6所述的方法,其中,所述端集管元件具有在内侧壁中的多个大致相等间隔的凹槽,在将过滤器元件的上游外周部插入在所述集管的所述内侧壁和所述外侧壁之间的所述步骤之后为紧邻每个所述袋之间的顶点在所述过滤介质的下游表面附近将加强杆放置在所述凹槽中的步骤。
9.按照权利要求8所述的方法,其中,所述加强杆的端部延伸至所述通道中并与所述集管成一体。
10.按照权利要求8所述的方法,该方法还包括紧邻每个所述加强杆在罩条的下游表面附近将所述过滤器元件的所述袋的所述顶点放置在所述罩条中的步骤。
11.按照权利要求10所述的方法,其中,所述罩条具有倒圆的下游表面。
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ES2467919T3 (es) | 2014-06-13 |
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US7905974B2 (en) | 2011-03-15 |
US20090031682A1 (en) | 2009-02-05 |
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