CN105688543B - 过滤部件及其制造方法 - Google Patents
过滤部件及其制造方法 Download PDFInfo
- Publication number
- CN105688543B CN105688543B CN201511035861.4A CN201511035861A CN105688543B CN 105688543 B CN105688543 B CN 105688543B CN 201511035861 A CN201511035861 A CN 201511035861A CN 105688543 B CN105688543 B CN 105688543B
- Authority
- CN
- China
- Prior art keywords
- end cap
- filter element
- filter
- rubber
- element according
- 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.)
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 15
- 229920001971 elastomer Polymers 0.000 claims abstract description 42
- 239000005060 rubber Substances 0.000 claims abstract description 42
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- 239000002482 conductive additive Substances 0.000 claims abstract description 17
- 239000000654 additive Substances 0.000 claims abstract description 9
- 230000000996 additive effect Effects 0.000 claims abstract description 7
- 239000000463 material Substances 0.000 claims description 46
- 239000000203 mixture Substances 0.000 claims description 27
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 16
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 14
- 229910002804 graphite Inorganic materials 0.000 claims description 10
- 239000010439 graphite Substances 0.000 claims description 10
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- VKYKSIONXSXAKP-UHFFFAOYSA-N hexamethylenetetramine Chemical compound C1N(C2)CN3CN1CN2C3 VKYKSIONXSXAKP-UHFFFAOYSA-N 0.000 claims description 7
- 239000011787 zinc oxide Substances 0.000 claims description 7
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- 229910052582 BN Inorganic materials 0.000 claims description 5
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical group N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 5
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- QAZLUNIWYYOJPC-UHFFFAOYSA-M sulfenamide Chemical compound [Cl-].COC1=C(C)C=[N+]2C3=NC4=CC=C(OC)C=C4N3SCC2=C1C QAZLUNIWYYOJPC-UHFFFAOYSA-M 0.000 claims description 2
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- CAVCGVPGBKGDTG-UHFFFAOYSA-N alumanylidynemethyl(alumanylidynemethylalumanylidenemethylidene)alumane Chemical compound [Al]#C[Al]=C=[Al]C#[Al] CAVCGVPGBKGDTG-UHFFFAOYSA-N 0.000 claims 1
- ZOOODBUHSVUZEM-UHFFFAOYSA-N ethoxymethanedithioic acid Chemical compound CCOC(S)=S ZOOODBUHSVUZEM-UHFFFAOYSA-N 0.000 claims 1
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Images
Classifications
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Abstract
一种特别是汽车的过滤部件(1),具有至少一个端盖(2、3)和与该端盖(2、3)连接的过滤介质(4),其中,至少一个端盖(2、3)具有橡胶和至少一个导热添加剂。在用于制造过滤部件(1)的方法中,至少一个端盖(2、3)至少部分地由橡胶和导热添加剂制成,其中,进行热硫化。
Description
技术领域
本发明涉及一种过滤部件。本发明还涉及一种用于制造这种过滤部件的方法。
背景技术
尽管本发明可应用于任意过滤部件和装置,但下面将针对汽车的液体过滤器或空气过滤器对本发明及其所基于的问题予以介绍。为了过滤用于汽车内燃机的液体或空气,往往使用折叠的或褶皱的过滤材料,比如过滤无纺布,其形成了褶皱包。为此将起初平面的单张过滤材料“之”字形地折叠。褶皱包被端盖保持,这些端盖安置到柱形褶皱包的顶面和底面上,该褶皱包形成了过滤介质。这种端盖例如可以由塑料制成。
褶皱包与端盖之间的连接必须流体密封,以便操作和接入到流体回路中。在过去,为此在制造相应的过滤部件时使用胶合剂、采用粘接或熔接工艺。希望能成本低廉地制得柔性的且与相应的过滤应用适配的端盖,并与相应的过滤介质连接。
发明内容
在这种背景下,本发明的目的在于,提出一种改进的过滤部件和用于过滤部件的改进的制造方法。
据此提出特别是用于汽车的过滤部件,其带有至少一个端盖和与该端盖连接的过滤介质,其中,至少一个端盖特别是在原材料中具有橡胶和导热添加剂,其中,优选将在热交联之前的端盖材料称为原材料。
特别是合成橡胶比如腈基丁二烯橡胶(NBR)或简写为丁腈橡胶、丁苯橡胶(SBR)或其混合物适合于制造用于在相应的过滤介质和相应端盖的例如其它稳固性部件之间的连接的橡胶材料。
端盖在此例如可以为多层构造,其中,面向过滤介质的区段可以构造成粘接层或粘接膜。端盖的背离过滤介质的侧面可以由塑料材料制成,或者由其它在过滤器结构中使用的材料制成。例如也可以考虑金属端盖,其借助于橡胶粘接膜安置到过滤介质上。端盖也可以只有橡胶材料。
过滤部件可以视为半制品,如果橡胶材料尚未硫化或者尚未完全硫化。硫化可以成本低廉地借助于导热添加剂在温度提高的情况下进行。在此优选将热量引入到端盖的材料或者橡胶材料中,这可简单地实现。
导热添加剂可以是导电的,例如是金属颗粒、石墨等,可以是半导电的,或者也可以是非导电的。导热添加剂适合于在硫化时改善橡胶材料中的热传递,由此促进热硫化。作为导电的或还有不导电的导热添加剂,原则上可以考虑氧化物、碳化物或氮化物。
在过滤部件的实施方式中,至少一个端盖可以具有特别是至少10PHR份额的石墨或碳黑。碳添加物导致在端盖的部分区域中的导电性。另外,所述碳添加物由于呈黑色而可以增加对IR辐射的吸收,这特别是可以有利于在使用IR辐射情况下进行热硫化。
下面提到的端盖尤其也指用于使得外面的端盖区段与过滤介质连接的粘接膜。
通过设置导热添加剂,特别是改善了借助于加热板将热量引入到粘接膜中,以便进行硫化过程。借助于导热添加剂,可以实现硫化和使得橡胶改善地交联。由此可以实现更快速的制造。也将简化地实现增大橡胶材料的体积,从而可以进行改善的“起泡沫”。特别是通过导热添加剂来改善在橡胶材料中的热传递,使得加热板的热量快速地通过橡胶材料从加热板传递到橡胶材料的远离加热板的区域。
端盖原材料的组分还可以具有:
作为导热添加剂,尤其可以考虑碳特别是石墨、金刚石、碳黑、金属颗粒特别是铁、铜、银等、六边形的或立方体的氮化硼、六边形的或立方体的氮化铝、氧化铝特别是α-氧化铝和/或碳化硅。借助于相应的导热添加剂,实现了橡胶材料的或者相应端盖区段的改善的导热性,由此可以在制造过程中进行加速的硬化和硫化。
在过滤部件的实施方式中,尤其是粘接膜形式的端盖包括特别是由二硫代氨基甲酸盐、亚磺酰胺和/或苯并噻唑的材料组构成的硫化加速剂。还可以添加氧化锌作为激活剂。在这些实施方式中特别是使用二苄基二硫代氨基甲酸锌。把硫化添加剂或硫化加速剂的混合物混合给橡胶材料。
通过相应的硫化加速剂,可以进一步简化且尤其是加速对相应的过滤部件的制造。通过使用所述物质,也可以改善例如对汽车应用中的工作液体的化学耐受性。在端盖中或上的相应的粘接膜例如特别耐受机油、燃油、尿素溶液或空气。
在这些实施方式中,橡胶的原材料即纯净的未交联的橡胶具有介于10和80MU之间的穆尼(Mooney)粘稠度。在一些特殊的实施方式中,穆尼粘稠度介于20和60MU之间。穆尼粘稠度借助于穆尼粘稠度计来测得。
在这些实施方式中,至少一个端盖流体密封地与过滤介质连接。特别是在使用所提出的带有导热物质、硫化加速剂和/或酚醛树脂的橡胶组分时会产生流体密封的连接,因为在温度相对低的情况下就已经发生了起泡沫,从而过滤介质的褶皱边被橡胶材料流体密封地包封。
还提出一种用于制造特别是汽车的过滤部件的方法,其中,过滤部件具有至少部分地由橡胶和导热添加剂制成的至少一个端盖。在该方法中,例如在混合特别是来自,二硫代氨基甲酸盐、亚磺酰胺、苯并噻唑的材料组的一种或多种硫化加速剂和/或作为激活剂的氧化锌的情况下,热学地、感应地或者借助于电磁的特别是红外的辐射将橡胶混合物硫化。
制得的过滤部件和端盖特别是如前所述地设计。在该方法的实施方式中,相应的橡胶混合物的原材料还可以在混合有酚醛树脂、硫磺、四氮六甲圜(乌洛托品)和/或硫化加速剂的情况下被硫化。
硫化例如热学地进行,其方式例如为,借助于加热板把红外辐射或热量投射到板状端盖上,特别是投射到包括橡胶的粘接区或连接区上。在本发明的实施方式中,通过感应或微波辐射来产生用于热硫化的热量辐射。感应式的硫化尤为有利,如果橡胶材料可以设有导电的或可感应地加热的物质。也可以考虑感应式加热。
借助于前述端盖,可以实现特别均匀地交联的橡胶区域,用于使得过滤介质与其它端盖材料粘接或连接。
在其它实施方式中,至少一个端盖具有由纤维增强的聚酰胺材料制成的层。端盖由此可以成本低廉地制得,且具有高强度。
在其它实施方式中,至少一个端盖流体密封地与过滤介质连接。特别是借助于橡胶材料使得至少一个端盖与过滤介质粘接或起泡沫。
在其它实施方式中,至少一个端盖具有矩形的造型。端盖例如为方形。替代地,端盖可以具有倒圆的例如圆形的造型。
过滤介质可以折叠或者波浪形地设计。作为折叠部,例如已知有“之”字形或“W”形折叠部。过滤部件可以被压铸,随后在压铸边上折叠,形成尖锐的折叠边棱。作为原材料,可以采用平面的相应地变形的单张过滤材料。
过滤介质例如是过滤织造织物、过滤非织造织物或过滤无纺布。过滤部件尤其可以采用纺粘无纺布法(Spinnvlies)或熔喷法(Meltblown)制得。此外,过滤部件可以被毡制(verlfilzen)或针织。过滤部件可以具有天然纤维比如棉花,或者具有人造纤维,其例如由聚酯、聚硫乙烯(Polyvinylsulfit)或聚四氟乙烯构成。在处理时,纤维朝向机器方向、相对于机器方向倾斜和/或与其垂直。过滤部件可以为单层或多层。要过滤的介质例如是空气。气态的介质或空气在此也包括气体或空气固态混合物和/或气体或空气液体混合物。确切地说,可以考虑工作要予以清洁的液体比如燃油、润滑剂、尿素溶液等。
该过滤部件可以应用于轿车、载重车、建筑机械、水上交通工具、有轨交通工具、空中交通工具,以及普遍地应用于空调技术、特别是应用在供暖空调设备、家用电器、燃料电池或楼宇工程中。这些汽车或交通工具可以靠电工作,和/或用燃料(特别是汽油、柴油或天然气)工作。对于楼宇工程,尤其考虑用于处理空气的静止式设备。
过滤部件尤其被构造成机油过滤器或燃油过滤器,且包括合适的过滤介质。也可以考虑作为用于尿素溶液的过滤部件的设计。过滤部件也可以形成汽车内燃机的空气过滤器,或者形成室内过滤器。
本发明的其它可行的实施方案也包括前面或下面针对这些实施例介绍的特征或方法步骤的未明确提及的组合。在这里,本领域技术人员也可以给过滤部件的相应的基本形式添加个别方面作为改进或补充。
本发明的其它设计是从属权利要求以及下述实施例的主题。下面借助实施例参照附图详述本发明。
附图说明
在这里:
图1为汽车的过滤部件的一个实施方式的示意性的立体图;
图2为过滤部件的端盖的一个实施方式的示意图。
具体实施方式
图1所示为汽车的过滤部件1的一个实施例的示意性的立体图。过滤部件1例如可以是空气过滤器或液体过滤器,特别是燃油过滤器。
该过滤部件1包括过滤介质4,该过滤介质被构造成由褶皱的(plissieren)过滤材料构成的褶皱包。通常把塑料无纺布材料“之”字形地折叠,用作过滤器材料。在形成闭合褶皱包的过滤介质4的褶皱型材9上,按图1的方向,在过滤介质4的每一端侧,即在顶侧和底侧设置有端盖2、3。过滤部件1具有至少一个端盖2、3,但优选有两个端盖2、3。端盖2、3尤其是流体密封地与过滤介质4连接。这里可以利用例如面向过滤介质4的粘接膜对端盖2、3与过滤介质4进行粘接。利用端盖2、3,过滤部件1得到一定的稳固性,且可以应用在相应的流体回路中。过滤介质2可以压入到端盖2、3的局部地起泡沫的材料中。连接接管6例如是上面的端盖2的一部分。类似地,下面的端盖3可以具有开口7,该开口可以用作接头。
按图1的方向,在顶侧示出了过滤介质4的褶皱边9。在例如作为空气过滤器或液体过滤器的工作中,要过滤的流体如空气流过被褶皱的过滤介质4增大的过滤器表面。通常,过滤介质4的或者过滤部件1的过滤材料和造型适配于规定的流向。例如,在图1中示出来自旁侧的原初空气RO,且示出了向上和向下的被过滤后的纯净空气RL。就此而言,按照图1的方向,柱形过滤介质4的面向内腔8的面是过滤部件1的流出侧面,而其外壳面是过滤部件1的流入侧面。在褶皱包4的内部设置有可选的位于端盖2、3之间的支撑部件5。
在图2中示意性地示出了过滤部件的端盖。图2在此示出端盖2,它包括多个层或区段。该端盖2在此具有承载材料2A,例如纤维增强的塑料材料,其借助于连接或粘接区段2B与过滤介质4连接。在这里,褶皱边9(参见图1)被遮盖住了,因而流体只能经由过滤介质4或接头6、7流动。粘接区段2B也可以称为粘接膜。尤其可以称其为膜式端盖,如果端盖材料例如由硫化橡胶材料构成。
在图2所示的实施方式中,设有包含丁腈橡胶(NBR)的区段2B,在相应的过滤部件1的制造过程中对该区段予以硫化。在此,所述硫化优选以热学方式例如采用硫化加速剂来进行。下面简单地称其为粘接膜2B。在下面仅示范性地将丁腈橡胶称为橡胶材料。原则上,橡胶材料普遍地适合于在过滤端盖中应用。
特别是在硬化的交联状态下,粘接膜2B是端盖2的一部分。其也称为膜式端盖。在这些实施方式中,膜式端盖2B的橡胶原材料由具有介于10和80MU之间特别是20和60MU之间的黏稠度的橡胶制得。
在此,粘接膜2B至少部分地由丁腈橡胶、合成橡胶制成。丁腈橡胶或NBR在很大程度上耐受汽车领域中的工作剂例如机油、润滑油、碳氢化合物、发动机燃烧空气、尿酸溶液等。
为了开始交联反应或硫化,必须克服激活能量EA,其中,反应速度k与温度相关,且用阿列纽斯方程予以描述:d(ln k)/dT=EA/R·T2(R:气体常数、T:温度)。因此,温度提高明显地体现在交联速度上。所以将导热添加剂加入到端盖2的原初物质配方中,该导热添加剂具有高的温度传导能力α。α与导热能力λ、密度ρ和比热容c有关:α=λ/(ρ·c)。例如,1.1810-6m2/s的石墨具有特别有利的温度传导能力。
粘接膜2B的NBR混合物包括导热添加剂,以便加速热硫化。导热添加剂在此尤其是碳、金属粉末、(六边形的)氮化硼、(六边形的)氮化铝、(α-)氧化铝和/或碳化硅。PHR是相应混合物的涉及基本聚合物的实质部分,这里尤其为NBR。
可选地,可以将特别是由二硫代氨基甲酸盐、亚磺酰胺、苯并噻唑和/或氧化锌的材料组构成的硫化加速剂用作硫化加速剂的激活剂。
申请人已研究了作为端盖的一部分应用在过滤部件中的、基于NBR的粘接膜的各种不同的配方。第一优选的配方包括至少一种来自如下组的导热添加剂:碳(石墨、碳黑或金刚石)、氮化硼(白石墨)、氮化铝、氧化铝、碳化硅、石墨和碳黑,组合以NBR橡胶。
具有橡胶的过滤器端盖或过滤器粘接膜的第二优选的配方包括第一种配方的导热添加剂和来自由二硫代氨基甲酸盐、亚磺酰胺和/或苯并噻唑构成的组的至少一个其它的硫化加速剂。
第三配方包括NBR橡胶、至少一种导热添加剂和硫化加速剂以及氧化锌作为硫化激活剂。可以考虑在NBR原初物质中有150PHR石墨、1PHR氧化锌和0.5phr二苄基二硫代氨基甲酸锌。
第四配方包括带有来自二硫代氨基甲酸盐、亚磺酰胺和/或苯并噻唑组的硫化加速剂的丁腈橡胶。还给NBR混合有元素硫、酚醛树脂、四氮六甲圜(乌洛托品)、至少一个来自碳(石墨、碳黑或金刚石)、氮化硼、氮化铝、氧化铝和/或碳化硅组的导热添加剂。第四配方可选地还含有氧化锌作为用于所用的硫化加速剂的激活剂。
第五配方包括与第一至第四配方相同的物质,并且还规定了一种物质作为处理辅助物,比如粘性剂或水。
可选地可以添加色素,以便调整橡胶的颜色。
所提出的第四和第五配方尤其适合于合适地调整端盖的硬度、弹性和化学特性。
导热添加剂在所述配方中以介于10和150phr之间的配给量使用。酚醛树脂在所述配方中以介于20和250phr之间的配给量使用。硫化加速剂在所述配方中以介于1和30phr之间的配给量使用。在需要的情况下,也可以混合有硫化延迟剂,以便提高耐储存性。
借助于所提出的配方可以有针对性地利用硫化工艺。已表明,相比于常用的粘接膜配方,缩短了用于热学地硫化的加热时间。此外,借助于所提出的膜式端盖或所使用的粘接膜进行至少部分的硫化,从而相应的端盖流体密封地与褶皱型材或褶皱边连接。
在相应的过滤部件的制造方法中,首先提供过滤介质,在该过滤介质上安置粘接膜,随后使得粘接膜热硬化。为此通过能量辐射来加热粘接膜。由此对橡胶材料进行硫化,从而使得该膜与过滤介质相互连接。硫化的橡胶材料特别是包夹褶皱边或褶皱型材8(参见图1)。
替代地或附加地,该膜可以用作在另一端盖材料之间的粘接剂,如图2中的2A所示。硫化特别是在温度介于50和350℃之间、优选介于120和160℃之间时进行。
在该制造方法的实施方式中,硫化过程的时长介于10和350s之间。
所提出的过滤部件、膜式端盖、粘接膜和制造方法允许改善地且简化地制造过滤部件。借助于所提出的配方,可以在橡胶材料中实现均匀的交联度。
尽管本发明已借助优选的实施例予以详述,但本发明并不局限于这些实施例,而是可以予以多种改型。“一个”在当前并不排除多个。此外,可以把其它物质加入到NBR配方中,比如色素或处理辅助物。
Claims (16)
1.一种过滤部件(1),带有至少一个端盖(2、3)和与该端盖(2、3)连接的过滤介质(4),其中,至少一个端盖(2、3)具有:橡胶和至少一种导热添加剂,
其中至少一个端盖(2、3)流体密封地与过滤介质(4)连接,并且其中至少一个端盖(2)的与过滤介质(4)直接连接的至少一个区段(2B)具有带有导热添加剂的橡胶材料,端盖具有纤维增强的塑料材料(2A),其借助于区段(2B)与过滤介质(4)连接,其特征在于导热添加剂具有石墨、金刚石、氮化物、氧化铝和/或碳化物。
2.如权利要求1所述的过滤部件,其中,至少一个端盖(2、3)具有介于10和150 phr之间的导热添加剂。
3.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2、3)至少部分地由带有一种或多种硫化加速剂的原材料制成。
4.如权利要求3所述的过滤部件,其中,所述原材料具有氧化锌。
5.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2、3)具有酚醛树脂。
6.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2、3)至少部分地由具有四氮六甲圜的原材料制成。
7.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2、3)至少部分地由具有硫磺和/或硫磺化合物的原材料制成。
8.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2、3)至少部分地由具有处理辅助剂的原材料制成。
9.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2、3)具有色素颗粒。
10.如权利要求1或2所述的过滤部件,其中,至少一个端盖(2)的、面向过滤介质(4)的、具有橡胶的区段(2B)被设置用于固定端盖层(2A)。
11.如权利要求1所述的过滤部件,其中,所述氮化物是氮化硼或氮化铝。
12.如权利要求1所述的过滤部件,其中,所述碳化物是碳化硅。
13.如权利要求3所述的过滤部件,其中,至少一个端盖(2、3)至少部分地由二硫代氨基甲酸盐、黄原酸盐、亚磺酰胺和/或噻唑的材料组制成。
14.如权利要求8所述的过滤部件,其中,所述处理辅助剂是烷基磺酸酯和/或碳氢化合物混合物。
15.一种用于制造用于汽车的、根据权利要求1-14中任一项所述的过滤部件(1)的方法,其中,过滤部件(1)具有至少部分地由橡胶和导热添加剂制成的至少一个端盖(2、3),其中,将橡胶热硫化。
16.如权利要求15所述的方法,其中,热硫化包括:把红外辐射或微波投射到端盖的成型的原材料上,或者感应地加热端盖(2、3)的成型的原材料,或者借助热传导进行加热。
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