CN113750650A - Preparation method of filter element - Google Patents
Preparation method of filter element Download PDFInfo
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- CN113750650A CN113750650A CN202011432976.8A CN202011432976A CN113750650A CN 113750650 A CN113750650 A CN 113750650A CN 202011432976 A CN202011432976 A CN 202011432976A CN 113750650 A CN113750650 A CN 113750650A
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/04—Additives and treatments of the filtering material
- B01D2239/0407—Additives and treatments of the filtering material comprising particulate additives, e.g. adsorbents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/10—Filtering material manufacturing
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Filtering Materials (AREA)
Abstract
The invention relates to a preparation method of a filter element, which integrates the filter element through a wet fiber molding process and comprises an impurity adsorbing body and a fiber body. The filter element is provided with an outer surface and/or an inner surface which are formed by a plurality of strip-shaped concave-convex structures connected edge to edge.
Description
Technical Field
The invention relates to a preparation method of a filter element, in particular to the technical field of production of filter elements for preparing various filter devices.
Background
Recently, the filter element made of glass fiber has been increasingly emphasized, because the glass fiber has the following advantages: heat resistance (which can be used in a high-temperature environment of 200 ℃ C. or higher after treatment), high strength, low shrinkage (dimensional stability), corrosion resistance, and smooth surface (low filtration resistance). Therefore, the existing technologies for manufacturing glass fiber are mostly divided into two types: 1. soaking the yarn in a glass fiber solution, weaving the fabric into glass fiber fabric, and then finishing the glass fiber filter element in a winding mode and the like; 2. the glass fiber is attached to the cloth after weaving. However, glass fibers also have disadvantages: is easy to be brittle (the shape is not easy to change after forming, and the loss rate is high).
Most of the existing artificial fiber filter elements use artificial fibers with lower melting points such as PP (polypropylene) or PET (polyethylene terephthalate) to carry out melt-blowing (spray-forming after melting). However, glass fiber is not suitable for melt-blown technology due to its high melting point, and is mostly processed after being formed into glass fiber cloth by the weaving method. Generally, a winding manner is used to produce a general filter element with a circular ring section (see fig. 1-2). If a filter element with a polygonal cross section (see fig. 3-4) needs to be manufactured, a paper folding method is usually adopted, that is, after the glass fiber cloth is folded in a positive and negative way, two ends of the cloth are fixed (or bonded) to form the filter element. Generally speaking, a filter element with a polygonal cross section can have a higher surface area to achieve a better filtering effect. However, the winding or recess processing method is prone to damage of the filter element due to the fragility of the glass fiber, so that the expected filtering function cannot be achieved.
The existing preparation methods of the activated carbon filter element for filtering mainly comprise sintering activated carbon, compressing activated carbon and extruding activated carbon. Sintering activated carbon: mixing an activated carbon powder material and a high-molecular hot-melting pore-forming material, pouring the mixture into a special mould, and sintering at the high temperature of 200-; because the polymer binding material can form open micropores in the sintering processing process, after being mixed with the activated carbon, the polymer binding material keeps the characteristic of large specific surface area of the activated carbon powder, has excellent pore-forming property and better filtering effect, and is more fully contacted with liquid; the processing technology is complex, and the capacity is limited. Compressing the activated carbon: mixing an activated carbon powder material and an inorganic liquid binder, pouring the mixture into a special die, performing high-pressure compression molding by using a press machine, demolding and drying; the process has high content of active carbon and good filtering effect, but when the inorganic bonding material is used, high-pressure forming is additionally adopted, so that the aperture of the filter element is difficult to control, and the pressure drop of the filter element is overlarge, thereby influencing the use. Compressing the activated carbon: mixing an activated carbon powder material and an inorganic liquid binder, pouring the mixture into a special die, performing high-pressure compression molding by using a press machine, demolding and drying; the process has high content of active carbon and good filtering effect, but when the inorganic bonding material is used, high-pressure forming is additionally adopted, so that the aperture of the filter element is difficult to control, and the pressure drop of the filter element is overlarge, thereby influencing the use. Extruding the activated carbon: the activated carbon is mixed with common hot melt resin and then placed into a screw extruder to be heated and extruded for molding. In the production process, the surface of the activated carbon is melted and wrapped by the hot-melt resin at high temperature, so that micropores of the activated carbon are blocked, the adsorption effect is lost, the production cost is low, and the yield is high. When in use, the utility model is a furnishing without any function.
For the preparation of activated carbon filter cartridges, see also japanese patent No.: jp 10-5580 discloses another method of salvaging slurry by sinking it into a slurry tank with fibers using a mold, however, because it uses a flanged upper cover (the opening and closing is time consuming) and the thickness of the filter cartridge cannot be freely controlled (the entire vessel needs to be filled). In addition, the slurry formulation cannot withstand high temperature and increase drying time (drying at 120 ℃ C. takes 12hr, and increasing to 140 ℃ C. causes strength reduction).
Accordingly, it would be desirable to provide a fiber glass filter element that can improve upon existing fiber glass filter elements and their existing methods of manufacture.
Disclosure of Invention
In order to solve the above problems of the prior art, a primary object of the present invention is to provide a method for manufacturing a filter element, which is capable of simplifying the process, reducing the manufacturing time, and relatively increasing the yield of the filter element by fully automatically manufacturing the filter element through a wet fiber molding process and integrally forming the entire structure of the filter element.
In order to achieve the purpose, the invention provides the following technical scheme: provided is a method for manufacturing a filter element, comprising the following steps: firstly, mixing a fiber body, an impurity adsorbent and a carrier to form slurry, wherein the impurity adsorbent is attached to the fiber body; then, a first mold is immersed into the slurry along a first direction; then, opening an absorbing unit, and absorbing a wet blank with a shape corresponding to the outer surface and a specific thickness on the outer surface of the first mold through a connecting channel arranged in the first mold and at least one opening on the outer surface of the first mold; closing the first mold and a second mold with the shape corresponding to that of the first mold to perform prepressing operation on the wet blank; and then, carrying out a heat drying operation on the wet blank to form a filter element.
In a preferred embodiment, a plurality of strip-shaped concave-convex structures connected edge to edge are formed on an inner surface of the wet blank by surrounding the strip-shaped concave-convex structures connected edge to edge on the inner surface of one of the first mold and the second mold, wherein the strip-shaped concave-convex structures of the wet blank form a plurality of end surfaces having an included angle between 0.5 degrees and 3 degrees with the first direction, and the thickness of the wet blank is between 0.6mm and 5 mm.
In a preferred embodiment, the radial cross-sectional shape of the plurality of elongated concave-convex structures of one of the first mold and the second mold is one of a star-mango shape, a petal shape, a gear shape, a carambola shape, a sun shape and a wave shape.
In a preferred embodiment, the filter element is provided with a positive or negative electric potential by the impurity adsorbent, and the impurity adsorbent is selected from at least one material of the group consisting of a cationic polymer and activated carbon.
In a preferred embodiment, when the impurity adsorbent includes the cationic polymer, the slurry further includes a fixing member for reinforcing a bonding force between the cationic polymer and the fibrous body.
In a preferred embodiment, the pre-pressing operation is performed on the wet blank by a specific gap value between the first mold and the second mold, and the specific gap value is between 1.1 and 1.2 times of a thickness of the filter element.
In a preferred embodiment, the operation time of the pre-pressing operation is 0.5 to 1 second, the operation time of the hot drying operation is 10 to 60 seconds, and the operation temperature of the hot drying operation is 160 ℃ or higher.
In a preferred embodiment, the filter element is a cup-shaped body, the bottom of the filter element is a curved surface or a plane surface, and the top of the filter element forms a first opening.
In a preferred embodiment, the preparation method of the filter element further comprises the following steps: firstly, cutting the bottoms of a plurality of filter elements along a direction vertical to the first direction to form a second opening; and then, mutually butting the filter elements at the first opening or the second opening to form a filter element assembly.
In a preferred embodiment, the fiber body is used for filtering harmful substances and/or suspended particles for human body, and the fiber body comprises at least one of natural fibers and chemical fibers, wherein the chemical fibers comprise glass fibers and non-glass fibers.
In a preferred embodiment, the fibrous body accounts for 60-99 wt% of the total of the fibrous body and the impurity adsorbent, and the impurity adsorbent accounts for 0-50 wt% of the total of the fibrous body and the impurity adsorbent.
In a preferred embodiment, when the impurity adsorbent is a cationic polymer, the zeta potential (zeta potential) of the filter element is between 15 and 53.
In a preferred embodiment, a surface density of an outer surface of the filter element is less than or equal to a surface density of an inner surface of the filter element.
In a preferred embodiment, a surface density of an outer surface of the filter element is made greater than a surface density of an inner surface of the filter element.
To solve the above problems of the prior art, the present invention also provides a method for manufacturing a filter cartridge, which integrally forms a filter cartridge through a wet fiber molding process and the filter cartridge is used for filtering liquid or gas. The preparation method of the filter element comprises the following steps: firstly, mixing a fiber body, an impurity adsorbent and a carrier to form slurry, wherein the impurity adsorbent is attached to the fiber body; then, a first mold is immersed into the slurry along a first direction; then, opening an absorbing unit, and absorbing a wet blank with a shape corresponding to the outer surface and a specific thickness on the outer surface of the first mold through a connecting channel arranged in the first mold and at least one opening on the outer surface of the first mold; and closing the first mold and a second mold corresponding to the first mold in shape to perform pre-pressing operation on the wet blank to form a filter element, wherein a plurality of strip-shaped concave-convex structures connected in edge-to-edge mode are formed on the inner surface of one of the first mold and the second mold in a surrounding mode, and a plurality of strip-shaped concave-convex structures connected in edge-to-edge mode are formed on the outer surface of the filter element in a surrounding mode.
In a preferred embodiment, the plurality of elongated concave-convex structures of the filter element form a plurality of end surfaces having included angles between 0.5 degrees and 3 degrees with the first direction, and the thickness of the wet blank is between 0.6mm and 5 mm.
In a preferred embodiment, the radial cross-sectional shape of the elongated concave-convex structures of one of the first mold and the second mold is one of a star-mango shape, a petal shape, a gear shape, a carambola shape, a sun shape and a wave shape.
In a preferred embodiment, the preparation method of the filter element further comprises the following steps: the filter element is provided with a positive or negative electric potential by the impurity adsorbent, and the impurity adsorbent is selected from at least one material in the material group consisting of a cationic polymer or activated carbon.
In a preferred embodiment, when the impurity adsorbent includes the cationic polymer, the slurry further includes a fixing member for reinforcing a bonding force between the cationic polymer and the fibrous body.
In a preferred embodiment, the preparation method of the filter element further comprises the following steps: the outer surface of the other mold of the first mold and the second mold is surrounded by a plurality of strip-shaped concave-convex structures which are connected in a side-to-side mode, so that a plurality of strip-shaped concave-convex structures which are connected in a side-to-side mode are formed on the inner surface of the filter element in a surrounding mode.
The invention provides the technical effects that: compared with the preparation process of the existing glass fiber filter element and the active carbon filter element (especially, a plane plate (such as glass fiber cloth) is folded at multiple positions and wound in multiple layers in a manual mode to form the polygonal appearance of the existing filter element), the preparation method of the filter element provided by the invention can integrally form the integral structure of the filter element through a fully automatic production procedure, so that the process is simplified, the preparation working hour is reduced, and the yield of the filter element is relatively increased; in addition, because the conventional filter element is formed by folding and winding the planar plate at multiple positions, the limited thickness of the planar plate is easy to limit the filtering thickness of each position of the filter element, and the preparation method of the filter element provided by the invention can selectively thicken the filtering thickness of any position of the filter element, thereby improving the filtering efficiency.
Drawings
Fig. 1 shows a schematic front perspective view of a filter insert according to a first preferred embodiment of the invention;
FIG. 2 depicts a schematic bottom perspective view of a filter cartridge according to a first preferred embodiment of the present invention;
FIG. 3 depicts a schematic cross-sectional view of a filter cartridge according to a first preferred embodiment of the invention;
FIG. 4 depicts an enlarged view of E1 according to FIG. 1;
FIG. 5 depicts a cartridge preparation apparatus according to a first preferred embodiment of the present invention;
FIG. 6 is a schematic view of the first mold and the second mold shown in FIG. 5;
FIG. 7 depicts a schematic cross-sectional view of a filter cartridge according to a second preferred embodiment of the invention;
fig. 8 shows a flow chart for the preparation of a filter cartridge according to a first preferred embodiment of the invention;
FIG. 9 depicts a flow diagram for the preparation of a filter cartridge according to a second preferred embodiment of the invention; and
fig. 10 shows a flow chart for the preparation of a filter cartridge according to a third preferred embodiment of the invention.
Detailed Description
The following description of the embodiments refers to the accompanying drawings, which are included to illustrate specific embodiments in which the invention may be practiced. The directional terms of the present invention, such as "up", "down", "front", "back", "left", "right", "inside", "outside", "side", etc., refer to the directions of the drawings. Accordingly, the directional terms used are used for the purpose of illustration and understanding, and are not used to limit the invention.
Referring initially to fig. 1-4, fig. 1 is a schematic front perspective view of a filter cartridge 100 according to a first preferred embodiment of the present invention; fig. 2 shows a schematic bottom perspective view of a filter cartridge 100 according to a first preferred embodiment of the present invention; fig. 3 shows a schematic cross-sectional view of a filter cartridge 100 according to a first preferred embodiment of the present invention. Fig. 4 shows an enlarged view of E1 from fig. 1.
The filter element 100 is integrally formed by a wet fiber molding process and is used to filter liquids or gases. The filter element comprises a fiber body 101, an impurity adsorbing body 102 and a fixing body 103. The fibrous body 101 includes at least one of natural fibers and chemical fibers, and the fibrous body 101 is used for filtering substances and/or suspended particles harmful to the human body, except for being the main structure of the filter element 100. The chemical fiber comprises glass fiber and non-glass fiber. The impurity adsorbent 102 is attached to the fibrous body 101 through the fixing body 103. Preferably, the fixing body 103 fixes the impurity adsorbent 102 on the fibrous body 101 by a physical or chemical means. In the preferred embodiment, when the impurity adsorbent 102 comprises a cationic polymer, the slurry further comprises the fixing member 103 and the impurity adsorbent 102 is a cationic polymer, so that the zeta potential (zeta potential) of the filter element 100 can be between 15 and 53; in another preferred embodiment, when the impurity adsorbent 102 is activated carbon only, the activated carbon can be attached to the fibrous body 101 mainly composed of glass fiber without the fixing member 103, so that the filter cartridge 100 can have an advantage of rapid drying. Since the impurity adsorbent 102 is at least one material selected from the group consisting of cationic polymers and activated carbon, the characteristics of the cationic polymers and activated carbon can make the filter element 100 have a positive or negative electric potential in the gas or liquid (such as water) to be filtered, and can be used for adsorbing impurities or bacteria or viruses. Preferably, the cationic polymer is a metal oxide or is a non-metal oxide.
In the preferred embodiment, the filter cartridge 100 is a cup-shaped body, and the cup-shaped body (i.e., the filter cartridge 100) includes a bottom 107 perpendicular to a first direction D1, an outer surface 105 connected to the bottom 107, an inner surface 112 opposite the outer surface 105, and a first opening 108 (at the top of the cup-shaped body) opposite the bottom 107. The outer surface 105 (like an outer surface 105) is surrounded by a plurality of strip-shaped concave-convex structures 150 connected edge to edge, and the strip-shaped concave-convex structures extend along the first direction D1.
The inner surface 112 (like an inner circumferential surface 112) of the filter element 100 also extends along the first direction D1 around the elongated concave-convex structure 150 forming a plurality of edge-to-edge connections. However, according to different designs, the plurality of elongated concave-convex structures 150 connected edge to edge may be formed on only one of the outer surface 105 or the inner surface 112, and the other opposite surface (i.e. the other of the outer surface 105 or the inner surface 112) is only a continuous plane or curved surface. For example, as shown in fig. 1, after the inner surface 112 is filled, only the outer surface 105 of the filter element 100 is formed with the plurality of elongated concave-convex structures 150. Alternatively, after the plurality of side-to-side connected elongated concave-convex structures 150 of the outer surface 105 are filled and leveled to form the appearance of the filter element 100 into a cylinder or a truncated cone, only the plurality of elongated concave-convex structures 150 are formed on the inner surface 112 of the filter element 100. The above-mentioned "filling", "removing" and "filling" are merely illustrative, and in practice, the operation only requires a direct change in the shape of the mold for preparing the filter element, and the filter element 100 is not processed.
Preferably, a specific distance G1 between the lowest end surfaces 106 of every two adjacent concave structures (or the highest end surfaces 106 of every two adjacent convex structures) of the plurality of elongated concave-convex structures 150 is greater than or equal to 1mm, so that the bridging phenomenon caused by the specific distance G1 being too short during the molding of the mold can be avoided.
In a preferred embodiment, a surface density of the outer surface 105 of the filter element 100 is less than or equal to a surface density of the inner surface 112; in another preferred embodiment, however, a surface density of the outer surface 105 is greater than a surface density of the inner surface 112. The two different surface densities of the inner and outer surfaces 105,112 of the filter cartridge 100 can increase the time that the liquid or gas to be filtered stays within the filter cartridge 100 and thus increase the filtration efficiency.
Preferably, the included angles F1 between the end surfaces 106 of the elongated concave-convex structures 150 of the outer surface 105 and the first direction D1 are between 0.5 and 3 degrees. In other words, a truncated cone is formed between said first opening 108 of said cup-shaped body and said bottom 107; that is, the plurality of elongated asperities 150 of the outer surface 105 are formed as a truncated cone of outer surface. In other embodiments, when the internal shape of the filter element 100 is not required, the inner surface 112 can also be the inner conical surface of a truncated cone, or the elongated concave-convex structures 150 of the inner surface 112 can be formed on the inner conical surface of a truncated cone. It should be noted that the purpose of the included angle F1 is to make the process of demolding the filter cartridge 100 easier.
Besides, the bottom 107 and the elongated concave-convex structures 150 of the outer surface 105 can be connected in a plane, and the connection between the bottom 107 and the elongated concave-convex structures 150 can also form at least one convex curved surface (as shown in fig. 1-3).
Preferably, the radial cross-sectional shape of the elongated concave-convex structures 150 of the filter element 100 is one of a star-mango shape, a petal shape, a gear shape, a carambola shape, a sun shape and a wave shape. As shown in fig. 2 and fig. 3, in which the filter element 100 of the integrally formed starburst concave-convex structure 150 is taken as an example, compared with the conventional filter element manufacturing method (manually folding a planar plate), the integrally formed filter element 100 and the manufacturing method thereof provided by the present invention not only can simplify the process and reduce the manufacturing time, but also can relatively increase the yield of the filter element 100, and increase the filtering thickness of the filter element 100 to improve the filtering efficiency.
Preferably, the bottom 107 of the cup (i.e., the filter element 100) is a convex curved surface or flat surface (not shown). Since the filter element 100 is formed by press-clamping both a pair of first mold 130 and second mold 140 (see fig. 6), when the bottom 107 of the cup-shaped body (i.e., the filter element 100) is convexly curved, it helps to prevent damage that may occur when the filter element 100 is removed from the mold. In other embodiments, the thickness of the convex curved surface of the bottom 107 of the cup-shaped body (i.e., the filter element 100) may be increased compared to the thickness of the filter element 100 at other locations by designing the first and second molds 130,140 (see fig. 6).
In a preferred embodiment of the present invention, a plurality of filter elements 100 are stacked in a same direction to form a multi-layer filter element assembly, and a specific space gap exists between every two filter elements 100 to separate every two filter elements 100, so that the time for the liquid or gas to be filtered to contact each filter element 100 can be further increased. In another preferred embodiment, the multi-layer filter element assembly is formed by overlapping two or more filter elements 100 having different fiber densities. For example, the outermost filter element 100 of the filter element assembly has a lower fiber density than the innermost filter element 100 of the filter element assembly; alternatively, the fiber density of the filter element 100 located innermost in the filter element assembly is lower than the fiber density of the filter element 100 located outermost in the filter element assembly.
Please further refer to fig. 1 and fig. 5. Fig. 5 shows a cartridge preparation apparatus 10 according to a first preferred embodiment of the present invention, which is capable of automatically mass-producing the integrated structure of the cartridge 100 through a wet fiber molding process. The filter element preparation apparatus 10 includes a slurry tank 175, a slurry 110, a suction unit 190 (generally, a vacuum pump), a first mold 130, a second mold 140, a driving unit 200 (generally, a driving component such as an air pressure rod, an oil pressure rod, etc.), and a heat generator (not shown), in general, for convenience of equipment maintenance, the driving unit 200 drives the first mold 130 to scoop the slurry stored in the slurry tank 175, so as to form a wet blank 100 attached to the first mold 130 (fig. 5 shows a state where the wet blank 100 is formed after the first mold 130 scoops the slurry from the slurry tank 175); then, the driving unit 200 moves the first mold 130 and the wet embryo 100 vacuum-absorbed by the first mold 130 to the second mold 140, so that the first mold 130 and the second mold 140 are closed to perform a pre-pressing operation on the wet embryo 100. Then, according to actual requirements, a baking operation can be continued on the premise that the second mold 140 is connected to the heater; the first mold (with the wet blank 100) may be closed with another mold and the hot baking may be performed. The heat drying operation may be performed by hot air and/or hot pressing. It should be noted that, in the preferred embodiment, the first mold 130 is a male mold and the second mold 140 is a female mold; however, the first mold 130 may be a female mold and the second mold 140 may be a male mold in different applications.
Preferably, the first mold 130 may further include a first net 135 and the second mold 140 may further include a second net 145, and the first net 135 and the second net 145 have fine meshes and have corresponding shapes to the first mold 130 and the second mold 140, so as to allow the filter element 100 to be easily separated from the first mold 130 after the filter element is dried. Here, it should be noted that: the difference between the wet blank, i.e., the filter element 100, and the difference between the wet blank and the thickness thereof (the wet blank is thicker and becomes thinner after pre-pressing and hot-drying operations) is only that the two are considered to be the same in this specification. Preferably, the first netting 135 and the second netting 145 may be omitted.
The slurry is mixed with a fiber body 101, a foreign matter adsorbent 102, a fixing body 103 and a carrier 104, wherein the carrier 104 can be water or other liquid substances according to different settings. For the fibrous body 101, the impurity adsorbing body 102, and the fixing body 103, reference is made to the above description. As described above, the fixing body 103 may not be used when the impurity adsorbent 102 is activated carbon. However, the preferred embodiment is explained when the impurity adsorbent 102 includes a cationic polymer, so that the filter cartridge 100 includes the fixing body 103; when the impurity adsorbent 102 is activated carbon only, the fixing member 103 is not required to be attached to the fibrous body 101.
Generally, the fiber body 101 includes natural fibers as well as artificial fibers. Rayon can be further classified as plastic fiber and glass fiber. When the weight percentage of the impurity adsorbent 102 in the total of the fibrous body 101 and the impurity adsorbent 102 is 35-50, the effect of water treatment is better; when the weight percentage of the glass fiber in the total of the fiber body 101 and the impurity adsorbent 102 is 50-99, the effect on air treatment is better. In a preferred embodiment, the weight percentage of the fibrous body 101 to the total of the fibrous body 101 and the impurity adsorbent 102 is 60-99, and the weight percentage of the impurity adsorbent 102 to the total of the fibrous body 101 and the impurity adsorbent 105 is 0-50. Because the glass fiber has high melting point and low water absorption property, the glass fiber is used as the fiber body 101, so that the filter element 100 can be dried and molded at a higher temperature (more than 160 degrees centigrade or even more than 200 degrees centigrade) in a short time, and further, the first mold 130 and the second mold 140 can be accelerated to rapidly produce the next filter element 100.
Compared with the prior art, the invention can mix the glass fiber, the fixing body 103 and the cationic polymer (or activated carbon) in the carrier (which can be water) under the operation environment of normal temperature and normal pressure, and automatically mass-produce the integral structure of the integrally-formed filter element 100 through innovative ways which are not disclosed by the existing preparation method of the filter element, such as slurry fishing, slurry sucking, air exhausting (removing excessive water in advance), mold closing prepressing, mold closing drying and the like, thereby greatly simplifying the process and working hours of preparing the filter element 100 by using the glass fiber and reducing the manual folding cost.
The suction unit 190 sucks a wet blank 100 having a shape corresponding to the outer surface 137 of the first mold 130 and a specific thickness on the outer surface 137 of the first mold 130 through a channel 193 disposed inside the first mold 130 and at least one opening 139 of the outer surface 137 of the first mold 130. Because the at least one opening 139 is disposed over the entire outer surface 137, when the suction unit starts pumping, most of the moisture in the wet embryo 100 is pumped out of the wet embryo 100 through the first mesh 135 (omitted if the mesh is not used), the at least one opening 139 and the air pipe 192 in sequence.
Preferably, when the first mold 130 is a male mold, the outer surface 137 of the first mold 130 surrounds and forms a plurality of strip-shaped concave-convex structures 150' connected edge to edge, so that the inner surface 112 of the wet blank 100 (also referred to as the filter element 100) correspondingly surrounds and forms the plurality of strip-shaped concave-convex structures 150 connected edge to edge; in other embodiments, as shown in fig. 6, the second mold 140 may be a male mold, and a plurality of strip-shaped concave-convex structures 150' connected edge to edge are formed around the outer surface of the second mold 140. Similarly, as shown in fig. 6, when the first mold 130 is a master mold, a plurality of strip-shaped concave-convex structures 150' connected side to side are formed around the inner surface of the first mold 130, so that the plurality of strip-shaped concave-convex structures 150 connected side to side are correspondingly formed around the outer surface 105 of the wet blank 100 (also referred to as the filter element 100); in other embodiments, the second mold 140 may be used as a master mold, and a plurality of strip-shaped concave-convex structures 150' connected edge to edge are formed around the inner surface of the second mold 140. The included angles F1 between the end surfaces 106 'formed by the elongated concave-convex structures 150' of the outer surface 137 and the first direction D1 are between 0.5 and 3 degrees, and the thickness of the wet blank 100 is between 0.6 and 5 mm. It should be noted that fig. 5 is only an illustration, and the outer surface 137 of the first mold 130 and the outer surface 147 of the second mold 140 are not actually included in the first direction D1 by an angle F1 of 0.5 to 3 degrees.
In detail, the pre-pressing operation is performed by closing the wet blank 100 through a specific gap value between the first mold 130 and the second mold 140, and generally, the specific gap value is between 1.1 and 1.2 times a thickness of the filter element 100. This is because the structure of the wet blank 100 is relatively loose as described above, and the pre-pressing operation is performed to further fix the shape of the product, but it is required to be slightly thicker than the predetermined thickness of the product, because the thickness is reduced due to the water loss in the subsequent hot-drying operation.
In the preferred embodiment, at least one opening 149 is also formed on the outer surface 147 of the second mold 140, and the suction unit 190 is connected to the second mold through an air pipe 192 and the communication passage 193. However, the second mold 140 may not be connected to the suction unit 190 according to actual requirements.
Referring to fig. 1 and fig. 5-6, fig. 6 is a schematic view of the first mold 130 and the second mold 140 shown in fig. 5. Wherein the size of the inside of the first mold 130 corresponding to the filter element 100 is slightly larger than the size of the outside of the second mold corresponding to the filter element 100, and as mentioned above, the angle F1 between the first direction D1 and the middle portion of the bottom 107 (i.e. the portion corresponding to the end surfaces 106) and the periphery 111 of the filter element 100 removed by the first mold 130 and the second mold 140 is 0.5 to 3 degrees, so as to facilitate the demolding.
Through repeated tests, the operation time of the pre-pressing operation is preferably 0.5-1 second; the operation time of the hot drying operation is 10-60 seconds, preferably 25-35 seconds; the operation temperature of the hot drying operation is more than 160 ℃; preferably 200 degrees celsius or higher. The final product thickness of the filter element 100 is 0.5-3 mm.
Referring again to fig. 1 and 6-7, the length of each filter element 100 (along the first direction D1) is limited by the dimensions of the slurry channel 175, the first mold 130, and the second mold 140. In other embodiments, to increase the length of the filter element 100, the bottom 107 of two filter elements 100 may be cut transversely along a direction perpendicular to the first direction D1, such that the bottom 107 of each filter element 100 forms a second opening 109 (see fig. 7), and then the peripheral edges 111 (substantially planar) of the two filter elements 100 at the first opening 108 are bonded together by abutting, thereby forming an elongated filter element assembly having the second openings 109 at opposite ends thereof. Without the peripheral edge 111, bonding by only the outer surface 105 (which is essentially a side of limited width) is time consuming and weak. In other embodiments, the two filter elements 100 may be bonded to the periphery of the second opening 109 instead of being abutted, so as to form an elongated filter element assembly, and two opposite ends of the elongated filter element assembly are respectively the first openings 108.
For the preferred embodiment, the included angle F1 between the end surfaces 106 of the elongated concave-convex structures 150 of the outer surface 105 of the filter element 100 and the first direction D1 is 0.5 to 3 degrees. In other words, from the bottom 107 of the filter element 100 toward the peripheral edge 111, the end surfaces 106 can present a flared bevel that facilitates the removal of the filter element 100 from the end surfaces 106' of the first mold 130. However, depending on the design, the mold may be designed such that the periphery 111 is not present. In other words, a truncated cone is formed between said first opening 108 of said cup-shaped body and said bottom 107; that is, the plurality of elongated asperities 150 of the outer surface 105 are formed as a truncated cone of outer surface.
In addition, since the shapes of the first mold 130 and the second mold 140 correspond to the shape of the filter element 100, for example, the radial cross-section of the elongated concave-convex structures 150' of one of the first mold 130 and the second mold 140 is also shaped like a star-mango, a petal, a gear, a carambola, a sun, or a wave. Therefore, when describing the shape of the first mold 130 and the second mold 140, the description is equally applicable to the shape of the filter element 100; similarly, when describing the characteristics (composition and shape) of the filter element 100, the same is true when describing the characteristics of the wet blank 100, and the differences are only the size (the size of the filter element 100 is slightly reduced by drying), the humidity (the size of the filter element 100 is slightly reduced by drying), and the like.
See fig. 1, 5 and 8. Fig. 8 shows a flow chart for preparing a filter cartridge according to a first preferred embodiment of the present invention. First, step S01 is executed to mix a fiber 101, a foreign substance adsorber 102, a fixing element 103 and a carrier 104 to form a slurry 110, wherein the foreign substance adsorber 102 is attached to the fiber 101 through the fixing element 103. Next, step S02 is performed, a first mold 130 is immersed in the slurry 110 along a first direction D1. Next, step S03 is executed to start a suction unit 190, and a wet blank 100 having a shape corresponding to the outer surface 137 of the first mold 130 and a specific thickness is absorbed on the outer surface 137 of the first mold 130 through a connecting channel 193 disposed inside the first mold 130 and at least one opening 139 of the outer surface 137 of the first mold 130. Next, step S04 is executed to press the first mold 130 away from the slurry 110 and close the first mold 130 with a second mold 140 corresponding to the first mold 130 to perform a pre-pressing operation on the wet blank 100. Next, in step S05, a thermal drying operation is performed on the wet blank 100 to form a filter element 100. As described above, when the impurity adsorbent 102 is activated carbon, the fixing body 103 in step S01 may be omitted.
See also fig. 1, 5, 8-9. Fig. 9 shows a flow chart for the preparation of a filter cartridge according to a second preferred embodiment of the invention. The difference between the present preferred embodiment and the first preferred embodiment lies in the removal step S05, and the present process is characterized in that the filter element can be formed without pre-pressing operation for the product with low requirement for the external dimension (or internal dimension) of the filter element.
See again fig. 1, 6, 8, 10. Fig. 10 shows a flow chart for the preparation of a filter cartridge according to a third preferred embodiment of the invention. The difference between the present preferred embodiment and the first preferred embodiment is that the steps S04-S05 are removed, and step S03 is followed by step S07, wherein the wet blank 100 is pre-pressed by surrounding a plurality of strip-shaped concave-convex structures 150' connected edge to edge on the outer surface (e.g. 147) of one of the first mold 130 and the second mold 140, and the inner surface 112 of the wet blank 100 (equivalent to the filter element 100) is surrounded by the plurality of strip-shaped concave-convex structures 150 connected edge to edge; further, the pre-pressing operation is performed on the wet blank 100 by surrounding a plurality of strip-shaped concave-convex structures 150' connected edge to edge on the inner surface of the other one of the first mold 130 and the second mold 140, so that the plurality of strip-shaped concave-convex structures 150 connected edge to edge are formed on the outer surface 105 of the wet blank 100 (equivalent to the filter element 100) by surrounding.
Preferably, each of the three flow diagrams described above can also be supplemented with a step of making a surface density of the outer surface 105 of the filter element 100 less than or equal to a surface density of the inner surface 112 of the filter element 100; preferably, a surface density of the outer surface 105 is greater than a surface density of the inner surface 112. By the difference of the surface density, the time for the liquid or gas to be filtered to stay in the filter element 100 is increased as much as possible, and the filtering effect is increased. For example, by reducing the surface density of the water inlet end portion of the filter element 100, liquid or gas to be filtered can more easily enter the filter element 100; meanwhile, the surface density of the water outlet end part of the filter element 100 is increased, so that the liquid or gas to be filtered is more difficult to leave the filter element 100, and the effect of increasing the Hydraulic Retention Time (HRT) is achieved.
Normally, the surface density of a filter element 100 is uniform, but the surface density of outer surface 105 may be increased by localized hot pressing, such as hot pressing only outer surface 105. Surface Roughness (RA) is similar to machining, except that the surface density is increased by pressing (or heating) to increase the local density to change the surface Roughness and further increase the time for the object (liquid or gas) to stay in the filter element 100 due to the increased density.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that the present invention is not limited to the details of the foregoing embodiment, and that the foregoing examples and description are provided merely for the purpose of illustrating the principles of the invention, and that various changes and modifications may be made without departing from the spirit and scope of the invention, which will fall within the scope of the invention as hereinafter claimed. The scope of the invention is to be defined by the appended claims.
Claims (18)
1. A method of making a filter element for use in filtering liquids or gases by integrally forming the filter element by a wet fiber molding process, and comprising:
mixing a fiber body, an impurity adsorbing body and a carrier to form slurry, wherein the impurity adsorbing body is attached to the fiber body;
a first mold immersed in the slurry in a first direction;
opening an absorption unit, and absorbing a wet blank with a shape corresponding to the outer surface and a specific thickness on the outer surface of the first mold through a channel arranged in the first mold and at least one opening on the outer surface of the first mold;
closing the first mold and a second mold with the shape corresponding to that of the first mold to perform prepressing operation on the wet blank; and
and carrying out a heat drying operation on the wet blank to form a filter element.
2. The method of making a filter cartridge of claim 1, further comprising: the inner surface of one of the first mold and the second mold is surrounded by a plurality of strip-shaped concave-convex structures which are connected in edge-to-edge mode, so that a plurality of strip-shaped concave-convex structures which are connected in edge-to-edge mode are formed on the outer surface of the filter element in an opposite mode, the plurality of strip-shaped concave-convex structures which are connected in edge-to-edge mode of the filter element form a plurality of tail end surfaces which form included angles with the first direction of 0.5-3 degrees, and the specific thickness of the wet blank ranges from 0.6mm to 5 mm.
3. The method of claim 2, wherein the plurality of elongated reliefs of one of the first mold and the second mold have a radial cross-sectional shape that is one of star-mango, petal, gear, carambola, sun, and wave.
4. The method of making a filter cartridge of claim 1, further comprising: the filter element is provided with a positive or negative electric potential by the impurity adsorbent, and the impurity adsorbent is selected from at least one material in the material group consisting of a cationic polymer or activated carbon.
5. The method of making a filter element according to claim 4 wherein, when said impurity adsorbent comprises said cationic polymer, said slurry further comprises a fixing member for reinforcing a bonding force between said cationic polymer and said fibrous body.
6. The method of making a filter cartridge of claim 1, further comprising: and pre-pressing the wet blank through a specific gap value between the first die and the second die, wherein the specific gap value is 1.1-1.2 times of the thickness of the filter element.
7. The method of making a filter element according to claim 1, wherein the pre-pressing operation is performed for a time period of 0.5 to 1 second, the heat-drying operation is performed for a time period of 10 to 60 seconds, and the heat-drying operation is performed at a temperature of 160 ℃ or higher.
8. The method of making a filter element according to claim 1 wherein said filter element is a cup and the bottom of said filter element defines a curved surface or a flat surface and the top of said filter element defines a first opening.
9. The method of making a filter cartridge of claim 8, further comprising: cutting the bottoms of the filter elements along a direction perpendicular to the first direction to form a second opening; and
and the filter elements are mutually butted at the first opening or the second opening to form a filter element assembly.
10. The method of making a filter element according to claim 1, wherein the fiber body comprises at least one of natural fibers and chemical fibers, the chemical fibers comprising glass fibers and non-glass fibers.
11. The method of claim 1, wherein the fiber comprises 60-99 wt% of the total of the fiber and the impurity adsorbent, and the impurity adsorbent comprises 0-50 wt% of the total of the fiber and the impurity adsorbent.
12. The method of claim 4, wherein the zeta potential of the filter element is between 15 and 53 when the impurity adsorbent is a cationic polymer.
13. The method of making a filter cartridge of claim 1, further comprising: a surface density of an outer surface of the filter element is less than or equal to a surface density of an inner surface of the filter element.
14. The method of making a filter cartridge of claim 1, further comprising: a surface density of an outer surface of the filter element is made greater than a surface density of an inner surface of the filter element.
15. A method of making a filter element for use in filtering liquids or gases by integrally forming the filter element by a wet fiber molding process, the method comprising:
mixing a fiber body, an impurity adsorbing body and a carrier to form slurry, wherein the impurity adsorbing body is attached to the fiber body;
a first mold immersed in the slurry in a first direction;
opening an absorption unit, and absorbing a wet blank with a shape corresponding to the outer surface and a specific thickness on the outer surface of the first mold through a channel arranged in the first mold and at least one opening on the outer surface of the first mold; and
the first mold and a second mold corresponding to the first mold in shape are closed to perform pre-pressing operation on the wet blank to form a filter element, wherein a plurality of strip-shaped concave-convex structures connected in edge-to-edge mode are formed on the inner surface of one of the first mold and the second mold in a surrounding mode, and a plurality of strip-shaped concave-convex structures connected in edge-to-edge mode are formed on the outer surface of the filter element in a surrounding mode relatively.
16. The method of claim 15, wherein the plurality of elongated reliefs of one of the first mold and the second mold have a radial cross-sectional shape that is one of star-mango, petal, gear, carambola, sun, and wave.
17. The method of making a filter cartridge of claim 15, further comprising: the filter element is provided with a positive or negative electric potential by the impurity adsorbent, and the impurity adsorbent is selected from at least one material in the material group consisting of a cationic polymer or activated carbon.
18. The method of making a filter cartridge of claim 15, further comprising: the outer surface of the other mold of the first mold and the second mold is surrounded by a plurality of strip-shaped concave-convex structures which are connected in a side-to-side mode, and then the inner surface of the filter element is relatively surrounded by a plurality of strip-shaped concave-convex structures which are connected in a side-to-side mode.
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| TW109119008A TWI733486B (en) | 2020-06-05 | 2020-06-05 | Manufacturing method for filter cartridge |
| TW109119008 | 2020-06-05 |
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| JPH06335632A (en) * | 1993-05-28 | 1994-12-06 | Hayashi Seisakusho:Yugen | Molded adsorbing body |
| JPH105580A (en) * | 1996-06-24 | 1998-01-13 | Kuraray Chem Corp | Activated carbon fiber molded adsorbent |
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| KR101735648B1 (en) * | 2015-12-30 | 2017-05-15 | 에스엔에스필텍(주) | Spinning nozzle member for manufacturing cylinder type cartridge carbon filter, cylinder type cartridge carbon filter manufacturing apparatus comprising thereof and cylinder type cartridge carbon filter manufactured using thereof |
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| JPH06335632A (en) * | 1993-05-28 | 1994-12-06 | Hayashi Seisakusho:Yugen | Molded adsorbing body |
| JPH105580A (en) * | 1996-06-24 | 1998-01-13 | Kuraray Chem Corp | Activated carbon fiber molded adsorbent |
| JP2005161308A (en) * | 2003-11-11 | 2005-06-23 | Yamatoyo Sangyo Kk | Filter |
| JP2007098362A (en) * | 2005-10-07 | 2007-04-19 | Nippon Sheet Glass Co Ltd | Cation adsorbing material and its manufacturing method |
| US20150272117A1 (en) * | 2014-03-31 | 2015-10-01 | Kimberly-Clark Worldwide, Inc. | Fibrous Web Comprising A Cationic Polymer For Capturing Microorganisms |
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| TWI733486B (en) | 2021-07-11 |
| TW202146099A (en) | 2021-12-16 |
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