DE102011107522A1 - Method and device for producing a filter element and filter element - Google Patents

Abstract

Disclosed is a method for producing a filter element by connecting two free end sections of at least one filter mat by means of ultrasonic welding, in which the end sections are thermally connected both from the outside and from the inside via a thermoplastic connecting element, and a device for performing such a method with a support body for supporting a central body portion of the connecting element. Furthermore, a filter element is disclosed, the end sections of which are connected to a connecting element, the connection to the connecting element taking place via an outer and inner surface of a filter mat.

Description

The present invention relates to a method for producing a filter element by connecting two free end portions of a filter mat or for joining two filter mats by ultrasonic welding according to the preamble of patent claim 1, an apparatus for performing such a method and a filter element according to the preamble of claim 15 ,

Filter elements with a filter mat or a bellows are conventionally joined together by a end-side bonding of the free end sections of the filter mats with a two-component adhesive. However, the use of the two-part adhesive requires adherence to certain guidelines regarding storage such as delivery and storage temperature, storage location and storage life. Likewise, exact metering quantities, processing temperatures and curing times must be observed. Furthermore, health regulations must be observed when processing the adhesive. In addition, a removal and disposal of excess adhesive is expensive.

From the EP 1 409 106 B1 a method for connecting two end portions of a filter mat for producing a tubular filter element is known in which the end portions are connected to a U-shaped connecting element or clip made of a thermoplastic material. The problem, however, is that at end portions with a low thermoplastic material content only an external thermal connection of the end sections takes place with the molten clip. In particular, when joining filter mats made of different materials, however, this one-sided thermal connection can lead to strength and leakage problems.

The object of the invention is to provide a method which eliminates the aforementioned disadvantages and has an improved thermal connection of the end sections independently of the filter mat materials, an apparatus for carrying out such a method and a filter element produced by this method.

This object is achieved by a method having the features of patent claim 1, by a device having the features of patent claim 7 and by a filter element having the features of patent claim 15.

In a method according to the invention for producing a filter element by connecting two free end sections of a filter mat or two filter mats by means of ultrasonic welding, the end sections are thermally connected to a thermoplastic connecting element from the outside. According to the invention, the connecting element is introduced in sections between the end sections, which are then thermally connected to one another from the inside with the connecting element.

The inventive method allows the inner and outer thermal connection of Filtermattenendabschnitten with a thermoplastic fastener and thus allows in particular the connection of filter mats regardless of their material or their material composition, since due to the projecting between the end portions connecting element always between the end portions sufficient thermoplastic material is present , By this two-sided thermal connection, the strength and tightness of a filter element produced in this way compared to the known one-sided external thermal connection is significantly improved. In addition, the inventive method requires in comparison to the above-described adhesive method no complicated guidelines regarding. The storage of the connecting element, handling, etc., so that automation and thus a shorter production time than in the known bonding method is possible.

In a preferred embodiment, the connecting element has a W-shaped cross section with two V-shaped sections, wherein the end sections are each received in one of the V-shaped sections. This ensures that the end portions are encompassed on both sides of the connecting element. In addition, the W-shaped cross-section of the region of the connecting element, which is arranged between the end portions, double-walled, so that such a connection element, for example, in particular for connecting Filtermattenendabschnitten with a very small proportion of thermoplastic material is suitable because always enough thermoplastic material for the production the internal thermal connection of the end sections with the connecting element is present. In particular, a storage of such a connection element is simple, since it can be stored in layers as a plate-like body and can only be folded to the W-profile immediately before welding.

In an alternative embodiment, the connecting element preferably has an E-shaped cross-section with two outer legs and one inner leg, wherein the end portions are each arranged between one of the outer legs and the inner leg.

In a variant of the method, the connecting element is supported between the end sections and laterally of the end sections, since this prevents the connecting element from resting on the end sections during positioning or being carried by them.

Advantageously, a gripped by the filter mat support basket is provided, with which the connecting element is connected. The support basket can be connected here, for example, with the introduced between the end portions of the connecting element. This has the advantage that in the method in a simple manner, the support basket is integrated and is fixed in position by the connection with the connecting element.

The support basket can be force, material and / or positively connected to the connecting element. This is done for example via a tongue and groove connection and additionally or alternatively by an ultrasonic welding process. In this case, the connecting element can be connected in addition to an ultrasonic welding with the filter element in the same process with the support basket.

A device according to the invention for producing a filter element by connecting two free end sections of a filter mat or of two filter mats by means of ultrasonic welding has a sonotrode and an anvil for applying sound to and clamping the end sections. The sonotrode and the anvil are movable relative to one another and delimit a processing space for arranging at least one connecting element for thermally connecting the free end sections to the connecting element from the outside. According to the invention, the device has a supporting body for supporting the connecting element between the end sections introduced into the processing space for thermally connecting the end sections from the inside to the connecting element. By the support body a stable positioning of the connecting element is ensured in the device, since this is supportable in a central region.

Preferably, in one, the connecting element-bearing end face of the support body is formed a recess for automatic positioning or alignment of the connecting element in the device.

In one embodiment, the device has a sonotrodenseitige support surface and an anvil side support surface for lateral support of the connecting element laterally of the support body, wherein between the support body and a support surface, a guide channel for inserting the end portions is formed in the processing space.

In order to facilitate insertion of the end sections into the processing space, the guide channels can be funnel-shaped in the insertion direction.

In a further embodiment of the invention, the support body is a umgester of the filter mat, in particular a substantially hollow cylindrical cross-section having, support basket. This is connected to the connecting element non-positively, material and / or positive, in particular via a tongue and groove connection and / or by an ultrasonic welding process.

In order to prevent contamination of the connection during welding, the device may have a cover element for closing the processing space.

In particular, the cover element can act as a stop for the connecting element, so that incorrect positioning of the connecting element during welding is prevented.

For better accessibility of the processing space, the cover element may be divided into two and have a sonotrodenseitigen and an anvil-side cover element portion.

According to the invention, a filter element has a filter mat. Their end portions are connected to a connecting element. Advantageously, the filter mat from the outside and inside with the connecting element material, force and / or positively connected. In particular, a thermal production method is suitable for bonding. Such a filter element has a high strength.

Preferably, the connecting element has a W or E-shaped cross section.

In a further embodiment of the invention, the filter element engages around a support basket, which is also non-positively, material and / or positively connected to the connecting element, in particular via a tongue and groove connection and / or by an ultrasonic welding process.

Other advantageous embodiments of the invention are the subject of further subclaims.

In the following preferred embodiments of the invention will be explained in more detail with reference to schematic representations. Show it:

1 a cross section through a device according to the invention, in which a filter mat and a connecting element for end-side connection of the filter mat is arranged;

2 a perspective view of the in 1 shown connecting element;

3 a perspective view of a connecting element according to another embodiment;

4 in a side view of a support basket for a filter element;

5 in a front view the support basket 4 ; and

6 the connection element 3 in a front view together with a section of the support basket 5 ,

As shown in 1 has a device according to the invention i for producing a filter element, for example for a hydraulic system, by connecting two free end portions 2 . 4 a pleated filter mat 6 with a plastic-based connection element 8th By ultrasonic welding a sonotrode 10 and an anvil 12 ,

The sonotrode 10 and the anvil 12 are each in a rail-guided longitudinal guide 14 . 16 a device block 18 . 20 relative to each other in the transverse direction of the connecting elements 8th guided. They each have an end surface 22 . 24 , which are arranged opposite to each other, and a processing space 26 for defining a joining zone for receiving the end sections 2 . 4 and the connecting element 8th limit laterally.

Bottom side is the processing room 26 by one at the device blocks 18 . 20 trained support surface 28 . 30 for lateral support of the connecting element 8th limited, each in a as shown in 1 downward vertical surface 32 . 34 pass. Opening side is the processing room 26 closed by a two-part lid member, which of a sonotrodenseitigen cover element section 36 and an anvil-side cover element section 38 is formed. The cover element sections 36 . 38 each have one of the support surfaces 28 . 30 facing lid surface portion 40 . 42 and a narrow side 44 . 46 which abut each other in a closed rest position. The cover element sections 36 . 38 are in their rest position via a respective spring 48 . 50 prestressed and parallel to the longitudinal guides 14 . 16 movable relative to each other.

In addition, the device has 1 one between the vertical surfaces 32 . 34 positioned support body 52 , The supporting body 52 has one in a common plane with the support surfaces 28 . 30 lying end face 54 for the middle support of the connecting element 8th in which a groove-like depression 56 for self-centering of the connecting element 8th in the device 1 is trained. The supporting body 52 has a rectangular cross section with two parallel side surfaces facing away from each other 58 . 60 that with the vertical surfaces 32 . 34 the device blocks 18 . 20 one guide channel each 62 . 64 form. The guide channels 62 . 64 each have in the area of the support surfaces 28 . 30 and the face 54 a constant cross section and are opposite to the insertion direction of the end portions 2 . 4 via corresponding inclined surfaces 66 . 68 the device blocks 18 . 20 expanded in a funnel shape.

The connecting element 8th consists of a thermoplastic material. It has according to the perspective representation in 2 an open W-shaped cross-section with an elongated extension of two plate-like outer element sections 70 . 72 and two plate-like inner element sections 74 . 76 is formed. The outer element sections 70 . 72 each forming an inner element section 74 . 76 a V-shaped section, each with an outer V-shaped gap 78 . 80 , The two inner element sections 74 . 76 together define a middle V-shaped space between them 82 looking in the vertical direction z opposite to the outer spaces 78 . 80 is open.

The outer element sections 70 . 72 each have an outer body edge extending in the longitudinal direction x 84 . 86 , The inner element sections 74 . 76 form a common inner body edge extending in the longitudinal direction x 88 with the outer body edges 84 . 86 lies in a common plane. In addition, the connecting element has 8th two middle longitudinal edges x extending body edges 90 . 92 , each from one of the outer element sections 70 . 72 in combination with one of the inner element sections 74 . 76 is formed and in a parallel plane to the outer body edges 84 . 86 and the inner body edge 88 lies.

To connect the two end sections 2 . 4 with the connecting element 8th By means of ultrasonic welding, the processing space 26 by moving apart the cover element sections 36 . 38 from its rest position as well as the sonotrode 10 and the anvil 12 against the respective spring force of the springs 48 . 50 open. Then the connecting element 8th such in the processing room arranged that the outer spaces 78 . 80 in the direction of the guide channels 62 . 64 are open. This is done with his outer body edges 84 . 86 on each one of the support surfaces 28 . 30 as well as with its inner body edge 88 in the depression 56 the face 54 of the support body 52 deposited, creating a self-centering of the connecting element 8th in the device 1 or in the processing room 26 he follows.

Subsequently, the filter mat 6 with their end sections 2 . 4 in the guide channels 62 . 64 introduced until the end sections 2 . 4 in the outer spaces 78 . 80 immerse and almost edge-sided on the element sections 70 . 72 . 74 . 76 issue. In this case takes place during insertion of the end sections 2 . 4 due to the inclined surfaces 66 . 68 the device blocks 18 . 20 an automatic positioning of the end sections 2 . 4 in the guide channels 62 . 64 and thus in the processing room 26 ,

After positioning the filter mat 6 in the device 1 becomes the editing room 26 through the now on to be moved lid element sections 36 . 38 closed, the lid surface sections 40 . 42 one stop each for the middle body edges 90 . 92 of the connecting element 8th form in the vertical direction z. Then the sonotrode 10 and the anvil 12 moved towards each other until the end faces 22 . 24 flat at the outer end portions 2 . 4 issue. This will be the connecting element 8th in the transverse direction y around its inner body edge 88 and its middle body edges 90 . 92 folded until the end sections 2 . 4 each sandwiched between one of the outer element sections 70 . 72 and one of the inner element sections 74 . 76 are clamped and the inner element sections 74 . 76 lie flat against each other and are thus oriented double-walled.

Then the actual ultrasonic welding process begins. Electric oscillations generated by a generator are converted into mechanical vibrations in a sound transducer or converter, translated by an amplitude transformation element into a preferred amplitude range and via the sonotrode 10 in the connecting element 8th as well as in the end sections 2 . 4 initiated. By reflection of the mechanical vibrations at the sound emitting end surface 22 the sonotrode 10 A standing wave forms, which absorbs the welding energy into the connecting element 8th and in the end sections 2 . 4 transfers. The the connecting element 8th and the end sections 2 . 4 transmitted vibrations are under a certain one of the anvil 12 applied contact pressure on the end surface 24 of the anvil 12 reflected. The plastic material of the connecting element 8th begins to soften and it forms in the joining zone due to the plasticized and highly damping plastic layer a sound barrier, which leads to an intense melting of the plastic material.

After sufficient plasticization or melting of the connecting element 8th and after a certain holding or cooling time while maintaining the contact pressure of the processing space 26 by moving apart the sonotrode 10 and the anvil 12 and the lid element sections 36 . 38 open and the with the connecting element 8th both externally and internally thermally interconnected end portions 2 . 4 are released, so that the end-connected filter mat 6 the device 1 can be removed.

3 shows in a perspective view a connecting element 94 in a second embodiment. This has a substantially E-shaped cross-section. A first and second leg 96 and 98 of the connecting element 94 are arranged substantially arcuately to each other. Along the crest line formed thereby is a bridge 100 formed, whose width seen in the web direction greater than that of the legs 96 and 98 is, making this one out of the thighs 96 and 98 protruding concave space protrudes. The jetty 100 points to his from the thighs 96 and 98 pointing away long side 102 one across the jetty 100 arranged spring bar 104 on. This serves to connect to a support basket, which is explained in more detail in the figures below. The spring bar 104 along with the jetty 100 have a substantially T-shaped cross-section.

The between the thighs 96 and 98 and the jetty 100 formed filter spaces 106 respectively. 108 serve to receive the end sections 2 . 4 the filter mat 6 out 1 ,

4 shows in a plan view and 5 in a front view a support basket 110 , This one has a lot of openings 112 , which serve as flow openings, for example, for a pressure medium to be filtered. The support basket 110 is from the filter mat 6 out 1 encompassable, with their end sections 2 and 4 then in the area of one in the outer shell of the support basket 110 trained groove 114 are arranged. The groove 114 extends parallel to the longitudinal axis of the support basket 110 over its entire length. In the 5 it can be seen that the groove 114 as a T-shaped undercut of a coat 116 of the support basket 110 is trained.

In the 6 is a section A of the support basket 110 out 5 enlarged together with a front view of the connecting element 94 shown. Through the groove 114 are in the coat 116 two mutually facing retaining tongues 118 . 120 educated. Between each other assigning faces of the retaining tabs 118 . 120 is a slot opening 122 the groove 114 formed by the bridge 100 of the connecting element 94 is passed in the inserted state. Is the connecting element 94 in the groove 114 used, so engage behind the retaining tongues 118 . 120 the spring bar 104 of the connecting element 94 , The connecting element 94 is from a front side 124 or 126 , please refer 4 , the support basket 110 here in the groove 114 introduced or inserted. Alternatively, the connecting element 94 radially to the support basket 110 be arranged and in the groove 114 be clipped.

The spring bar 104 , the bridge 100 and the groove 114 in 6 are designed such that this tongue and groove connection leads to a positive connection. In addition, the tongue and groove connection can be designed such that the connecting element 94 with the support basket 110 in addition to the form-fitting holder is also held non-positively. Additionally or alternatively to the tongue and groove connection, the connecting element 94 with the support basket 110 be materially bonded via the ultrasonic welding process.

In the manufacture of the filter element, the connecting element 94 with the support basket 110 connected by the tongue and groove connection and in the device according to 1 arranged, wherein the supporting body 52 through the support basket 110 is replaced. The ultrasonic welding process then takes place according to the 1 ,

Alternatively, the connecting element 94 without the support basket 110 with the filter mat 6 out 1 be welded, with the connecting element 94 then for example via his spring bar 104 on the support body 52 supported. After welding, then the connecting element 94 together with the filter mat 6 on the support basket 110 be arranged, wherein the connecting element 94 then with his spring bar 104 in the groove 114 is introduced.

If the ultrasonic welding process is carried out together with the support basket 110 , so could additionally the connecting element 94 with the support basket 110 be welded in these methods by the Ultraschallverscheißung.

Disclosed is a method for producing a filter element by connecting two free end portions of at least one filter mat by means of ultrasonic welding, in which the end portions are thermally connected both from the outside and inside via a thermoplastic connecting element, and an apparatus for performing such a method with a support body for supporting a central body portion of the connecting element. Furthermore, a filter element is disclosed, the end portions of which are connected to a connecting element, wherein the connection with the connecting element takes place via an outer and inner surface of a filter mat.

LIST OF REFERENCE NUMBERS

1

contraption

2

end

4

end

6

filter mat

8th

connecting element

10

sonotrode

12

anvil

14

longitudinal guide

16

longitudinal guide

18

device block

20

device block

22

end face

24

end face

26

working space

28

support surface

30

support surface

32

vertical space

34

vertical space

36

Cover elements section

38

Cover elements section

40

Cover surface section

42

Cover surface section

44

narrow sides

46

narrow sides

48

feather

50

feather

52

support body

54

face

56

deepening

58

side surface

60

side surface

62

guide channel

64

guide channel

66

sloping surface

68

sloping surface

70

outer element section

72

outer element section

74

inner element section

76

inner element section

78

outer space

80

outer space

82

middle space

84

outer body edge

86

outer body edge

88

inner body edge

90

middle body edge

92

middle body edge

94

connecting element

98

leg

98

leg

100

web

102

long side

104

spring bar

106

filter chamber

108

filter chamber

110

support cage

112

openings

114

groove

116

coat

118

holding tongues

120

holding tongues

122

slot opening

124

front

126

front

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1409106 B1 [0003]

Claims (17)

Method for producing a filter element by connecting two free end sections ( 2 . 4 ) at least one filter mat ( 6 ) by ultrasonic welding, the end sections ( 2 . 4 ) from the outside thermally with a connecting element ( 8th ), characterized by the steps of: - the connecting element ( 8th ) in sections between the end sections ( 2 . 4 ), and - the end sections ( 2 . 4 ) from the inside thermally with the connecting element ( 8th ) get connected. Method according to claim 1, wherein the connecting element ( 8th ) has a W-shaped cross section with two V-shaped sections and the end sections ( 2 . 4 ) are each received in a V-shaped section. Method according to claim 1, wherein the connecting element ( 94 ) an E-shaped cross section with two outer legs ( 96 . 98 ) and an inner thigh ( 100 ) and the end sections ( 2 . 4 ) between each of the outer and the inner leg ( 96 . 98 . 100 ) to be ordered. Method according to claim 1, 2 or 3, wherein the connecting element ( 8th ) between the end sections ( 2 . 4 ) and laterally of the end sections ( 2 . 4 ) is supported. Method according to one of the preceding claims, wherein a, in particular a substantially hollow-cylindrical cross-section having, support basket ( 110 ) provided by the filter mat ( 6 ) and with the connecting element ( 94 ) connected is. Method according to claim 5, wherein the support basket ( 110 ) with the connecting element ( 94 ), non-positively, material and / or positively, in particular via a tongue and groove connection and / or by an ultrasonic welding process, is connected. Contraption ( 1 ) for producing a filter element by connecting two free end portions ( 2 . 4 ) a filter mat ( 6 ) by means of ultrasonic welding, with a sonotrode ( 10 ) and with an anvil ( 12 ) for applying sound and clamping the end sections ( 2 . 4 ), the sonotrode ( 10 ) and the anvil ( 12 ) are movable relative to each other and a processing space ( 26 ) for arranging at least one connecting element ( 8th ) for thermally connecting the free end portions ( 2 . 4 ) with the connecting element ( 8th ) from the outside, characterized by a supporting body ( 52 ) for supporting the connecting element ( 8th ) between the in the processing room ( 26 ) ( 2 . 4 ) for thermally connecting the end sections ( 2 . 4 ) from the inside with the connecting element ( 8th ). Device according to claim 7, wherein in one the connecting element ( 8th ) supporting face ( 54 ) of the supporting body ( 52 ) a recess ( 56 ) for positioning the connecting element ( 8th ) is trained. Apparatus according to claim 7 or 8, wherein the side of the support body ( 52 ) a sonotrodenseitige support surface ( 28 ) and an anvil-side support surface ( 30 ) for lateral support of the connecting element ( 8th ) is arranged and between the support body ( 52 ) and one support surface each ( 28 ) a guide channel ( 62 . 64 ) for introducing the end sections ( 2 . 4 ) into the processing room ( 26 ) is formed. Apparatus according to claim 9, wherein the guide channels ( 62 . 64 ) in the insertion direction of the end sections ( 2 . 4 ) are tapered funnel-shaped. Device according to one of claims 7 to 10, wherein the supporting body ( 110 ) one of the filter mat ( 6 ) umgriffener, in particular a substantially hollow cylindrical cross-section having, support basket ( 110 ). Apparatus according to claim 11, wherein the support basket ( 110 ) with the connecting element ( 94 ), non-positively, material and / or positively, in particular via a tongue and groove connection and / or by an ultrasonic welding process, is connected. Device according to one of claims 7 to 12, wherein a cover element for closing the processing space ( 26 ) is provided. Apparatus according to claim 13, wherein the cover element is divided into two and one at the sonotrode ( 10 ) fastened lid element section ( 36 ) and one on the anvil ( 12 ) fastened lid element section ( 38 ) having. Filter element with a filter mat ( 6 ), whose end sections ( 2 . 4 ) with a connecting element ( 8th . 94 ), characterized in that the filter mat ( 6 ) from outside and inside with the connecting element ( 8th . 94 ) material, force and / or positive, in particular via a thermal production process, is connected. Filter element according to claim 15, wherein the connecting element ( 8th . 94 ) has a W or E-shaped cross-section. Filter element according to claim 15 or 16, wherein the filter element is a support basket ( 110 ), wherein this with the connecting element ( 94 ) non-positively, material and / or form-fitting, in particular via a tongue and groove connection and / or by an ultrasonic welding process, is connected.

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