DE102013014688A1 - Filter element and method for producing the same - Google Patents

Abstract

A filter element (1) comprises at least one end plate (2, 3) and a filter medium (4), wherein the at least one end plate (2, 3) is produced by means of a generative manufacturing method, whereby the at least one end plate (2, 3) a Has layer-shaped material structure, and wherein the filter medium (4) with the at least one end plate (2, 3) is fluid-tight manner. In a method for producing such a filter element (1), the at least one end disk (2, 3) is produced by means of a generative manufacturing method and the filter medium (4) is connected in a fluid-tight manner to the at least one end disk (2, 3).

Description

Technical area

The present invention relates to a filter element. Furthermore, a manufacturing method for a corresponding filter element will be described.

Known filter elements are formed for example from between two cover plates or end plates present endless bellows. In this case, a star-shaped folded filter medium is created in the manner of a cylinder and closed the base and top surface of the cylinder with the end plates. The fluid to be filtered, such as fuel, enters the filter element through the filter medium and filtered out of the filter element through an opening provided in one of the end plates. In the automotive sector, pre-series of such filter elements are tested, for example, in storage trials or leak tests.

State of the art

The DE 10 2005 024 238 A1 describes a filter element with two end disks, wherein a filter medium is arranged between the end disks. The end plates are produced for example by means of an injection molding process. To connect the end plates with the filter medium they are melted by means of thermal radiation and the filter medium is pressed into the molten material.

Against this background, the present invention has for its object to provide an improved filter element.

Disclosure of the invention

This object is achieved by a filter element having at least one end disk and a filter medium, wherein the at least one end disk is produced by means of a generatven manufacturing method. As a result, the at least one end disk has a layered material structure. The filter medium is connected in a fluid-tight manner to the at least one end disk.

The filter element may be configured to filter air or operating fluids such as water, oil, urea solution or fuel, especially diesel fuel, kerosene or gasoline. The filter element is preferably used in motor vehicles, trucks, construction machines, watercraft, rail vehicles, aircraft or in building technology.

In the present case, a generative manufacturing method or generative layer construction method is understood to be a production method in which the at least one end plate is formed with the aid of a layered material application. The layers are preferably fused together. As a result, the end plate is fluid-tight. The end plate can have at least microscopically detectable a layered material structure. That is, compared to an injection molded end plate, an end plate made by a generative manufacturing method may have an inhomogeneous material structure. Examples of generative manufacturing methods include stereolithography, selective laser melting, selective laser sintering, melt layering, laminated object manufacturing, 3D printing or the like.

Initial samples of filter elements may have end plates made with such additive manufacturing techniques. The end plates are made of polyamide powder, for example. This makes it possible to dispense with the production of initial samples, in particular a costly injection mold. The filter element preferably has the same technical properties, chemical resistance and filter effect of a filter element produced in series, in which, for example, the end plates are produced by means of an injection molding process. As a result, meaningful insertion tests, tightness tests or the like can already be carried out with the initial samples of the filter element. Furthermore, the filter element can be made very quickly by the use of a generative manufacturing process without the need for time-consuming and costly injection molding.

In embodiments of the filter element, the at least one end plate is made of a polyamide material or a polypropylene material. Preferably, polyamide powder or polypropylene powder are used to produce the at least one end disk. Alternatively, any plastic materials can be used. These materials are also preferably used in mass production of the filter element application. As a result, an initial pattern of the filter element has the same technical properties as a series component. Furthermore, even in a series production of the filter element, the at least one end disk can be produced by means of a generative production method.

In further embodiments of the filter element, the at least one end disk has metal particles, glass particles or soot particles. In particular, the metal particles, glass particles or Soot particles are mixed into the plastic powder used to produce the at least one end disk. As a result, the mechanical properties, such as the stiffness of the end plate can be adapted to the application. By the addition of soot particles, for example, the absorption of heat energy is improved in the at least one end plate, whereby it is easier to melt. The plastic powder may have any admixtures suitable, for example, to absorb infrared radiation, ultraviolet radiation, microwave radiation or the like. As a result, a particularly fast and uniform melting of the end plate can be achieved.

In further embodiments of the filter element, this has two end disks, wherein the filter medium is provided as a continuous bellows formed filter body between the end plates. The filter medium is in particular a filter body of flat and zigzag-shaped folded filter material. The zigzag-shaped filter material forms the filter medium as a star-shaped continuous bellows. Preferably, an inflow / outflow opening is provided on at least one of the two end disks, through which fluid can flow into or out of the filter element.

In embodiments of the filter element, the filter medium is fused or glued to the at least one end plate. Alternatively, the filter medium may, for example, be fused with one of the end plates and glued to the other. When melting the filter medium with the at least one end plate can be dispensed with the additional use of an adhesive.

Furthermore, a method for producing a filter element with at least one end disk and a filter medium is proposed. In this case, the at least one end plate is produced by means of a generative manufacturing method, whereby the at least one end plate has a layered material structure. The filter medium is fluid-tightly connected to the at least one end disk. The fluid-tight connection of the filter medium with the at least one end plate is preferably a final method step. Preferably, two end plates are fluid-tightly connected to the filter medium.

In embodiments of the method, the at least one end plate is produced by means of a selective laser sintering method, a stereolithography method or a melt-layer method. Alternatively, other generative manufacturing methods, such as 3D printing, laminated object manufacturing or the like can be used. As a result, a fast and flexible production of the end plates without a mold is possible.

In further embodiments of the method, the filter medium is fused or glued to the at least one end plate. Preferably, a surface of the end disk facing the filter medium is melted. In particular, the surface is melted so deeply that the filter medium is embedded in the end plate after being pressed into the molten material.

In further embodiments of the method, the filter medium is pressed into a melted surface of the at least one end plate. As a result, a fluid-tight connection of the filter medium is achieved with the end plate.

In embodiments of the method, the surface of the at least one end plate is melted by means of infrared radiation. The infrared radiation may have a wavelength of 700 nm to 1500 nm, preferably less than 1200 nm. As a result, the surface of the at least one end plate can be melted without contact. As a result, a thread formation of the material of the at least one end disk is prevented in comparison to a melting process contacting the end disk. Alternatively, the surface of the at least one end plate can be melted, for example by means of laser beams or a heatable plate. Furthermore, the surface can be melted, for example by means of microwave radiation or ultraviolet radiation.

Further possible implementations of the invention also include not explicitly mentioned combinations of features or method steps described above or below with regard to the exemplary embodiments. The skilled person will also add individual aspects as improvements or additions to the respective basic form of the invention.

Further embodiments of the invention are the subject of the dependent claims and the embodiments of the invention described below. Furthermore, the invention will be explained in more detail by means of embodiments with reference to the accompanying figures.

Brief description of the drawings

It shows:

1 a schematic sectional view of an embodiment of a filter element.

In the figures, identical or functionally identical elements, unless otherwise indicated, have been given the same reference numerals.

Embodiment (s) of the invention

The 1 shows a schematic sectional view of an embodiment of a filter element 1 , The schematically illustrated filter element 1 preferably comprises a first or upper end plate 2 and a second or lower end disc 3 , Between the two end discs 2 . 3 is a filter medium 4 intended. The end discs 2 . 3 are preferably with the filter medium 4 connected fluid-tight.

The filter medium 4 is in particular a filter body of flat and zigzag folded filter material. The zigzag-shaped filter material forms the filter medium 4 as a star-shaped endless bellows, which essentially forms a cylindrical surface. The filter medium 4 can from the inside of a fluid-permeable support structure 5 to be supported. The support structure 5 can be cylindrical. Preferably, the slot structure 5 a grid. The support structure 5 prevents collapse of the filter medium 4 , The filter medium 4 can be embedded in the end plates. That is, the filter medium 4 can in the at least partially melted end discs 2 . 3 be pressed.

The filter element 1 may be adapted to filter air or operating fluids such as water, oil, urea solution or fuel, especially diesel fuel, kerosene or gasoline. Preferably, the filter element finds 1 Application in motor vehicles, trucks, construction machines, watercraft, rail vehicles, aircraft or in building technology.

Each or at least one of the end discs 2 . 3 can a, in particular centrally disposed, inflow / outflow 6 . 7 exhibit. In the inflow / outflow opening 6 . 7 For example, in each case a resource connection may be introduced. Alternatively, one of the end discs 2 . 3 without such inflow / outflow opening 6 . 7 be executed. For example, in embodiments of the filter element 1 only the end plate 2 an inflow / outflow opening 6 on.

To be cleaned fluid, such as oil or fuel can from a raw side RO of the filter element 1 through the filter medium 4 through into one of the support structure 5 bounded interior of the filter element 1 flow, with the support structure 5 a collapse of the filter medium 4 prevented. In this case, the fluid with the aid of the filter medium 4 filtered. The purified fluid occurs on a clean side RL of the filter element 1 out of this. In particular, the purified fluid exits the inflow / outflow port 6 . 7 from the filter element 1 out.

The end discs 2 . 3 or at least one of the end discs 2 . 3 is preferably produced by means of a generative manufacturing process or generative layer-building process. In the following, for simplicity, only one end plate will be used 2 . 3 Referenced. In the present case, a generative production method is to be understood as meaning a production method in which the end plate 2 . 3 , is made of a plurality of superimposed layers of a material. The material layers are materially connected to each other, in particular fused.

Examples of additive manufacturing processes include stereolithography, selective laser melting, selective laser sintering, melt coating, laminated object manufacturing, 3D printing or the like. Because of the end disc 2 . 3 produced by the additive manufacturing process, this has a layered material structure. That is, in a material cut of the end plate 2 . 3 At least in a microscopic view, a layered material structure can be seen.

The end plate made using the generative manufacturing process 2 . 3 is preferably made of a polyamide material or a polypropylene material. In particular, for the production of the end plate 2 . 3 Polyamide powder or polypropylene powder application. The polyamide powder or the polypropylene powder may be filled, for example, with metal particles, glass particles or soot particles. That is, the plastic powder is before the production of the end plate 2 . 3 mixed with the desired amount of filler. This shows the end plate 2 . 3 Metal particles, glass particles or soot particles on. Metal particles and / or glass particles can increase the strength of the end plate 2 . 3 increase. Soot particles can affect the absorption properties of the end plate 2 . 3 change, so that it is better melted, for example, with the help of infrared radiation.

The filter medium 4 is with the end disc 2 . 3 preferably connected fluid-tight, in particular fused or glued. For merging the at least end plate 2 . 3 with the filter medium 4 becomes a surface 8th . 9 the at least one end disc 2 . 3 melted. The melting can take place, for example, with the aid of microwave radiation, heat radiation, infrared radiation, laser radiation or the like. Alternatively, the surface 8th . 9 the end plate 2 . 3 be fused touching by means of a heating mirror. Here, the heated heating mirror touches the surface 8th . 9 , Alternatively, the end disc 2 . 3 with the Glued filter medium or otherwise be connected fluid-tight. Preferably, the filter medium 4 with both end discs 2 . 3 fused, glued and / or otherwise connected fluid-tight.

A method of manufacturing the filter element 1 with at least one end disc 2 . 3 and the filter medium 4 has the following process steps. The at least one end disc 2 . 3 is produced using a generative manufacturing process. The filter medium 4 comes with the at least one end disc 2 . 3 fluid-tight connected, in particular fused or glued. For merging the filter medium 4 with the at least one end plate 2 . 3 becomes the surface 8th . 9 the at least one end disc 2 . 3 melted. Subsequently, the filter medium 4 into the melted surface 8th . 9 the at least one end disc 2 . 3 pressed.

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

• DE 102005024238 A1 [0003]

Claims (10)

Filter element ( 1 ) with at least one end plate ( 2 . 3 ) and a filter medium ( 4 ), wherein the at least one end plate ( 2 . 3 ) is produced by means of a generative manufacturing method, whereby the at least one end plate ( 2 . 3 ) has a layered material structure, and wherein the filter medium ( 4 ) with the at least one end plate ( 2 . 3 ) is connected in a fluid-tight manner. Filter element according to claim 1, wherein the at least one end plate ( 2 . 3 ) is made of a polyamide material or a polypropylene material. Filter element according to claim 1 or 2, wherein the at least one end plate ( 2 . 3 ) Metal particles, glass particles or soot particles. Filter element according to one of claims 1 to 3, wherein the filter element ( 1 ) two end discs ( 2 . 3 ), and wherein the filter medium ( 4 ) formed as endless bellows formed filter body between the end plates ( 2 . 3 ) is provided. Filter element according to one of claims 1 to 4, wherein the filter medium ( 4 ) with the at least one end plate ( 2 . 3 ) is fused or glued. Method for producing a filter element ( 1 ) with at least one end plate ( 2 . 3 ) and a filter medium ( 4 ), wherein the at least one end plate ( 2 . 3 ) is produced by means of a generative manufacturing process, whereby the at least one end plate ( 2 . 3 ) has a layered material structure, and wherein the filter medium ( 4 ) with the at least one end plate ( 2 . 3 ) is fluid-tightly connected. Method according to claim 6, wherein the at least one end plate ( 2 . 3 ) is produced by means of a selective laser sintering method, a stereolithography method or a melt-layering method. Method according to claim 6 or 7, wherein the filter medium ( 4 ) with the at least one end plate ( 2 . 3 ) is fused or glued. Method according to claim 8, wherein the filter medium ( 4 ) in a melted surface ( 8th . 9 ) of the at least one end plate ( 2 . 3 ) is pressed. Method according to claim 9, wherein the surface ( 8th . 9 ) of the at least one end plate ( 2 . 3 ) is melted by means of infrared radiation.

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