DE102017213596B4 - Method for producing a filter element of a liquid filter and stamp for such a method - Google Patents
Method for producing a filter element of a liquid filter and stamp for such a method Download PDFInfo
- Publication number
- DE102017213596B4 DE102017213596B4 DE102017213596.4A DE102017213596A DE102017213596B4 DE 102017213596 B4 DE102017213596 B4 DE 102017213596B4 DE 102017213596 A DE102017213596 A DE 102017213596A DE 102017213596 B4 DE102017213596 B4 DE 102017213596B4
- Authority
- DE
- Germany
- Prior art keywords
- stamp
- filter
- recess
- filter fabric
- fabric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000000034 method Methods 0.000 title claims abstract description 35
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- 239000007788 liquid Substances 0.000 title claims abstract description 19
- 239000004744 fabric Substances 0.000 claims abstract description 87
- 239000004033 plastic Substances 0.000 claims abstract description 47
- 229920003023 plastic Polymers 0.000 claims abstract description 47
- 238000003825 pressing Methods 0.000 claims abstract description 41
- 238000003466 welding Methods 0.000 claims abstract description 41
- 238000010438 heat treatment Methods 0.000 claims abstract description 15
- 239000012815 thermoplastic material Substances 0.000 claims abstract description 7
- 238000004023 plastic welding Methods 0.000 claims description 2
- 238000002844 melting Methods 0.000 description 15
- 230000008018 melting Effects 0.000 description 15
- 239000011148 porous material Substances 0.000 description 11
- 230000035515 penetration Effects 0.000 description 7
- 239000002131 composite material Substances 0.000 description 6
- 239000002245 particle Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 4
- -1 polypropylene Polymers 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 241001295925 Gegenes Species 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000004202 carbamide Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
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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
- B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
- B01D39/083—Filter cloth, i.e. woven, knitted or interlaced material of organic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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- B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
- B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
- B29C66/30326—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined in the form of porosity
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
- B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
- B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1426—Filtration means
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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- Engineering & Computer Science (AREA)
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Filtering Materials (AREA)
Abstract
Verfahren zur Herstellung eines Filterelements eines Flüssigkeitsfilters, wobei das Verfahren folgende Schritte umfasst:-- Bereitstellen (100) eines Filtergehäuses (1) aus einem thermoplastischem Kunststoff mit einer Schweißzone (2);-- Bereitstellen (200) eines Filtergewebes (3), welches mit dem Filtergehäuse (1) in der Schweißzone (2) verschweißbar ist,-- Erwärmen (300) der Schweißzone (2) des Filtergehäuses (1) derart, dass sich eine Kunststoffschmelze (4) bildet;-- Anordnen (400) des Filtergewebes (3) in der Schweißzone (2);-- Anpressen (500) des Filtergewebes (3) gegen die Schweißzone (2) mittels eines Stempels (5) in einer Anpressrichtung (A), wobei der Stempel (5) mit einer Stempelfläche (6) auf das Filtergewebe (3) aufgesetzt wird, wobei der Stempel (5) in der Stempelfläche (6) eine Aussparung (7) aufweist,wobei der Schritt des Erwärmens (300) mittels eines heißen Gases (10) oder mittels einer Heizplatte (12) bewirkt wirdoderwobei der Stempel (5) als eine Sonotrode (30) für einen Ultraschallschweißprozess ausgebildet ist,wobei die Schritte des Erwärmens (300) und des Anpressens (500) zumindest zeitweise gleichzeitig ausgeführt werden.A method for producing a filter element of a liquid filter, the method comprising the following steps: - providing (100) a filter housing (1) made of a thermoplastic material with a welding zone (2); - providing (200) a filter fabric (3) which can be welded to the filter housing (1) in the welding zone (2), - heating (300) the welding zone (2) of the filter housing (1) in such a way that a plastic melt (4) is formed; - arranging (400) the filter fabric (3) in the welding zone (2); - pressing (500) the filter fabric (3) against the welding zone (2) by means of a stamp (5) in a pressing direction (A), the stamp (5) having a stamp surface ( 6) is placed on the filter fabric (3), the stamp (5) having a recess (7) in the stamp surface (6), the step of heating (300) by means of a hot gas (10) or by means of a heating plate ( 12) is effected or the punch (5) as a sonotrode (30) for a n ultrasonic welding process is formed, wherein the steps of heating (300) and pressing (500) are carried out at least temporarily at the same time.
Description
Gebiet der ErfindungField of the invention
Die Erfindung betrifft ein Verfahren zur Herstellung eines Filterelements eines Flüssigkeitsfilters sowie einen Stempel für ein derartiges VerfahrenThe invention relates to a method for producing a filter element of a liquid filter and a stamp for such a method
Stand der TechnikState of the art
Aus dem Stand der Technik ist die Herstellung von Filterelementen für Flüssigkeitsfilter, z.B. für Diesel, Benzin oder für Harnstofflösung von SCR-Systemen (SCR = „selective catalytic reaction“) in der Abgasreinigung bekannt. Dabei kann ein Filtergewebe zur Abscheidung von Partikeln aus der zu reinigenden Flüssigkeit fluiddicht mit einem Filtergehäuse aus einem thermoplastischen Kunststoff beispielsweise stoffschlüssig verbunden werden, z.B. durch Kleben, Schweißen oder durch Umspritzen mit Kunststoff.The production of filter elements for liquid filters, e.g. for diesel, gasoline or for urea solution of SCR systems (SCR = "selective catalytic reaction") in exhaust gas cleaning is known from the prior art. A filter fabric for separating particles from the liquid to be cleaned can be connected in a fluid-tight manner to a filter housing made of a thermoplastic material, for example by adhesive bonding, welding or by injection molding with plastic.
Bei den aus dem Stand der Technik bekannten Schweißverfahren wird das Filtergehäuse mit dem Filtergewebe verbunden. Dabei wird der Kunststoff des Filtergehäuses in einer definierten Schweißzone erwärmt bis sich eine Kunststoffschmelze bildet, die in das Filtergewebe eindringt und nach dem Schweißen einen Formschluss zwischen Filtergehäuse und Filtergewebe bildet.In the welding process known from the prior art, the filter housing is connected to the filter fabric. The plastic of the filter housing is heated in a defined welding zone until a plastic melt is formed which penetrates the filter fabric and, after welding, forms a form fit between the filter housing and the filter fabric.
Ein derartig hergestelltes Filterelement eines Flüssigkeitsfilters ist aus der
Aus der
Offenbarung der ErfindungDisclosure of the invention
Die Erfindung geht aus von der Erkenntnis, dass bei herkömmlichen Schweißverfahren das Filtergewebe mit flächigen Stempeln auf die Kunststoffschmelze gedrückt bzw. angepresst wird.The invention is based on the knowledge that in conventional welding processes the filter fabric is pressed or pressed onto the plastic melt with flat stamps.
Durch die Flächenpressung wird dabei das Filtergewebe verdichtet und das Eindringen von Kunststoffschmelze des Filtergehäuses in das Filtergewebe erschwert. Dies führt dazu, dass das Filtergewebe nur in geringer Tiefe durchdrungen wird und der Formschluss in einer Verbundzone nach dem Abkühlen unzureichend sein kann.The surface pressure compresses the filter fabric and makes it difficult for plastic melt from the filter housing to penetrate into the filter fabric. This means that the filter fabric is only penetrated to a small depth and the form fit in a composite zone may be insufficient after cooling.
Es kann daher ein Bedarf bestehen, den Formschluss zwischen dem Filtergewebe und dem Filtergehäuse in der Verbundzone zu verbessern, so dass das Filterelement belastbarer ist und weniger Ausschuss bei der Fertigung entsteht. Auch kann der Bedarf nach einer erhöhten Lebensdauer des Filterelements bestehen.There may therefore be a need to improve the form fit between the filter fabric and the filter housing in the composite zone, so that the filter element is more resilient and less waste occurs during manufacture. There may also be a need for an increased service life of the filter element.
Vorteile der ErfindungAdvantages of the invention
Dieser Bedarf kann durch den Gegenstand der vorliegenden Erfindung gemäß den unabhängigen Ansprüchen gedeckt werden. Vorteilhafte Ausführungsformen der vorliegenden Erfindung sind in den abhängigen Ansprüchen beschrieben.This need can be met by the subject matter of the present invention according to the independent claims. Advantageous embodiments of the present invention are described in the dependent claims.
Im Rahmen der Anmeldung werden die Ausdrücke „umfassen“ und „aufweisen“ synonym verwendet, solange nichts anderes ausdrücklich erwähnt wird.In the context of the registration, the terms “comprise” and “have” are used synonymously, unless otherwise expressly mentioned.
Gemäß einem ersten Aspekt der Erfindung wird ein Verfahren zur Herstellung eines Filterelements eines Flüssigkeitsfilters vorgeschlagen. Das Verfahren weist folgende Schritte auf
- -- Bereitstellen eines Filtergehäuses aus einem thermoplastischem Kunststoff mit einer Schweißzone,
- -- Bereitstellen eines Filtergewebes, welches mit dem Filtergehäuse in der Schweißzone verschweißbar ist,
- -- Erwärmen der Schweißzone des Filtergehäuses derart, dass sich eine Kunststoffschmelze bildet;
- -- Anordnen des Filtergewebes in der Schweißzone;
- -- Anpressen des Filtergewebes gegen die Schweißzone mittels eines Stempels in einer Anpressrichtung, wobei der Stempel mit einer Stempelfläche auf das Filtergewebe aufgesetzt wird, wobei der Stempel in der Stempelfläche eine Aussparung aufweist.
- - Provision of a filter housing made of a thermoplastic material with a welding zone,
- - Provision of a filter fabric which can be welded to the filter housing in the welding zone,
- - heating the welding zone of the filter housing in such a way that a plastic melt is formed;
- - placing the filter fabric in the welding zone;
- - Pressing the filter fabric against the welding zone by means of a stamp in a pressing direction, the stamp with a stamp surface being placed on the filter fabric, the stamp having a recess in the stamp surface.
Durch das vorgeschlagene Verfahren wird vorteilhaft das Eindringen der Kunststoffschmelze beim Herstellen des Filterelements während des Schritts des Anpressens verbessert. Denn im Bereich der Aussparung wird das Filtergewebe nicht zusammengedrückt bzw. es ist auf der dem Stempel zugewandten Seite nicht von der Stempelfläche belegt. Dadurch kann die Kunststoffschmelze durch das Filtergewebe hindurch in die Aussparung des Stempels eindringen und es wird ein verbesserter Formschluss erzielt. Dies vermindert vorteilhaft den Ausschuss bei der Herstellung, verbessert die Belastbarkeit des Filterelements und erhöht dessen Lebensdauer.The proposed method advantageously improves the penetration of the plastic melt during the production of the filter element during the pressing step. This is because the filter fabric is not compressed in the area of the recess or it is not covered by the stamp surface on the side facing the stamp. As a result, the plastic melt can penetrate through the filter fabric into the recess of the punch and an improved form fit is achieved. This advantageously reduces rejects during manufacture, improves the load-bearing capacity of the filter element and increases its service life.
Bei dem Flüssigkeitsfilter kann es sich z.B. um einen Kraftstofffilter zur Abscheidung von Partikeln aus z.B. Benzin oder Diesel handeln. Es kann sich jedoch auch um einen Flüssigkeitsfilter zur Abscheidung von Partikeln aus einer wässrigen Harnstofflösung für SCR-Systeme handeln.The liquid filter can be, for example, a fuel filter for separating particles from, for example, gasoline or diesel. It can however, it is also a liquid filter for separating particles from an aqueous urea solution for SCR systems.
Bei dem Filtergewebe kann es sich z.B. um eine Filtermembran oder ein Filtervlies handeln, welches Poren mit einer Größe im Bereich von 10µm bis 200µm aufweist. Die Kunststoffschmelze kann vorzugsweise die Poren durchdringen und so das Filtergewebe nach ihrem Erstarren formschlüssig an dem Filtergehäuse befestigen. Der Formschluss ist dabei unlösbar, d.h. ohne die erneute Zuführung von Wärme kann die Verbindung zwischen Filtergewebe und Filtergehäuse nicht zerstörungsfrei wieder gelöst werden.The filter fabric can be, for example, a filter membrane or a filter fleece, which has pores with a size in the range from 10 µm to 200 µm. The plastic melt can preferably penetrate the pores and thus attach the filter fabric to the filter housing in a form-fitting manner after it has solidified. The form fit cannot be released, i.e. the connection between the filter fabric and the filter housing cannot be released again without being destroyed without the renewed supply of heat.
Das Filtergewebe kann z.B. aus einem Kunststoff gebildet sein bzw. einen Kunststoff umfassen. Beispielsweise kann das Filtergewebe Polypropylen umfassen bzw. aus Polypropylen gebildet sein.The filter fabric can for example be formed from a plastic or comprise a plastic. For example, the filter fabric can comprise polypropylene or be formed from polypropylene.
Das Filtergewebe kann dabei eine Dicke von 100µm bis 5mm aufweisen, bevorzugt von 200µm bis 1,8mm, ganz besonders bevorzugt von 0,5mm bis 1,2mm. Beispielsweise beträgt die Dicke 1,2mm oder 1,5mm.The filter fabric can have a thickness of 100 μm to 5 mm, preferably 200 μm to 1.8 mm, very particularly preferably 0.5 mm to 1.2 mm. For example, the thickness is 1.2mm or 1.5mm.
Das Filtergehäuse ist aus einem thermoplastischen Kunststoff gebildet. Beispielsweise kann das Filtergehäuse als Material Polyethylen (PE) umfassen, bevorzugt sogenanntes „high density“ Polyethylen (HD-PE). Es kann beispielsweise als ein Trägerrahmen für eine Filtermembran ausgebildet sein. Es ist jedoch auch möglich, dass es sich um eine oder zwei Endkappen handelt, gegebenenfalls mit einem dazwischen angeordneten Stützrohr oder Stützrahmen, wobei dann das Filtergewebe mit der bzw. den Endkappe(n) durch den Schweißprozess verbunden wird und/oder mit dem Stützrohr bzw. dem Stützrahmen.The filter housing is made of a thermoplastic material. For example, the filter housing can comprise polyethylene (PE) as material, preferably so-called “high density” polyethylene (HD-PE). It can be designed, for example, as a support frame for a filter membrane. However, it is also possible that it is one or two end caps, optionally with a support tube or support frame arranged between them, in which case the filter fabric is connected to the end cap (s) by the welding process and / or to the support tube or the support frame.
Die Schweißzone ist als derjenige Bereich des Filtergehäuses zu verstehen, in welchem der Kunststoff erwärmt und zum Schmelzen gebracht wird und der nach Beendigung des Schweißprozesses mit dem Filtergewebe zumindest teilweise in eine Verbundzone übergeht, in der das Filtergewebe mit dem Filtergehäuse unlösbar verbunden ist. Die Schweißzone kann dabei z.B. auf einer Oberfläche des Filtergehäuses ausgebildet sein, die dem Filtergewebe zugewandt ist. Die Wärmezufuhr im Schritt der Erwärmung kann dabei während oder vor dem Schritt des Anpressens erfolgen.The welding zone is to be understood as that area of the filter housing in which the plastic is heated and melted and which at least partially merges with the filter fabric after the welding process has ended, in which the filter fabric is inextricably linked to the filter housing. The welding zone can for example be formed on a surface of the filter housing that faces the filter fabric. The supply of heat in the heating step can take place during or before the pressing step.
Das Anpressen erfolgt dabei derart, dass das Filtergewebe entlang der Anpressrichtung zwischen dem Filtergehäuse und dem Stempel angeordnet ist.The pressing takes place in such a way that the filter fabric is arranged along the pressing direction between the filter housing and the stamp.
Dadurch, dass die Stempelfläche außerhalb der Aussparung eine plane Ebene ausbildet wird vorteilhaft eine besonders gute Verbindung zwischen Filterelement und Filtergehäuse bewirkt. Denn dadurch kann das Filtergewebe während des Anpressens nicht verrutschen. Auch wird das Filtergewebe nicht punktuell zu stark belastet, wodurch das Risiko für eine Leckage durch Rissbildung sinkt. Falls das Schweißverfahren als Ultraschallschweißen ausgeführt wird und der Stempel eine Sonotrode ist, so wird die Ultraschall-Energie des Stempels durch eine plane Ebene besonders gleichmäßig in die Schmelzzone eingetragen, wodurch die Verbundzone besonders reproduzierbar gleichmäßig ausgebildet werden kann.The fact that the stamp surface forms a flat plane outside the recess advantageously results in a particularly good connection between the filter element and the filter housing. Because this prevents the filter fabric from slipping while it is being pressed on. The filter fabric is also not excessively stressed at certain points, which reduces the risk of leakage due to the formation of cracks. If the welding process is carried out as ultrasonic welding and the punch is a sonotrode, the ultrasonic energy of the punch is introduced particularly evenly into the melting zone through a flat plane, whereby the bond zone can be made particularly reproducible and uniform.
Dadurch, dass die Aussparung eine Höhe relativ zu der Stempelfläche entlang der Anpressrichtung aufweist, die wenigstens der Dicke des Filtergewebes im unverpressten Zustand entlang der Anpressrichtung entspricht wird vorteilhaft bewirkt, dass das Filtergewebe im Bereich der Aussparung beim Anpressvorgang so gut wie gar nicht oder gar nicht verpresst wird. Dadurch kann die Kunststoffschmelze besonders gut die Poren des Filtergewebes durchdringen. Dadurch wird vorteilhaft eine besonders gute formschlüssige Verbindung zwischen Filtergewebe und Filtergehäuse erzeugt.The fact that the recess has a height relative to the stamp surface along the pressing direction which corresponds at least to the thickness of the filter fabric in the unpressed state along the pressing direction has the advantageous effect that the filter fabric in the area of the recess is virtually nonexistent or not at all during the pressing process is pressed. This allows the plastic melt to penetrate the pores of the filter fabric particularly well. This advantageously creates a particularly good form-fitting connection between the filter fabric and the filter housing.
In einer Ausführungsform ist vorgesehen, dass die Aussparung in einem auf eine ebene Fläche aufgesetzten Zustand in allen Richtungen senkrecht zur Anpressrichtung gegenüber einer Außenumgebung des Stempels abgeschlossen ist. Mit anderen Worten: die Aussparung ist seitlich durch Wände begrenzt, deren Stirnflächen Teil der Stempelfläche sind. Die Richtungen senkrecht zur Anpressrichtung können als laterale Richtung bezeichnet werden.In one embodiment it is provided that the recess, when placed on a flat surface, is closed in all directions perpendicular to the pressing direction with respect to an external environment of the stamp. In other words: the recess is delimited laterally by walls, the end faces of which are part of the stamp surface. The directions perpendicular to the pressing direction can be referred to as the lateral direction.
Dadurch lässt sich das Eindringen der Kunststoffschmelze in das Filtergewebe besonders gut und reproduzierbar steuern. Denn dann kann die Kunststoffschmelze nach dem Durchdringen des Filtergewebes nicht seitlich verlaufen. Dadurch wird vorteilhaft verhindert, dass die Kunststoffschmelze seitlich in nicht erwünschte Bereiche fließt.In this way, the penetration of the plastic melt into the filter fabric can be controlled particularly well and reproducibly. Because then the plastic melt cannot run sideways after it has penetrated the filter fabric. This advantageously prevents the plastic melt from flowing laterally into undesired areas.
Dadurch, dass in die Aussparung ein fluidleitender Kanal mündet, wobei im Schritt des Anpressens durch den Kanal hindurch in der Aussparung ein Unterdruck angelegt wird lässt sich vorteilhaft die Taktzeit verkürzen. Denn durch den Unterdruck kann die Kunststoffschmelze wesentlich schneller durch die Poren des Filtergewebes im Bereich der Aussparung bewegt werden. Auch wird dadurch Energie gespart, da die Wärme zum Schmelzen des Kunststoffs kürzer zugeführt werden muss. Gleichzeitig kann dadurch die Qualität der Verbundzone nach dem Erkalten, also des Formschlusses, verbessert werden. Denn der Unterdruck sorgt für ein besonders gleichmäßiges Eindringen von Kunststoffschmelze in das Filtergewebe im Bereich der Aussparung.The fact that a fluid-conducting channel opens into the recess, with a negative pressure being applied in the recess in the step of pressing through the channel, the cycle time can advantageously be shortened. Because of the negative pressure, the plastic melt can be moved much faster through the pores of the filter fabric in the area of the recess. This also saves energy, since the heat for melting the plastic has to be supplied for a shorter period of time. At the same time, this can improve the quality of the bond zone after cooling, i.e. the form fit. Because the negative pressure makes for a special Even penetration of plastic melt into the filter fabric in the area of the recess.
Besonders vorteilhaft ist es, wenn die Aussparung bei Anlegen des Unterdrucks in allen Richtungen senkrecht zur Anpressrichtung gegenüber einer Außenumgebung des Stempels abgeschlossen ist. Denn dann kann keine Luft aus dem Außenraum des Stempels den Unterdruck zusammenbrechen lassen.It is particularly advantageous if, when the negative pressure is applied, the recess is closed off in all directions perpendicular to the pressing direction with respect to an external environment of the stamp. Because then no air from the outside of the stamp can collapse the negative pressure.
Der Kanal kann z.B. in einer von der Stempelfläche abgewandten Seite des Stempels in die Aussparung münden. Dadurch kann der Stempel besonders einfach und flach gebaut werden.The channel can, for example, open into the recess on a side of the punch facing away from the punch surface. As a result, the stamp can be built particularly simply and flat.
Jedoch ist es auch möglich, den Kanal seitlich, also in einer lateralen Richtung in die Aussparung münden zu lassen. Dadurch kann vorteilhaft ein unerwünschtes Ansaugen flüssiger Kunststoffschmelze in den Kanal und damit sein Verstopfen vermieden werden.However, it is also possible to have the channel open laterally, that is to say in a lateral direction, into the recess. As a result, an undesired sucking in of liquid plastic melt into the channel and thus its clogging can advantageously be avoided.
Der Kanal kann auch durch ein Schutzelement, z.B. ein Gitter, vor einem Verstopfen durch angesaugte Kunststoffschmelze oder Schmutzpartikel geschützt werden.The channel can also be protected from clogging by sucked in plastic melt or dirt particles by a protective element, e.g. a grille.
In einer Weiterbildung ist vorgesehen, dass der Schritt des Erwärmens mittels eines heißen Gases oder mittels einer Heizplatte bewirkt wird. Dadurch kann das Verfahren besonders kostengünstig und mit geringem technischem Aufwand durchgeführt werden.In a further development it is provided that the step of heating is effected by means of a hot gas or by means of a heating plate. As a result, the method can be carried out particularly cost-effectively and with little technical effort.
Dadurch, dass der Stempel als eine Sonotrode für einen Ultraschallschweißprozess ausgebildet ist, wobei die Schritte des Erwärmens und des Anpressens zumindest zeitweise gleichzeitig ausgeführt werden wird vorteilhaft eine besonders präzise Herstellung des Formschlusses bewirkt. Denn durch die Verwendung des Stempels als Sonotrode wird der Eintrag der Schmelzenergie auf eine genau definierte Fläche, nämlich die Stempelfläche, konzentriert. Dadurch sinkt auch das Risiko, Bereiche des Filtergehäuses außerhalb der Schmelzzone aufzuschmelzen und damit Poren des Filtergewebes außerhalb der Schmelzzone zu verstopfen.The fact that the stamp is designed as a sonotrode for an ultrasonic welding process, with the steps of heating and pressing being carried out at least temporarily at the same time, advantageously results in a particularly precise production of the form fit. Because by using the punch as a sonotrode, the input of the melt energy is concentrated on a precisely defined area, namely the punch surface. This also reduces the risk of melting areas of the filter housing outside the melting zone and thus clogging pores of the filter fabric outside the melting zone.
Gemäß einem zweiten Aspekt der Erfindung wird ein Stempel für die Herstellung eines Filterelements eines Flüssigkeitsfilters mittels eines Kunststoffschweißprozesses vorgeschlagen. Der Stempel weist eine Stempelfläche auf, wobei der Stempel in der Stempelfläche eine Aussparung aufweist. Dadurch kann vorteilhaft der Stempel beim Anpressen auf ein Filtergewebe gegen ein Filtergehäuse beim Schweißprozess eine besonders gute formschlüssige Verbindung zwischen dem Filtergewebe und dem Filtergehäuse bewirken. Denn im Bereich der Aussparung kann eine Kunststoffschmelze wesentlich einfacher durch unverpresstes und damit nicht verdichtetes Filtergewebe eindringen. Dadurch kann ein Formschluss zwischen Filtergewebe und Filtergehäuse dreidimensionaler erfolgen als ohne die Aussparung, da die Kunststoffschmelze höher in das Filtergewebe eindringen kann.According to a second aspect of the invention, a stamp for the production of a filter element of a liquid filter by means of a plastic welding process is proposed. The stamp has a stamp surface, the stamp having a recess in the stamp surface. As a result, the stamp can advantageously bring about a particularly good form-fitting connection between the filter fabric and the filter housing when it is pressed onto a filter fabric against a filter housing during the welding process. Because in the area of the recess a plastic melt can penetrate much more easily through unpressed and therefore uncompacted filter fabric. As a result, a form fit between the filter fabric and the filter housing can take place in a more three-dimensional manner than without the recess, since the plastic melt can penetrate higher into the filter fabric.
Dadurch, dass die Stempelfläche außerhalb der Aussparung eine plane Ebene ausbildet wird vorteilhaft beim Herstellen des Filterelements mittels des Stempels eine besonders gute Verbindung zwischen Filterelement und Filtergehäuse bewirkt. Denn dadurch kann das Filtergewebe während des Anpressens nicht verrutschen. Auch wird das Filtergewebe nicht punktuell zu stark belastet, wodurch das Risiko für eine Leckage durch Rissbildung sinkt. Falls das Schweißverfahren als Ultraschallschweißen ausgeführt wird und der Stempel eine Sonotrode ist, so wird die Ultraschall-Energie des Stempels durch eine plane Ebene besonders gleichmäßig in die Schmelzzone eingetragen, wodurch die Verbundzone besonders reproduzierbar gleichmäßig ausgebildet werden kann.Because the stamp surface forms a flat plane outside the recess, a particularly good connection between the filter element and the filter housing is advantageously brought about when the filter element is produced by means of the stamp. Because this prevents the filter fabric from slipping while it is being pressed on. The filter fabric is also not excessively stressed at certain points, which reduces the risk of leakage due to the formation of cracks. If the welding process is carried out as ultrasonic welding and the punch is a sonotrode, the ultrasonic energy of the punch is introduced particularly evenly into the melting zone through a flat plane, whereby the bond zone can be made particularly reproducible and uniform.
In einer Weiterbildung ist vorgesehen, dass die Aussparung in einem auf eine ebene Fläche aufgesetzten Zustand in allen Richtungen senkrecht zur Anpressrichtung gegenüber einer Außenumgebung des Stempels abgeschlossen ist. Mit anderen Worten: die Aussparung ist seitlich durch Wände begrenzt, deren Stirnflächen Teil der Stempelfläche sind. Die Richtungen senkrecht zur Anpressrichtung können als laterale Richtung bezeichnet werden.In a further development, it is provided that the recess, when placed on a flat surface, is closed in all directions perpendicular to the pressing direction with respect to an external environment of the stamp. In other words: the recess is delimited laterally by walls, the end faces of which are part of the stamp surface. The directions perpendicular to the pressing direction can be referred to as the lateral direction.
Dadurch lässt sich das Eindringen der Kunststoffschmelze in das Filtergewebe beim Herstellen des Filterelements besonders gut und reproduzierbar steuern. Denn dann kann die Kunststoffschmelze nach dem Durchdringen des Filtergewebes nicht seitlich verlaufen. Dadurch wird vorteilhaft verhindert, dass die Kunststoffschmelze seitlich in nicht erwünschte Bereiche fließt.As a result, the penetration of the plastic melt into the filter fabric during the manufacture of the filter element can be controlled particularly well and reproducibly. Because then the plastic melt cannot run sideways after it has penetrated the filter fabric. This advantageously prevents the plastic melt from flowing laterally into undesired areas.
Dadurch, dass in die Aussparung ein fluidleitender Kanal mündet, wobei durch den Kanal hindurch in der Aussparung ein Unterdruck anlegbar ist lässt sich vorteilhaft die Taktzeit verkürzen. Denn durch den Unterdruck kann die Kunststoffschmelze wesentlich schneller durch die Poren des Filtergewebes im Bereich der Aussparung bewegt werden. Gleichzeitig kann dadurch die Qualität der Verbundzone nach dem Erkalten, also des Formschlusses, verbessert werden. Denn der Unterdruck sorgt für ein besonders gleichmäßiges Eindringen von Kunststoffschmelze in das Filtergewebe im Bereich der Aussparung.The fact that a fluid-conducting channel opens into the recess, with a negative pressure being able to be applied through the channel in the recess, the cycle time can advantageously be shortened. Because of the negative pressure, the plastic melt can be moved much faster through the pores of the filter fabric in the area of the recess. At the same time, this can improve the quality of the bond zone after cooling, i.e. the form fit. Because the negative pressure ensures a particularly uniform penetration of plastic melt into the filter fabric in the area of the recess.
Besonders vorteilhaft ist es, wenn die Aussparung bei Anlegen des Unterdrucks in allen Richtungen senkrecht zur Anpressrichtung gegenüber einer Außenumgebung des Stempels abgeschlossen ist. Denn dann kann keine Luft aus dem Außenraum des Stempels den Unterdruck zusammenbrechen lassen.It is particularly advantageous if the recess in all when the negative pressure is applied Directions perpendicular to the pressing direction is completed with respect to an external environment of the stamp. Because then no air from the outside of the stamp can collapse the negative pressure.
Der Kanal kann z.B. in einer von der Stempelfläche abgewandten Seite des Stempels in die Aussparung münden. Dadurch kann der Stempel besonders einfach und flach gebaut werden.The channel can, for example, open into the recess on a side of the punch facing away from the punch surface. As a result, the stamp can be built particularly simply and flat.
Jedoch ist es auch möglich, den Kanal seitlich, also in einer lateralen Richtung in die Aussparung münden zu lassen. Dadurch kann vorteilhaft ein unerwünschtes Ansaugen flüssiger Kunststoffschmelze in den Kanal und damit sein Verstopfen vermieden werden.However, it is also possible to have the channel open laterally, that is to say in a lateral direction, into the recess. As a result, an undesired sucking in of liquid plastic melt into the channel and thus its clogging can advantageously be avoided.
Der Kanal kann auch durch ein Schutzelement, z.B. ein Gitter, vor einem Verstopfen durch angesaugte Kunststoffschmelze oder Schmutzpartikel geschützt werden.The channel can also be protected from clogging by sucked in plastic melt or dirt particles by a protective element, e.g. a grille.
Zeichnungendrawings
Weitere Merkmale und Vorteile der vorliegenden Erfindung werden dem Fachmann aus der nachfolgenden Beschreibung beispielhafter Ausführungsformen, die jedoch nicht als die Erfindung beschränkend auszulegen sind, unter Bezugnahme auf die beigelegten Zeichnungen ersichtlich.Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which, however, are not to be interpreted as limiting the invention, with reference to the accompanying drawings.
FigurenlisteFigure list
-
1 : eine schematische Darstellung des Verfahrens;1 : a schematic representation of the process; -
2a-2c : drei Zustände während der Herstellung eines Filterelements mit einem Verfahren aus dem Stand der Technik;2a-2c : three states during the manufacture of a filter element with a method from the prior art; -
3a-3c : drei Zustände während der Herstellung eines Filterelements mit einem Verfahren gemäß einer Ausführungsform der Erfindung.3a-3c : three states during the manufacture of a filter element with a method according to an embodiment of the invention.
Das Verfahren weist folgende Schritte auf:
- --
Bereitstellen 100 eines Filtergehäuses1 aus einem thermoplastischem Kunststoff mit einerSchweißzone 2 ; - --
Bereitstellen 200 eines Filtergewebes 3 , welches mit dem Filtergehäuse1 inder Schweißzone 2 verschweißbar ist, - --
Erwärmen 300 der Schweißzone 2 des Filtergehäuses1 derart, dass sich eine Kunststoffschmelze4 bildet; - --
Anordnen 400 desFiltergewebes 3 inder Schweißzone 2 ; - --
Anpressen 500 desFiltergewebes 3 gegen dieSchweißzone 2 mittels eines Stempels5 in einer Anpressrichtung A, wobei derStempel 5 mit einer Stempelfläche6 auf das Filtergewebe 3 aufgesetzt wird, wobei derStempel 5 in der Stempelfläche6 eine Aussparung 7 aufweist.
- -- Provide
100 a filter housing1 made of a thermoplastic material with awelding zone 2 ; - -- Provide
200 afilter fabric 3 , which with the filter housing1 in thewelding zone 2 is weldable, - - warming up
300 thewelding zone 2 of the filter housing1 such that a plastic melt4th forms; - - Arrange
400 of thefilter fabric 3 in thewelding zone 2 ; - - Press down
500 of thefilter fabric 3 against thewelding zone 2 by means of astamp 5 in a pressing direction A, thepunch 5 with a stamp face6th on thefilter fabric 3 is put on, with thestamp 5 in the stamp area6th a recess7th having.
In den
In
Beim Zusammenpressen im zweiten Schritt (
In den
Das Verfahren unterscheidet sich von dem Verfahren aus den
Zusätzlich verbessert wird in dem dargestellten Ausführungsbeispiel das Eindringen der Kunststoffschmelze
Der Unterdruck U in der Aussparung
In
Der Stempel
Claims (9)
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DE10317971A1 (en) * | 2002-04-23 | 2003-11-13 | Aisan Ind | Laser welding |
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DE19925098A1 (en) | 1999-06-01 | 2000-12-07 | Bosch Gmbh Robert | Disposable filter for fuel |
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DE10317971A1 (en) * | 2002-04-23 | 2003-11-13 | Aisan Ind | Laser welding |
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