EP2869906A1

EP2869906A1 - Method and device for manufacturing filter elements and filter element

Info

Publication number: EP2869906A1
Application number: EP13736541.7A
Authority: EP
Inventors: Markus Röhrig
Original assignee: Mann and Hummel GmbH
Current assignee: Mann and Hummel GmbH
Priority date: 2012-07-09
Filing date: 2013-07-09
Publication date: 2015-05-13
Also published as: DE102012013470A1; US20150114191A1; WO2014009357A1; US20180168404A1; CN104411380A; DE112013003453A5

Abstract

The invention describes a method for cutting filter media. A filter medium (129) is first of all provided with stamped formations, and after the stamping operation, the filter medium (129) is at least sectionally cut with the aid of a water jet, a laser beam, an ultrasonic cutting device or a cutter, wherein the point of impact of the water jet, the laser beam, the ultrasonic cutting device or the cutter on the filter medium is moved relative to the filter medium. After cutting, the filter medium (129) is folded.

Description

description

Method and device for manufacturing filter elements and filter element Technical field

The invention relates to a method and a device for manufacturing filter elements, in particular a separation method for filter media in the manufacturing process of a filter element and a filter element.

State of the art

From EP 1 144083 B1 a filter element is known in which a support passes through a recess in the filter element. In particular, for a housing which is suitable for receiving flat filter elements, then a support between the opposite centers of the housing shells can be achieved. These points would be those with the largest vibration amplitude in a component vibration. In this way, therefore, by providing only one support can achieve a significant stiffening effect. The recess is completely sealed by providing an additional seal to the support, so that a reliable filter function is ensured without secondary air. The introduced into this filter element recess may be rectangular according to a particularly advantageous embodiment. It is oriented so that two of the opposite rectangular edges, which are referred to as transverse edges, parallel to the fold edges. In particular, the edges may be formed by the fold edges themselves. Such a recess can be achieved most economically in terms of manufacturing technology. It can be introduced, for example by water jet cutting or laser beam cutting in the already folded filter medium.

From EP0645170B a cutting device is known, which separates the folded and provided with the glue beads filter medium into individual filter elements. The cutting device cuts through the filter medium transversely to the transport device. The control signal for the cutting process is triggered by a sensor which scans the respective glue bead end or the glue bead start or a measuring point arranged on the filter means and generates a control pulse on the basis of this signal. Filter elements produced by the method have the advantage that the outer contour can be optimally adapted to the existing space, wherein both one and both end faces of the filter element can be angled. There is also the ability to also taper only parts of a front edge to adapt the contour of the filter element to the edges of the filter housing.

For the production of filter elements with recesses or for the cutting of filter elements, a more flexible, cheaper, better integrated into the manufacturing process process is needed. Particularly advantageous is a method that builds without inventory, i. E. "online" is feasible. In the described method, the filter elements are each manufactured, stored, and then takes place a cutting process. In particular, a method which has a better quality than e.g. Drills or saw deliver that regularly lead to particles that are undesirable in the further process and must be eliminated. Advantageous would be as lint-free processes that can produce exact edges with fewer particles.

Disclosure of the invention

A method for separating filter media is proposed, in which a filter medium is provided with embossing in one method step. Embossments can e.g. be designed as transverse embossing, which are transverse to a conveying direction of the filter medium, and serve for easier folding of the filter medium in a later process step. Embossments can e.g. be produced by embossing rollers. After embossing, the filter medium is at least partially separated with the aid of a water jet, laser beam or even an ultrasonic separation device, or a cutter, as is known from material processing, in which a knife is guided in the manner of a plotter over the filter medium.

The separation of the filter medium can thereby produce holes in the filter medium, so be made in the form of closed curves. The separation can be carried out in the conveying direction or across it or at any angle. Separation lines along any given pattern can also be introduced into the filter medium. In this case, the filter medium can essentially be present as a flat sheet. The impact point of the water jet, laser beam, the ultrasonic separation device or the cutter on the filter medium moves during the separation process relative to the filter medium. Only after the filter medium has been separated, the filter medium is folded. The dividing line can also be introduced in the form of a perforation as an alternative to a coherent dividing line. Removal of a portion of the filter media may occur prior to pleating after the separation operation or at the deployed pleats. For example, a bellows along a perforated running dividing line can be canceled or from a bellows a recess can be pushed out. This removal from or on the bellows facilitates the process of re-folding.

As an alternative method for separating filter media, it is proposed that a filter medium is first folded. After folding, at least part of the folds are at least partially pulled apart again. The filter medium, in which the folds are already formed, possibly even with an additional embossing step, is thus flattened again. The filter medium may in this case again be completely flat or still have the fold shape in a more or less flattened shape. Advantageously, the entire filter medium is placed in this flatter shape when passing through a device for separating the filter medium. However, it may also remain in sections in the folded form and only be flattened in areas in which a separation is to take place. In the region of the wrinkles, which are at least partially pulled apart again, the filter medium is then conveyed over the filter medium by means of a water jet, a laser beam or an ultrasonic separation device or a cutter, as is known in the field of fabric processing is performed, at least partially separated. The separation of the filter medium can thereby produce holes in the filter medium, so be made in the form of closed curves. The separation can take place in the conveying direction or transversely thereto or at any angle. Separation lines along any given pattern can also be introduced into the filter medium. The impact point of the water jet, laser beam, the ultrasonic separation device or the cutter on the filter medium moves relative to the filter medium. After the separation process, the wrinkles are set up again. The dividing line can also be introduced in the form of a perforation as an alternative to a coherent dividing line. Removal of a portion of the filter medium may occur prior to refolding after the separation operation or at the deployed folds. For example, A bellows can be broken off along a perforated dividing line or a bellows can be used to push out a cut-out. This removal from or on the bellows facilitates the process of re-folding.

In the alternative method, in which the wrinkles are first set up and then pulled apart again, the film is preferably also applied before the first fold-up. termedium. By embossing, as in the other alternative, wrinkling can be facilitated or facilitated, spacers can be introduced into the filter medium and embossments can also serve as reference points for control of the separation process, eg relative positioning of the separation site on the medium.

The proposed methods can be used for the separation of a variety of filter media. In particular, these are paper and cellulosic filter media, nonwovens, and plastic-based filter media, e.g. Nonwovens or fabrics, in particular of polyester, polyethylene, polyamide, polystyrene, but also cellulose mixed fiber media, various meltblown or spunbound media or combinations of the foregoing, e.g. Cellulose as carrier for further media layers. From the medium used, the selection of the separation method laser, water jet, ultrasound or cutter can be dependent. For example, a water jet separation may be less suitable for a cellulosic medium as it may absorb and swell water. The proposed methods can also each be used in parallel, multi-lane, in one process, e.g. Two lanes or three lanes can have two or three laser perforations for separating the bellows and a recess in each of the lanes.

In the case of a preferred variant, a sealing mass trace, in particular a hot melt adhesive trace, is applied to the filter medium at least in sections next to the dividing line introduced with the aid of the water jet, the laser beam, the ultrasonic separation device or the cutter prior to folding or reinstalling the folds. In this way, for example, a lateral sealing of the folding pockets by means of the sealing mass trace. Subsequent lateral sealing of the folding pockets, z. B. by means of a glued sideband, can be omitted.

In the method, the filter medium is preferably conveyed and, at least at times at the same time as the conveying movement of the filter medium, the water jet, laser beam, ultrasonic separation device or cutter are also moved. As a result, filter elements can be efficiently separated from the filter media web or even produce recesses in bellows.

A particularly efficient and flexible method results by the relative movement of the point of impact based on the filter medium at least temporarily composed of the conveying movement of the filter medium and an additional movement, and wherein the additional movement at least at times comprises a movement component parallel to the conveying direction and / or a movement component parallel to the conveying direction. Thanks to a parallel component, the conveying speed can also temporarily exceed the separation speed, since the point of impact can be moved at least temporarily in the conveying direction. Thanks to a vertical component, relatively freely selectable gradients of the parting line can be generated.

In particular, such methods result in the case of a variant in which the point of impact of the water jet, laser beam, the ultrasonic separation device or the cutter is moved relative to the filter medium along a path which extends at least partially obliquely to the conveying direction and / or at least partially curved.

Preferably, by means of the water jet, laser beam, the ultrasonic separation device or the cutter into the filter medium, as already mentioned, at least one hole or a recess completely surrounded by filter medium is introduced. The methods for separating filter media are advantageously integrated into a production process for filter elements. As a result, a method can be realized that builds without inventory, i. "online" is feasible, since an easy integration into the bellows production is possible and not only a finished, folded bellows must be further processed. Preferably, in the manufacture of the filter element after folding or reinstating the folds on the folded filter medium, a seal is provided which is provided for sealing engagement with a filter housing. For a variety of applications, attaching a seal surrounding the filter element is advantageous. As a sealing material in particular polyurethane foam has been proven. According to the invention, a device for separating a filter medium is proposed which comprises a conveying device for a filter medium, an embossing device for introducing impressions into the filter medium; a water jet separation device, laser beam separation device, an ultrasonic separation device or a cutter and a folding line device, which is mounted in the conveying direction of the filter medium after the water jet separation device, laser beam separation device, ultrasonic separation device or the cutter; includes.

Alternatively, a device for separating a filter medium is proposed which a conveying device for a filter medium; a folding device for folding the filter medium, a device for pulling the folds, a water jet separating device, laser beam separating device, an ultrasonic separation device or a cutter, which is mounted in the conveying direction of the filter medium after the device for unfolding the folds; and a pleat erector mounted downstream of the water jet separator, laser beam separator, ultrasonic separator or cutter in the conveying direction of the filter medium; includes.

The control of the movement of the laser beam relative to the filter medium may preferably be done by mirrors. Preferably, the deflection of the beam is controlled by at least two mirrors, e.g. can be moved quickly via galvanometer drives. The third dimension of depth focusing can be done with the help of a movable and steerable lens.

These devices for separating a filter medium may advantageously be integrated into parts of a device for producing a filter element. According to the invention, a filter element is likewise produced using the described production method.

According to the invention is also a filter element comprising a bellows, wherein the outer end edges of the bellows are cut with a laser beam or perforated with a laser beam and then separated. In a preferred embodiment, the filter elements are designed as a flat air filter.

Brief description of the drawings

1 a and b show a filter element with a recess,

Fig. 2 shows an apparatus for producing a filter element, in which the bellows is separated.

Embodiment (s) of the invention

Figures 1 a and b show a detail of a filter element 1 12, a so-called filter cartridge, in cross-section, once longitudinally to fold edges 128 of the filter paper or filter medium 129 (Figure 1 b) and once across it (Figure 1 a). In both cases, the cut runs centrally through the recess 124, wherein it is clear that this has a rectangular cross-section in the plane of the drawing. Perpendicular to the plane of the recess 124 has a circular cross-section. Along the folding canals 128, the recess 124 has a transverse edge 130 and at right angles thereto a front edge 131. The additional seal 125 is molded onto the upper edge forming the raw side of the filter element 1 12 and consists of PUR foam. It has the same profile as attached to end edges 132 and side edges 133 edge seal 1 17, which also consists of PUR foam.

To seal the end edges 131, the additional seal 125 can be pulled down to the lower side of the clean side of the filter element 12 forming edge. However, this is not shown in FIGS. 1 a and 1 b. The sealing of the respectively adjacent filter pleats or the lateral sealing of the folding pockets is effected here by a sealing mass trace of hotmelt adhesive applied on one side, a so-called glue bead 134, which can be seen in FIG. 1a in the plan view of the end edge 131.

According to Figure 1 a, the glue bead 134 is only in the region of the recess 124. However, it is just as possible to extend them to the side edges 132 of the filter element 1 12, whereby a stabilizing effect in the transverse direction of the folds comes about. The position of the glue beads 134 can also be seen in FIG. 1 b, where they are shown in dashed lines. The end edges 133 of the filter element are also closed by glue beads 134a.

The recess 124 has been introduced, wherein the filter medium 129 has been initially provided with embossments. After embossing, the filter medium 129 was at least partially separated by means of a water jet, laser beam, ultrasonic separation device or a cutter, i. H. either completely severed or perforated. In this case, the impact point of the water jet, laser beam, ultrasonic separation device or cutter was moved onto the filter medium relative to the filter medium 129. After separation, the filter medium 129 was folded. The glue beads 134 were applied before this folding process. The pleated filter media 129 is optionally conveyed through a curing oven. From the thus finished bellows, the recess was then pushed out and then the seals 1 17 and 125 attached.

Alternatively, the recess 124 has been introduced, wherein the filter medium 129 was initially folded. After folding, at least part of the folds were at least partially pulled apart again. In the region of the folds, which are at least partially pulled apart again, the filter medium 129 was at least partially cut by means of a water jet, a laser beam, an ultrasonic separation device or cutter. isolated. The impact point of the water jet, laser beam, the ultrasonic separation device or the cutter on the filter medium 129 moved relative to the filter medium 129. After separation, the wrinkles were set up again, the glue beads 134 were applied before this second folding process. The pleated filter media 129 is optionally conveyed through a curing oven. If necessary, the recess was pushed out of the thus finished bellows and then the seals 1 17 and 125 were attached.

A device 200 for carrying out a method for producing a filter element 1 12 is shown in the schematic figure 2. First, the filter medium 129, e.g. the filter paper, taken in the form of a filter media web of a drum 217 and along a conveying direction 201, which extends in particular perpendicular to the folding edges 128 produced later produced by the device 200.

In a first processing step, the filter medium 129 is guided between a lower and an upper embossing roller 218. The lower embossing roller is not visible in the drawing. This is located directly under the embossing roller 218. By means of these embossing rolls, creasing edges 219 are impressed into the filter medium 129. In addition, nubs, reinforcing beads or spacers can be embossed. Alternatively or additionally, the filter medium 129 can also be folded and stretched again in a prefolding station 202. The embossed or re-stretched filter medium 129 is fed to a separator 203. The separating device 203 has a laser cutting unit. The laser cutting unit comprises at least one deflection device for the laser cutting beam, by means of which the point of impact of the laser beam on the filter medium 129 both parallel to the conveying direction 201 of the filter medium 129 (in Figure 2 from top to bottom and vice versa) and perpendicular to the conveying direction 201 of the filter medium 129 (in Figure 2 from left to right and vice versa) can be moved. The working area in which the laser cutting beam can be moved extends over the entire width of the filter medium web and also has a sufficient extent in the conveying direction 129. For example, two separate deflection devices can be provided, by means of which one laser cutting beam in each case can be moved into a partial area of the working area.

The movement of the impact point through the deflection device can take place simultaneously with the conveying movement of the filter medium 129, so that the resulting relative tivbewegung of Ausreffpunkts based on the filter medium 129 from the conveying movement and the controlled by the deflecting movement of the impact point results.

By means of the laser beam, the filter medium 129 can be severed along a coherent dividing line. Alternatively, a perforation can be introduced and the complete transection will take place later. In the example shown, a closed dividing line 205 for forming the recess 124 and a dividing line 204 extending obliquely to the conveying device are introduced into the filter medium 129. If the dividing line 205 is a contiguous dividing line, the inner cut-out on the laser cutting unit can be removed downwards via its extraction system.

The laser cutting unit is characterized by a particularly high dynamics compared to other cutting units with alternative cutting tools. Thanks to this high dynamics, recesses, such as the recess 124 shown, can be introduced into the moving filter medium 129.

From the filter medium 129 equal two different filter elements 1 12 (one with and one without recess 124) are produced, which are arranged transversely to the conveying direction 201 side by side. It can, for example, but two identical filter elements 1 12 are produced side by side. Depending on the design of the filter elements 1 12, this results in a reduction of the waste.

Subsequently, the filter medium 129 is provided with the required glue beads 134, 134a. For this purpose, two glue application devices 221, 222 are initially provided. These each consist of a spindle 223, 224, on which carrier heads 225, 226 are located. On each of these carrier heads 225, 226 two glue application nozzles 227 are arranged in each case. While the filter medium 129 is moved under the glue application devices 221, 222 according to the arrow 201, the application of the glue beads 134, 134 a. The spindles 223, 224 are rotated accordingly, so that the carrier heads 225, 226 perform a transverse movement. The carrier head 226 serves to apply glue beads 134 on both sides of the recess 124. The carrier head 225 is used to apply glue beads 134a along the parting line 204. Both produce two glue beads 134, 134a on the upwardly facing side of the passing filter medium 129.

The carrier heads 225, 226 can also be moved with a belt or toothed belt become. In particular, when using a toothed belt, it is possible to position the carrier heads with very high accuracy. In addition, the adjustment speed is slightly higher in a belt or toothed belt drive than in a threaded spindle. Of course, it would also be possible to produce filter elements 1 12 alone with a glue application device or to carry out the process. Depending on the arrangement of the glue beads, however, it may be necessary for this glue application device to be brought from the end position to the starting position at a very high speed, in order to avoid gluing of a longer intermediate piece, provided that the glue application nozzles are not stopped. The gluing of two to three folds transversely to the transport direction can possibly be accepted. If a gluing is caused by several folds, this intermediate piece can not be used, and unnecessary waste would result. In addition, by means of a single glue bead application device, at least at a certain distance, not two glue beads running side by side in the conveying direction, as required in the example, can be applied.

In addition to the glue applicators 221, 222, two glue applicators 232, 233 are provided. These produce glue beads 134a at the two end faces. After the application of all glue beads 134, 134a, the zigzag folding of the filter material is carried out via a platen 236.

Optionally, one or more further glue discharge devices may be provided after the pleated plate 236 (not shown). If necessary, they apply a glue bead to the folded bellows, which serves not as a seal but as a support glue bead. Furthermore, as an option, the device 200 also has a curing oven 240, through which the folded filter medium 129 is conveyed.

Subsequently, the folded filter medium 129 is separated, in particular transversely to the conveying direction 201 (along the fold edges 128) at a separating station 250. If necessary, perforated contours are expressed. This can be done automatically or manually. This results in individual bellows, which are then still in a further workstation 260 with seals 1 17, 125 are provided. For example, they are placed there individually in casting bowls and z. B. to be cured PUR foam added.

It is understood that in a modified design between individual processing an intermediate storage or at least a conversion to the following station can be performed.

Claims

claims

1 . A method of separating filter media, comprising the steps of: a. a filter medium (129) is provided with embossments (219), b. after embossing, the filter medium (129) is at least partially separated with the aid of a water jet, a laser beam, an ultrasonic separation device or a cutter, whereby the point of impact of the water jet, laser beam, ultrasonic separation device or cutter on the filter medium (129) relative to the filter medium (129) moved, c. after separation, the filter medium (129) is folded.

2. A method for separating filter media, comprising the following steps a. a filter medium (129) is folded, b. after folding, at least part of the folds are at least partially pulled apart again, c. in the region of the wrinkles, which are at least partly pulled apart again, the filter medium (129) is at least partially separated with the aid of a water jet, a laser beam, an ultrasonic separation device or cutter, the point of impact of the water jet, laser beam, ultrasonic separation device or cutter on the filter medium relative to the filter medium (129) moves, d. after separation, the wrinkles are set up again.

3. The method according to any one of the preceding claims, wherein prior to folding or re-establishing the folds at least in sections next to a introduced using the water jet, the laser beam, the ultrasonic separation device or the cutter separation line (204, 205) a sealing mass trace, in particular hot melt adhesive track (134, 134a) is applied to the filter medium (129).

4. The method according to any one of the preceding claims, wherein the filter medium by means of the water jet, the laser beam, the ultrasonic separation device or the cutter along a contiguous parting line (204, 205) is separated.

5. The method according to any one of the preceding claims, wherein the filter medium paper and cellulose-based filter media, nonwovens and plastic-based filter media, fleece or fabric, in particular of polyester, polyethylene, polyamide or polystyrene, but also cellulose mixed fiber media, meltblown or spunbound -Media, or combinations of the preceding ones.

6. The method according to any one of the preceding claims, wherein the filter medium is conveyed and the point of impact of the water jet, the laser beam, the ultrasonic separation device or the cutter at least temporarily simultaneously with the conveying movement of the filter medium is also moved, wherein the relative movement of the point of impact relative to the Filter medium (129) at least temporarily composed of the conveying movement of the filter medium (129) and an additional movement, and wherein the additional movement at least temporarily a component of movement parallel to the conveying direction (201) and / or a Bewegungsungskom- component parallel to the conveying direction (201).

7. The method according to any one of the preceding claims, wherein the filter medium (129) is conveyed in at least one conveying direction (201), and the impact point of the water jet, the laser beam, the ultrasonic separation device or the cutter is moved relative to the filter medium (129) along a path which runs at least in sections at an angle to the conveying direction (201).

8. The method according to any one of the preceding claims, wherein the filter medium is conveyed in at least one conveying direction (201), and the impact point of the water jet, the laser beam, the ultrasonic separation device or the cutter relative to the filter medium (129) along an at least partially curved path is moved ,

9. The method according to any one of the preceding claims, wherein by means of the water jet, the laser beam, the ultrasonic separating device or the cutter into the filter medium (129) a completely of filter medium (129) surrounding recess (124) is introduced.

A method of manufacturing a filter element (12-12) comprising a method of separating filter media according to any one of the preceding claims.

1 1. A manufacturing method of a filter element (12-12) according to claim 10, wherein after the folding or re-positioning of the pleats on the pleated filter medium (129), a seal (1,17,125) is provided which is provided for sealing engagement with a filter housing.

12. A manufacturing method for a filter element according to claim 1 1, wherein the seal (1 17) around the filter element (1 12) is formed circumferentially.

13. A manufacturing method for a filter element according to claim 1 1 or 12, wherein the seal (1 17, 125) is made of polyurethane foam.

14. A device for separating a filter medium (129), comprising a conveying device for a filter medium, an embossing device (128) for introducing impressions (219) into the filter medium (129), a water jet separating device, laser beam separating device (203), an ultrasonic separating device or a cutter and a pleat erector (236) disposed in the conveying direction (201) of the filter medium (129) after the water jet separating device, laser beam separating device, ultrasonic separating device or the cutter.

15. A device for separating a filter medium (129), comprising a conveying device for a filter medium (129); a folding device (202) for folding the filter medium; a wrinkle pulling-out device (202), a water jet separating device, laser beam separating device (203), ultrasonic separating device, or a cutter mounted in the conveying direction (201) of the filtering medium (129) after the folding pull-out device (202) and a folding erecting device (236) mounted in the conveying direction (201) of the filtering medium (129) after the water jet separating device, laser beam separating device (203), ultrasonic separating device or the cutter.

16. Device (200) for producing a filter element, comprising a device for separating a filter medium (129) according to one of claims 14 or 15.

17. Filter element (1 12) produced by a manufacturing method according to one of claims 10 or 13.

18. Filter element (1 12), in particular according to claim 17, comprising a bellows whose outer end edges are cut with a laser beam.