WO2010014713A1 - Filtre avec matériau filtrant moulé en place - Google Patents

Filtre avec matériau filtrant moulé en place Download PDF

Info

Publication number
WO2010014713A1
WO2010014713A1 PCT/US2009/052109 US2009052109W WO2010014713A1 WO 2010014713 A1 WO2010014713 A1 WO 2010014713A1 US 2009052109 W US2009052109 W US 2009052109W WO 2010014713 A1 WO2010014713 A1 WO 2010014713A1
Authority
WO
WIPO (PCT)
Prior art keywords
housing
lumen
pleats
thermoplastic
filter medium
Prior art date
Application number
PCT/US2009/052109
Other languages
English (en)
Inventor
Edward Kandel
Original Assignee
Illinois Tool Works Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Illinois Tool Works Inc. filed Critical Illinois Tool Works Inc.
Publication of WO2010014713A1 publication Critical patent/WO2010014713A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0002—Casings; Housings; Frame constructions
    • B01D46/0012—In-line filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/01—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements
    • B01D29/012—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/01—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements
    • B01D29/016—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements with corrugated, folded or wound filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0002—Casings; Housings; Frame constructions
    • B01D46/0015—Throw-away type filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2201/00—Details relating to filtering apparatus
    • B01D2201/34—Seals or gaskets for filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/42—Details of membrane preparation apparatus

Definitions

  • the present invention relates generally to filter elements for filtering fluids and, more particularly, to an improved filter and method of fabricating the same.
  • Fluid filters are used in a variety of applications including automobile fuel lines, washing machine water lines, medical IV or blood lines and the like, where they serve to filter foreign material from a flowing fluid including gases or liquids.
  • Such filters may use a filter material in the form of a sheet, such as a porous nonwoven fabric, supported in a housing that defines a passageway through which the fluid must flow.
  • the filter material is positioned in the passageway to intercept the flow, and may be pleated or corrugated to increase its surface area within the area of the passageway.
  • the housing of a filter element provides walls that protect the filter material and that resist the pressure of flowing fluid.
  • the housing may include end caps providing for connection points to other fluid conduits such as hoses, tubes or the like.
  • the present invention provides a filter in which the margins of the filter material are molded directly into the housing during an injection molding process.
  • Specially designed mold core pins provide the ability to pleat and support the filter material during the molding process.
  • supporting ribs can be fabricated to support the pleats at the pleat edges thereby allowing thinner filter material and larger amplitude pleating for increased surface area in small passageways.
  • the present invention provides a method of manufacturing a filter in which a sheet filter medium having margins is folded into pleats.
  • a molding tool is used to support the pleats of the sheet filter medium and, while the pleats are so supported, to mold a rigid thermoplastic housing around the pleats to embed the margins within the thermoplastic, the thermoplastic housing defining a lumen through which fluid may pass by passage through the filter medium as retained and supported by the housing.
  • the lumen may curve at regions of the housing in which the margins of the pleats are embedded.
  • the pleats may be substantially rectilinear to have fold edges where the sheet filter material is folded and a mold core of the molding tool may provide a passage at the fold edges allowing admission of thermoplastic to provide a supporting rib of thermoplastic passing along the fold edge and crossing the lumen.
  • the rib may be adhered to a convex side of the fold edge.
  • the mold core of the molding tool may provide inwardly extending ledges from opposite inner walls of the lumen to support fold edges of the pleats adjacent to the walls of the housing orienting the sheet material to pass into the walls of the housing along a plane substantially perpendicular to an axis of the lumen.
  • the molding tool may include at least one core components moving to define the lumen, the core component having pleat formers for forming the sheet filter medium into the pleats as the core component moves.
  • the pleat formers may include a truncated triangular prism element, a truncated apex of the prism providing passage for a supporting rib attached to a pleat fold.
  • the present invention also includes the resulting filter having a thermoplastic housing providing a rigid housing defining a lumen through which fluid may pass along an axis between an entrance aperture and an exit aperture.
  • a sheet filter medium is formed in substantially rectilinear pleats having fold edges and unfolded margins and supported within the lumen between the entrance aperture and exit aperture so that the fold edges are substantially perpendicular to the axis.
  • the unfolded margins are embedded in the thermoplastic housing so that fluid may pass through the lumen only by passing through the sheet filter medium.
  • FIG. 1 is a perspective view of an embodiment of a filter of the present invention having a housing (in phantom) holding a pleated filter material;
  • Fig. 2 is a cross-sectional view through the filter of Fig. 1 showing the position of ribs supporting the pleated filter material;
  • FIG. 3 is perspective view of a molding system, in an open state, suitable for producing the filter of Figs. 1 and 2;
  • Fig. 4 is a cross-section taken along lines 4-4 of the molding system of Fig. 3 in a closed state;
  • Fig. 5 is a figure similar to that of Fig. 4 showing the molding system in a closed state immediately prior to the injection of thermoplastic;
  • Fig. 6 is a cross-sectional view similar to that of Fig. 2 of an alternative embodiment of the filter of the present invention showing multiple pleats and end caps providing for connections to second fluid conduits;
  • Fig. 7 is a plan view of the filter of Fig. 2 showing portions of filter material outside of the housing that are removed during the manufacturing process;
  • Fig. 8 is a view of the precut filter blank that may be used in the present invention.
  • Fig. 9 is a perspective view of a transparent housing having flexible double walls for priming operation.
  • Fig. 10 is a front elevation overview of the housing of Fig. 9 showing compression of the outer walls without distortion of the inner filter supporting walls.
  • the present invention provides a filter element 10 having an outer housing 12 defining a lumen 14 through which a fluid (not shown) may pass between an entrance aperture 16 and an exit aperture 18.
  • the housing 12 may be a substantially cylindrical tube extending along an axis 20.
  • a sheet filter material 22 Positioned within the lumen 14, is a sheet filter material 22 being, for example, a porous nonwoven or woven fabric, screen or mesh, having pore sizes selected to filter foreign material from the fluid passing through the lumen 14.
  • the sheet filter material 22 may be formed in a pleat to increase its surface area within the cross- section of the lumen 14.
  • a single triangular pleat is formed having an apex 24 centered within the lumen 14 and base edges 26 attached to an inner wall of the housing 12.
  • the apex 24 follows a fold edge 30 of the sheet filter material 22 along an axis perpendicular to axis 20 providing equal acute angles between the axis 20 bisecting the pleat and two downwardly extending portions of the sheet filter material 22 as pass from the apex 24 to the base edges 26.
  • the base edges 26 follow fold edges 34 of the sheet filter material 22 directing the downwardly extending portions outward along cross-sectional plane 38 normal to axis 20 into the walls of the housing 12.
  • a thermoplastic rib 32 spans the cross-section of the lumen 14 perpendicular to the axis 20 and along the fold edge 30 to support an outside or convex face of the fold edge 30 at the apex 24.
  • the rib 32 is adhered to the sheet filter material 22 during the molding process in which molten thermoplastic of the rib 32 fuses to or infuses into the sheet filter material 22.
  • thermoplastic ledges 36 extend inwardly from the walls of the housing 12 near the base edges 26 to support an underside or convex face of fold edges 34 at the base edges 26 as similarly adhered to the sheet filter material 22.
  • Margins 40 of the periphery of the sheet filter material 22 at the base edges 26 and all along the pleat near the outer edge of the lumen are embedded in the walls of the housing 12. In this way all fluid passing between the entrance aperture 16 and the exit aperture 18 must pass through sheet filter material 22.
  • the filter of Figs. 1 and 2 may be fabricated in an injection molding process employing a molding tool 41 providing first and second opposed mold halves 42 and 44 and corresponding opposed first and second mold cores 46 and 48 each independently movable along axis 50 generally corresponding to axis 20 of the molded filter element 10.
  • each mold half 42 and 44 may provide for concentric first cylindrical bores 52 and 54 and second cylindrical bores 56 and 58, respectively, aligned with axis 50.
  • the first bores 52 and 54 are of greater diameter than the second bores 56 and 58 and define by their diameter the outer diameter of the housing 12.
  • the second bores 56 and 58 are equal to the diameter of the inner wall of the housing 12 and match the diameter of the shafts of the mold cores 46 and 48, respectively, passing therethrough.
  • the larger bores 56 and 58 are positioned adjacent to opposed faces 60 of the mold halves 42 and 44, such faces 60 that abut during molding, and the bores 52 and 54 are displaced to the outer edges of the mold halves 42 and 44.
  • the shafts of the mold cores 46 and 48 are cylindrical and aligned with axis 50 and with axes of the bores 52 and 54 to slide through the bores 52 and 54 in a manner that provides sealing against passage of molten thermoplastic.
  • Opposed faces 62 of the mold cores 46 and 48 that abut during the molding process provide pleat formers 64 and 66 being approximately complementary shapes so as to interfit when the mold cores 46 and 48 are brought together.
  • the pleat former 64 for a single pleat, per the filter element 10 of Fig. 1, is a triangular prism having a cross-section that is nearly an isosceles triangle conforming generally to the pleated surface of the sheet filter material 22 shown in Figs. 1 and 2.
  • the apex of the prism of pleat former 64 nearest mold core 46 is truncated or flattened to provide a passageway for the rib 32 described above.
  • the pleat former 66 is a triangular notch whose walls describe a triangular prism complementing that of the pleat former 64 except for the truncation of the apex of pleat former 64.
  • a spool 68 of sheet filter material 22 positioned outside the molding tool 41 may feed sheet filter material 22 between the faces 60 of the mold halves 42 and 44 along the cross-sectional plane 38 normal to the axis 50 where the mold halves 42 and 44 abut when the molding tool 41 is closed.
  • the sheet filter material 22, as so positioned, may advance between molding operations as will be described.
  • sheet filter material 22 may be advanced between the mold halves 42 and 44, and the open mold cores 46 and 48 may be brought together along axis 50 while mold halves 42 and 44 remain separated.
  • This process of drawing together mold cores 46 and 48 gathers a portion of the sheet filter material 22 between the pleat formers 64 and 66 beginning the formation of a single pleat as shown.
  • a slight tension 67 may be maintained on opposite ends of the sheet filter material 22 to pull the sheet filter material 22 tightly over the pleat former 64.
  • the mold halves 42 and 44 may be brought together around the mold cores 46, clamping the sheet filter material 22 therebetween in a manner to prevent the egress of thermoplastic material.
  • the early stages of this clamping may be used, in part, to provide the tension 67 on the sheet filter material 22 described above.
  • the sheet filter material 22 will be pulled tightly against the apex of pleat former 64 leaving a channel 70 between the apex of the pleat former 64 and the corresponding mating pleat former 66.
  • This channel 70 may be filled by thermoplastic material through an injection port (not shown) providing thermoplastic for the housing 12 and for the supporting rib 32 for the sheet filter material 22.
  • the sheet filter material 22 near the base edges 26 may be pulled tightly against the pleat former 66 leaving a channel 72 between corresponding portions of the pleat former 64 and 66 such as forms the ledges 36 extending inwardly from bores 58 and 56 of the mold halves 42 and 44.
  • the inner walls of the bores 56 and 58 and outer walls of the shafts of mold cores 46 and 48 also provide channel 80 that forms the wall of the housing.
  • these channels 72, 80, and 70 are filled with thermoplastic material per conventional molding techniques, the sheet filter material 22 will be fully supported and sealed with in housing 12.
  • the margins 90 of the sheet filter material 22 will be wholly embedded within the housing 12 of the filter and in one embodiment, depicted in Fig. 7, the sheet filter material 22 may be trimmed by a die cutting operation during molding by cutting edges incorporated into the mold halves 42 and 44 or elsewhere to remove excess material. Alternatively as shown in Fig.
  • the sheet filter material 22 may be pre-trimmed to provide a first tapering curvilinear sections 82 on either side of a line of the fold edge 30 and second arcuate sections 84 conforming generally to the cuts that would be made as described in Fig. 7.
  • the trimming of the sheet filter material 22 is such that it does not extend through the walls of the housing.
  • the present invention contemplates at the housing 12 may be joined to end caps 86 (only one shown) either separately attached or integrally molded to the housing 12 and that may provide junctions communicating with tubing or hoses 88 or the like. Similarly, multiple pleats may be formed from the sheet filter material 22 with multiple supporting ribs 32 using the technique described above. It will be understood that the housing 12 need not be cylindrical but maybe of arbitrary shape.
  • thermoplastic material used in the molding may be a conventional polymer or may be other materials including electrically conductive materials.
  • the sheet filter material 22 may also be material such as metal screens or other filter media.
  • the housing 12 may be rectangular in outline to provide a generally rectangular cross-sectional lumen 14 with integrally molded end caps 86 to define an internal filter volume.
  • the margins 40 of the filter material may be embedded in first opposed housing walls 92a and 92b respectively, the latter extending the full height of the filter volume along axis 50 but only a portion of the width of the filter volume to allow fluid flow there about.
  • the housing walls 92a and 92b are contained inside of outer housing walls 94a and 94b parallel to and flanking housing walls 92a and 92b and within housing walls 96a and 96b perpendicular to housing walls 94a and 94b and attached thereto and perpendicular to housing walls 92a and 92b but not attached thereto.
  • These walls of the housing 12 may be molded of the transparent flexible material such as vinyl.
  • a user may grasp the outer surface of the housing 12 with their fingers and thumb 100 pressing on the walls 94a and 94b to compress the walls 94a and 94b inward to reduce the internal filter volume to provide a priming or slight pumping action thereby.
  • This distortion of walls 94a and 94b is isolated from the inner walls 92a and 92b preventing undesired tension or distortion of the filter material 22 held thereby.

Abstract

L'invention porte sur un filtre à fluide qui comporte un matériau filtrant en feuille plissée avec des marges directement moulées en place sur le boîtier de support. Des supports de plis s'étendant à travers la lumière du boîtier peuvent supporter les plis à leurs arêtes de pliage.
PCT/US2009/052109 2008-08-01 2009-07-29 Filtre avec matériau filtrant moulé en place WO2010014713A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US8573708P 2008-08-01 2008-08-01
US61/085,737 2008-08-01

Publications (1)

Publication Number Publication Date
WO2010014713A1 true WO2010014713A1 (fr) 2010-02-04

Family

ID=41610715

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2009/052109 WO2010014713A1 (fr) 2008-08-01 2009-07-29 Filtre avec matériau filtrant moulé en place

Country Status (1)

Country Link
WO (1) WO2010014713A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120251874A1 (en) * 2011-03-29 2012-10-04 Minhyung Guen Secondary battery

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1201395A1 (fr) * 2000-10-30 2002-05-02 Filtertek Inc. Procédé combiné pour plier des matériaux filtrants et mouler un ensemble filtrant
US20020144942A1 (en) * 2001-04-10 2002-10-10 Denton Donald Ray Filter element and method of making
US7282140B2 (en) * 2001-03-02 2007-10-16 Filtertek Inc. Sump filter with filter element cartridge

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1201395A1 (fr) * 2000-10-30 2002-05-02 Filtertek Inc. Procédé combiné pour plier des matériaux filtrants et mouler un ensemble filtrant
US7282140B2 (en) * 2001-03-02 2007-10-16 Filtertek Inc. Sump filter with filter element cartridge
US20020144942A1 (en) * 2001-04-10 2002-10-10 Denton Donald Ray Filter element and method of making

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120251874A1 (en) * 2011-03-29 2012-10-04 Minhyung Guen Secondary battery

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