Classifications

• • 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
  • B01D29/11—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 bag, cage, hose, tube, sleeve or like filtering elements
  • B01D29/111—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
  • B01D29/11—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 bag, cage, hose, tube, sleeve or like filtering elements
  • B01D29/13—Supported filter elements
  • B01D29/15—Supported filter elements arranged for inward flow filtration
  • B01D29/21—Supported filter elements arranged for inward flow filtration with corrugated, folded or wound sheets
• • 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
  • B01D29/11—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 bag, cage, hose, tube, sleeve or like filtering elements
  • B01D29/13—Supported filter elements
  • B01D29/23—Supported filter elements arranged for outward flow filtration
  • B01D29/232—Supported filter elements arranged for outward flow filtration with corrugated, folded or wound sheets
• • 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
  • B01D29/50—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 multiple filtering elements, characterised by their mutual disposition
  • B01D29/56—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 multiple filtering elements, characterised by their mutual disposition in series connection
  • B01D29/58—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 multiple filtering elements, characterised by their mutual disposition in series connection arranged concentrically or coaxially
• • 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
  • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
  • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
  • B01D46/523—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material with means for maintaining spacing between the pleats or folds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
  • B01D2275/10—Multiple layers

Definitions

• the invention relates to a method for producing a filter element, comprising a first filter medium having individual filter folds, and a second filter medium surrounding the filter folds at least partially in the manner of a mat-like filter jacket, which is composed of individual fibers.
• Such a filter element with a first filter medium in the form of a filter material, which has star-shaped folded individual filter folds, and a second filter medium in the form of a proppant has become known from DE 10 2005 014 360 A1.
• the support means extends at least partially in the distance between two adjacent filter folds and / or on the inside circumference and / or outside circumference of the filter folds and is designed to be fluid-permeable.
• the respective proppant is provided with filter-active substances or even built up from these filter-active substances, so that the second filter medium serves to reduce the lifetime reducing influence of fluid constituents, such as specific aging products or other fluid damaging media.
• the filter active substances mentioned serve as a kind of particle eaters and can be used for example in the integration with a foam-like
• the support means is formed of a porous, in particular sponge-like basic structure as the base matrix, wherein due to the inherent elasticity of the basic structure, the outer filter folds engage in the foam material and convexly projecting protrusions of the support means engage in the existing spaces between adjacent filter folds of the filter material.
• the proppant can be built up from so-called bicomponent fiber systems by means of a melting process.
• the support means or second filter medium is manufactured independently of the folded filter material or the first filter medium and then arranged around this.
• the proppant is in the form of a matrix of self-bonding plastic and / or natural fibers which are at least partially fibrillated.
• a method for producing a filter element with a filter medium which has successive folds in at least one surface area is disclosed in DE 602 1 1 579 12.
• a filter is formed, the filter comprising the shape of a filter member, the mold comprising a filter portion molding surface for molding a filter portion and a frame portion forming the filter portion molding surface.
• the nonwoven fabric is deposited in the form of fibers with a substantially constant thickness on the mold section, so that the corresponding filter section of the filter from the nonwoven fabric, ie, the fibers and the grid of the mold section is formed.
• WO 2009/088647 A1 relates to a method for producing a filter element with a two-layer filter medium.
• the fluid filter medium has a first layer of microfibers having an average diameter of at least 1 ⁇ m and a second layer of a mean diameter of submicrofibrils having less than 1 ⁇ m, at least one of the fiber groups being oriented and the two layers being contiguous to each other.
• both layers are first manufactured independently of each other, in particular provided with the desired orientation of the fibers, and then placed next to each other.
• the fluid filter medium may be formed tubular cylindrical with concentrically arranged filter layers.
• the second, in particular inner layer can be folded up in a star shape.
• DE 101 09 474 C1 proposes a process for the production of nonwovens, in which nano- and / or microfibers by an electrostatic
• Spinning process of a polymer melt or a polymer solution is generated and deposited into a nonwoven, wherein a web-shaped carrier material is arranged between at least two trained as electrodes for generating an electric field sprayer or is passed and each side of the substrate with the nano and generated by means of Absprüh wornen / or microfibers coated with opposite polarity.
• a nonwoven fabric produced by this method can be used as the filter material.
• the reliability of operation depends to a great extent on the proper condition of the fluids concerned.
• relevant operating fluids As lubricating oils, fuels and hydraulic fluids, as well as process waters and air streams are contaminated with impurities containing colloidal or present as solid particles impurities are to make particularly high demands on the efficiency of the filter devices.
• the present invention seeks to provide an inexpensive, suitable method for producing a filter element with a filter medium having at least in a surface area consecutive folds and is fixed in a simple manner in all operational requirements in position and / or with which at least one prefiltration can be realized.
• this object is achieved by a method having the features of claim 1 in its entirety. Characterized in that the formation of the individual fibers, a solid base material is transferred into a melt which is sprayed or sprayed on at least one nozzle device with the addition of a fluidic carrier stream in directional fiber form on the first filter medium such that the individual fibers, at least after contact with solidify the first filter medium to form the filter jacket and that for a successive jacket structure of the second filter medium during the fiber application, the respective nozzle device and the pleated first filter medium perform a relative movement to each other and / or that the nozzle device in predetermined spraying or spraying the fiber application along the Outside contour of the first filter medium is made a production of technically simple way of arranging and applying the first filter medium with its filter pleats in any phase of operation stabilizing fiber composite.
• the fibers are applied to the filter medium in such a way that the applied fibers hold the folds in position and / or form a pre-filter or post-filter stage for the filter medium.
• the fibers may be applied to form at least one fiber web between the pleats and thus maintain the pleats in position during operation of the filter element.
• the fibers are preferably applied over the entire, the effective filter surface of the filter element defining surface of the filter medium, also an effective pre- or Nachfilterkno is created depending on the flow direction of the filter medium.
• the filter strength of the pre-filter or post-filter stage formed in this way can be adjusted step-by-step in almost any desired manner by the applied layer thickness of the individual fibers. Even a varying over the surface of the filter medium layer thickness is made possible by the inventive application of fibers to the filter medium. In this way, a cost-effective, adapted to the particular customer requirements producing a filter element with extremely resistant construction, in particular based on its inflow side, created.
• the application or application of individual fibers according to the invention is suitable for use in To stabilize the individual filter folds, in particular aligned in the axial direction filter folds, in cylindrical and oval filter elements. If the individual filter folds are held in their position by the individual fibers in a stabilizing manner, they can not unintentionally come into contact with each other during the filtration process, which would otherwise reduce the effective filter area. Accordingly, a filter element produced according to the invention also serves to maintain the desired filter performance constant.
• a suitable fiber material in particular in the form of a thermoplastic material
• a shrinking process occurring can be used to determine the fibers not only by the material bond at the edges and interstices of the filter folds, but also by a resulting and remaining radially acting force component of the pulling force caused by the shrinkage process.
• the force directed radially with respect to a cylindrical, pleated filter medium results in a certain penetration of the fibers or of the homogeneous filter mantle formed by the fibers between the individual filter folds.
• a filter element made in accordance with the invention is that the fibers are able to form a seamless layer or a seamless filter jacket when applied over the entire surface to the filter medium, since this is very thin due to its adjustable fiber thickness and thus multilayered in the manner of a Continuous orders are orderable. It does not require any additional connection technology to otherwise provided connections of a pre-filter material on the main filter stage of a filter element, as tei lweise in the prior art is shown. In addition, it is thereby also possible to change the filter fineness, for example, by the selected fiber density over the entire wall thickness of the fiber cladding.
• the fiber sheath is used as a prefilter, wherein starting from the filter fineness of the folded filter medium from a high filter fineness to a lower filter fineness to the outside, this is selectively changed, whereby at the respectively upstream surface of the fiber sheath Larger particles are filtered off than, for example, in deeper, the pleated filter medium closer layers of the fiber cladding.
• the individual fibers can be arranged particularly advantageously at an angle to the longitudinal axis of the cylindrical filter element or to the longitudinal axis of the folds of the filter medium of about 20 ° to 90 °, wherein it is expedient, the fibers of their longitudinal direction forth transversely, ie at an angle of about 90 °, to the longitudinal axes of the folds on the filter medium. It is particularly advantageous to change the fiber course in fibers applied by means of a winding process in such a way that the fibers, for example, intersect in their orientation over the entire layer thickness of the fiber cladding. It may also be advantageous to arrange the fibers in a similar manner to a chaotic orientation, as is known from pressed filter mats.
• the fibers can, as already explained, in principle be applied to all sides of a filter medium, but in particular on the filtrate and / or on the non-filtrate side of a filter medium. It has surprisingly been found for a person of ordinary skill in the art that even at small layer thicknesses of a fiber application according to the invention from about a thickness of 1 mm to 2 mm already an excellent fixation of filter folds of a filter medium can be achieved. Depending on the intended use of the filter element, it may well make sense to provide fiber layer thicknesses up to about 6 mm or more on the filter medium.
• the filter fineness of the fiber cladding is freely selectable; However, it is advantageous to select a greater filter fineness than in the corresponding filter medium surrounded by the fiber cladding so as to achieve a useful pre-filter stage in the manner of a coarse filter for a gaseous or liquid medium.
• an adhesive bond with the folds of the filter medium takes place during a fiber application, in particular an adhesive bond in the manner of a hot bond. The latter is particularly the case when the base material of the fibers for liquefaction and to form a fanning in slats must be heated with subsequent fiber formation.
• the fiber layer may be imparted with one or more further functions, such as a definable electrical polarity, chemical and / or physical preference for certain substances to be filtered or the like, by selecting certain fiber materials or even additives corresponding to the base material of the fibers which may also have antibacterial character in the field of pharmaceutical application.
• Methods of filtering solid suspended solids from fluids by means of filter media are often based on the use of filter aids or adjuvants to pre-filter the fluid-based fluid mixture regularly and extend the service life of a filter element.
• the application of individual fibers according to the invention to a predefined filter medium is particularly ideally suited to the top of the fiber cladding or even during the order of the Fibers apply filter aids and / or embed.
• the pertinent intrinsic injection method can prevent a densely packed soil layer or filter cake of solid material from settling on the surface of the fiber cladding or filter element to affect the effectiveness of the main filter stage in the form of the filter medium.
• Filter aids work with non-deformable suspended solids by increasing the overall porosity and thus the loading capacity of the filtration system.
• filter aids slow the passage of non-deformable solids on the surface of the filter media, where they then readily enter the pore structure and block the flow of the liquid.
• filter aids interrupt the formation of the packed solid layer or filter cake. Filter aids are therefore less effective at depositing non-deformable suspended particles as compared to deformable suspended particles.
• Stepped filter beds such as glass microbeads or non-spherical filter aids, such as low density porous materials, such as silicates, oxides, carbonates, silica, polymers, or other low bulk density porous materials can be applied to the cladding .
• Other filter aids may consist of activated carbon or be formed from ion exchange resins, antioxidant additives, etc.
• a variant of the method according to the invention for producing the filter element provides at least the following further method steps: Liquefying a possibly in a solid state base material of the fibers,
• a base material for the fibers which is present in the form of granules, is heated and liquefied and conveyed and atomized by means of an extruder device to an injection or spraying device, in particular to a hydraulically atomising nozzle.
• the nozzle for forming the fibers may also be a multi-component nozzle, in particular a two-fluid nozzle bringing a carrier air flow to the base material melt, wherein the liquid base material within the nozzle body or outside of the nozzle body merges with the carrier air stream for the purpose of atomizing the liquid base material and the transport to the filter medium becomes.
• the base material for the fibers are preferably thermoplastic see plastics or thermoset one- or two-component Plastics. Furthermore, so-called bicomponent fibers with a predefinable staple length can be used for the fiber material.
• a particularly preferred production method for a fiber cladding according to the invention is a so-called "spun spray" method in which a solid base material for the fibers, for example a thermoplastic, is first transferred from a preferred granulate form into a melt
• the central nozzle channel is surrounded by a ring channel for carrier air, wherein the carrier air, which may also be heated, or a hot gas at a common exit surface of the nozzle are fed to the melt stream.
• the base material molecules initially present in this way in the melt are aligned and define a fibrous form which crystallizes upon contact with the filter medium and solidifies under shrinkage
• the carrier air as a fluidic carrier stream, another working gas such as nitrogen, but also be used a liquid medium.
• the filter medium in the form of, for example, cylindrical, longitudinally folded filter pleats is held in rotation, in the spray or spray area of the two-fluid nozzle, which then reciprocates in the longitudinal direction of the filter medium and thus a fiber cladding with successively increasing layer thickness on the pleated filter medium produced. Also, the pertinent application nozzle can stand still and the filter medium at the same time move in its rotation in the longitudinal direction back and forth.
• the cooled and trimmed fiber cladding can be imprinted with images or characters, such as company logos or the like.
• images or characters such as company logos or the like.
• the specifiable functional layering also contributes to this, and the functionality of the spun-spray layer can be controlled, for example as regards its polarity, the activity of the interface or the incorporation of additives.
• the filter element according to the invention can thus be adjusted in a wide range in terms of dirt holding capacity, flow behavior and stability (Durchfluß crispermüdung).
• the selected arrangement when using the Spunspray layer as upstream pre-filter stage and downstream Nachfilterski seen in the direction of flow of the filter medium before and after the medium, the selected arrangement can be used as a so-called.
• Migration brake i. Dirt particles of the filter medium itself by the filter media material used in each case can be safely collected and controlled via the downstream Spunspray layer, so that the other media circuit is spared from pertinent internal contamination components of the filter.
• FIG. 1 shows a partial, schematic cross section through a filter element with fiber cladding produced according to the invention
• FIG. 2 shows a plan view of a cross-sectional area through a fiber-clad filter element produced according to the invention
• FIG. a schematic representation of an apparatus for performing a method according to the invention for the manufacture of the filter element, a schematic cross section through a two-substance nozzle for generating and for applying fibers to the filter medium of the filter element; a schematic representation of the jet constriction emerging from the two-fluid nozzle in Figure 4 melt of the base material of the fibers under the influence of a carrier air flow; and a schematic representation of the increasing orientation of the molecules into the base material for the fibers during and after passage through the binary nozzle.
• a pleated filter medium 2 made of a filter mat of conventional design is shown in a partially schematically illustrated cross-section, which has individual folds 4 at regular intervals, which are lined up in a sinusoidal manner.
• the cylindrically curved filter medium 2 starting from the planar position according to FIG. 1 is part of a cylindrical filter element 1 shown in FIG. 2, which serves to filter a liquid or gaseous fluid.
• the filter medium 2 has a multilayer structure and can be formed in a conventional manner from a stacking of several layers, for example formed of fleece and fiber materials and individual fabrics. Perforated tubes and perforated expanded metal coats are used in particular the formation of an inner support tube 2 'for the filter medium.
• the Expanded metal sheath or the perforated metal pipe uses a stainless steel or tinned steel; but there are also plastic solutions for the formation of the inner support tube 2 'possible.
• the filter medium 2 engages with its fold edges on the inside circumference on the outer peripheral side of the support tube 2 '.
• the filter element can then in the usual way with a support tube and two end caps provided as tradable filter device in the usual filter housing (not shown) used interchangeably.
• a fiber layer is applied to a surface region 3 of the filter medium 2.
• the fiber layer is, as shown in FIG. 2, laid over the entire surface as a fiber cladding 6 around the outside of the cylindrical filter medium 2 in an approximately constant layer thickness.
• a base material 7 designed as a thermoplastic material is used for producing the fibers 5, the granules being supplied by the extruder device 9 driven by a speed-controllable electric motor 13.
• the plastic granules is held for this purpose in a reservoir 1 with funnel-shaped bottom and by means of the heating or Melting device 10 liquefied, for example at a temperature of about 190 ° C.
• the plastic melt then passes with further heating up to 285 ° C and reducing its viscosity, together with an increase in pressure up to about 35 bar, to which as a two-fluid nozzle 1 1, as shown in Figure 4 in more detail , formed spraying and spraying 8.
• the process shown process is preferably carried out continuously; but can also be carried out discontinuously with predetermined interruptions.
• 4 shows a schematically drawn longitudinal section through the two-fluid nozzle 1 1 for the formation of fibers 5 for the purpose of order on the in Figure 3 schematically shown cylindrical filter element 1, as shown in a cross-sectional view closer in Fig.2.
• the two-substance nozzle 1 1 is basically used for mixing or merging a hot carrier air stream 12 and the plastic melt of the base material 7.
• the two-fluid nozzle 1 1 is formed from a cylindrical first and outer nozzle body 16 having an upper access area or an inlet opening 1 7 for the carrier air flow 12th having.
• a second inner nozzle body 18 is arranged centrally, wherein the second nozzle body 18 has an access channel 19 for the liquid base material 7 in its interior.
• the base material 7 enters the inner nozzle body 18 into the inlet channel 19 at a pressure of about 35 bar and at a temperature of about 280 ° C. coming from the extruder device 9 and the screw channel 15.
• the nozzle body 18 has a narrowing at a conical acute angle channel guide, the conically narrowing nozzle-like access channel 19 narrows by a multiple of the diameter of the Blasluftkanals 20.
• the access channel 19 has at its free lower end an outlet opening 21 with a conical edge, wherein it projects into an outlet opening 23 of the first nozzle body 16.
• first nozzle body 16 encloses the extent of the second nozzle body 18 with radial and axial spacing to form the Blas Kunststoffkanals 20 fully.
• the two adjacent outlet openings 21 and 23 are so far coaxial with the longitudinal axes of the respective nozzle body 18 and 1 6 arranged.
• the outlet opening 21 with its edge of the inner nozzle body 18 is so spaced from the outlet opening 23 of the outer nozzle body 1 6 that results in a reduced Ausströmquerrough for the carrier air flow 12 and thus an acceleration in the exit region of the liquid base material 7.
• FIG. 5 illustrates the effect of the accelerating carrier air flow 12 when leaving the two-component nozzle 1, resulting in jet constriction of the plastic melt and, as shown in particular in FIG. 6, a successive alignment of the initially chaotically present molecules of the base material 7 in the spray jet in the formation of the respective fiber 5. This results in a stabilized by internal molecular arrangement fiber structure with very low optical birefringence values.
• the proposed filter element 1 with its outside of the filter medium 2 is used in a device 25 shown in principle such that it under rotation can be moved around its longitudinal axis 24 in the region of the two-fluid nozzle 1 1 according to the indicated double arrow, whereby a uniform application of fibers 5 but also a specific in its mass distribution of the fibers 5 controlled order of these fibers 5 can be made on the folded filter medium 2.
• a fiber sheath 6 defined in any desired filter fineness can thereby be applied to the fold edges of the pleated filter medium 2.
• the hot applied, the fibers 5 forming base material 7 in this case also passes between the folds 4, wherein a mass concentration between the folds 4 can be possible to a predeterminable extent.
• the base material 7 has a sticky surface in its heated, molten form and, under certain circumstances and depending on the material used for the filter medium 2, can also be connected to the fold edges or fold backs of the filter medium 2 in a materially bonded manner.
• FIG. 1 further clarifies, accumulations of base material 7 acting as spacers 27 are formed between the folds 4 by indentations of the fibers 5.
• the fibers 5 are aligned approximately transversely to the longitudinal direction of the folds and thus transversely to the longitudinal axis 24 of the filter element 1.
• a fiber application with changing fiber application direction is to be regarded as particularly advantageous here, since the pertinent solution to high burst and collapse compressive strengths for the entire filter element leads.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Filtering Materials (AREA)
• Filtering Of Dispersed Particles In Gases (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

Country Status (6)

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Families Citing this family (6)

Citations (8)

Family Cites Families (24)

• 2009
  • 2009-09-12 DE DE102009041401A patent/DE102009041401A1/de not_active Withdrawn
• 2010
  • 2010-09-07 WO PCT/EP2010/005474 patent/WO2011029568A1/de not_active Ceased
  • 2010-09-07 CN CN201080040344.5A patent/CN102574032B/zh not_active Expired - Fee Related
  • 2010-09-07 JP JP2012528261A patent/JP5898078B2/ja active Active
  • 2010-09-07 US US13/261,209 patent/US20120213926A1/en not_active Abandoned
  • 2010-09-07 EP EP10754687.1A patent/EP2475444B1/de not_active Not-in-force

Patent Citations (8)

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