WO2011140963A1 - 滤芯及其制造方法 - Google Patents

滤芯及其制造方法 Download PDF

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Publication number
WO2011140963A1
WO2011140963A1 PCT/CN2011/073843 CN2011073843W WO2011140963A1 WO 2011140963 A1 WO2011140963 A1 WO 2011140963A1 CN 2011073843 W CN2011073843 W CN 2011073843W WO 2011140963 A1 WO2011140963 A1 WO 2011140963A1
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Prior art keywords
fiber layer
filter
fiber
layer
skeleton
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PCT/CN2011/073843
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English (en)
French (fr)
Inventor
朱明箴
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北京世珍一诺科技有限公司
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Publication of WO2011140963A1 publication Critical patent/WO2011140963A1/zh

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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
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • 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
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/0036—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions by adsorption or absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1216—Pore size
    • 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
    • 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
    • B01D2275/30—Porosity of filtering material

Definitions

  • the present invention relates to a filter element and a method of manufacturing the same, and more particularly to a filter element for a vehicle filter and a method of manufacturing the same. Background technique
  • Traditional automotive filters such as air filters, fuel filters and oil filters, mainly include sawdust filters, fiber nonwoven filters, single meltblown fiber filters, metal filter cartridges, and paper shield cartridges.
  • the sawdust filter has small air permeability and large resistance.
  • the single process of the process cylinder is cumbersome and unsuitable for industrial production.
  • the fiber non-woven filter element needs to be attached with metal mesh support and weight due to the soft material, and the process is cumbersome and does not meet the requirements of the development of the filter element without metallization.
  • the metal mesh filter has poor filtering precision, high weight and high cost.
  • the single meltblown fiber filter is formed by single radial winding after melting of the single component fiber, and the collapse deformation under high temperature and high pressure affects the filtering effect.
  • the widely used paper shield filter has a single hole diameter, low filtration precision, small amount of dirt, and easy to produce filter cake effect under temperature and pressure, resulting in short service life. Summary of the invention
  • the present invention aims to solve at least one of the technical problems existing in the prior art.
  • an object of the present invention is to provide a metal-free low application range, high filtration precision, large dirt holding capacity, high stiffness, long service life, and recycling. Carbon filter cartridge.
  • another object of the invention is to provide a method of manufacturing a filter element according to the first aspect of the invention.
  • an embodiment of the present invention provides a filter element which is cylindrical and includes an inner fine filter fiber layer, an adsorbent fiber layer, a medium fine filter fiber layer, and a skeleton in order from the inside to the outside in the radial direction.
  • the filter element according to the present invention is composed of a plurality of fiber layers, and the inner fine filter fiber layer, the middle fine filter fiber layer and the outer coarse filter fiber layer mainly serve as a filtering function, and the filter pore diameter gradually increases from the inner side to the outer side, and the filter element has The five-layer gradient multi-aperture increases the filtration area and the amount of dirt.
  • the filtration precision is high, the filtration effect is good, and the service life is greatly extended.
  • the adsorption fiber layer acts as an adsorption function, for example, it can filter out the minimum of the filtered medium shield.
  • the filter element according to an embodiment of the present invention can be used as a filter element of an air cleaner, a fuel filter, and an oil filter.
  • filter element according to an embodiment of the invention may also have the following additional technical features:
  • the filter pore size of each of the inner fine filter fiber layer, the middle fine filter fiber layer and the outer coarse filter fiber layer gradually increases in a radial gradient from the inside to the outside.
  • the inner fine filter fiber layer, the medium fine filter fiber layer and the outer coarse filter fiber layer are composed of polyester fiber, or nylon fiber or PP fiber.
  • the layer of adsorbent fibers is composed of carbon fibers or plant fibers.
  • the skeleton fiber layer is composed of glass fibers, or polyurethane fibers, or polyhexene fibers.
  • An active agent is embedded in the skeleton fiber layer and the outer coarse filter fiber layer.
  • the active agent is a mixture of polyene polyamine anion exchange resin particles and zeolite particles in a ratio of 1: 1 by weight, and the weight mixing ratio of the anion exchange resin particles to the cation exchange resin particles is 1:2.
  • An embodiment of another aspect of the present invention provides a method of manufacturing a filter cartridge, comprising the steps of:
  • A hot-melting the filter fiber pellets into a cylindrical inner fine filter fiber layer
  • the filter fiber pellets are interlaced and wound into a cylindrical shape, and during the melt-blown process, the adsorption fibers and the skeleton fibers are respectively wound in the middle of the filter fiber layer, so that the filter element is It can produce industrial bills, can be industrialized, and has high efficiency.
  • the controllable filtration precision can be achieved by controlling the winding diameter and the density.
  • the method of manufacturing a filter element according to an embodiment of the present invention may further have the following additional technical features:
  • the method of manufacturing a filter element according to the present invention may further comprise embedding an active agent in the skeleton fiber layer and the outer coarse filter fiber layer.
  • the filter fiber pellet is a polyester fiber, or a nylon fiber or a PP fiber pellet
  • the adsorbent fiber layer is composed of carbon fiber or plant fiber
  • the skeleton fiber layer is composed of glass fiber, or polyurethane fiber, or poly Made of olefin fibers.
  • FIG. 1 is a front cross-sectional view of a filter cartridge in accordance with an embodiment of the present invention
  • Figure 2 is a top plan view of the filter element shown in Figure 1;
  • FIG. 3 is a schematic view of an apparatus for manufacturing a filter element according to an embodiment of the present invention.
  • Figure 4 is a partially enlarged schematic view of the apparatus for manufacturing a filter element shown in Figure 3;
  • FIG. 5 is a schematic flow chart of a method of manufacturing a filter element according to an embodiment of the present invention. detailed description
  • a filter element according to an embodiment of the present invention will be described below with reference to the accompanying drawings.
  • a filter element for a vehicle oil filter is taken as an example for description.
  • the filter element according to an embodiment of the present invention is not limited to use for an oil filter, and may be used, for example, for an air cleaner or a fuel filter.
  • the filter element has a cylindrical shape, for example, a cylindrical shape, and includes an inner fine filter fiber layer 1, an adsorbent fiber layer 2, and a medium fine in order from the inside to the outside in the radial direction.
  • the filtration pore size of the inner fine filter fiber layer 1 is smaller than the filtration pore size of the middle fine filter fiber layer 3, and the filtration pore diameter of the medium fine filter fiber layer 3 is smaller than the filtration pore diameter of the outer coarse filter fiber layer 5.
  • the filter pore size is also radially inward from the inside out.
  • the inner and outer layers are progressive Special construction, with greater dirt holding capacity, excellent five-layer filtration, perfect combination of high-efficiency adsorption and physical interception filtration, so that the shield particles filtered from the outside to the inside are gradually reduced along the radial direction of the filter element.
  • the innermost layer of the filter element is wound into a cylindrical shape by the filter fibers, thereby forming an inner fine filter fiber layer 1 for filtering the particle size of the small shield, and the filter pore diameter of the inner fine filter fiber layer 1 is radial.
  • the gradient gradually increases from the inside to the outside.
  • the adsorbent fiber layer 2 is wound on the inner fine filter fiber layer 1, for example, the high-density nano-adsorbing linear fiber is used to form the adsorptive fiber layer 2, and by providing the adsorbent fiber layer 2, the filtered filter can be filtered. Bacteria, such as those used in air filters, can adsorb and filter out bacteria in the air.
  • the medium and fine filter fiber layer 3 is wound on the outer side of the adsorbent fiber layer 2. As described above, the filter pore diameter of the medium fine filter fiber layer 3 is larger than the filtration pore size of the inner fine filter fiber layer 1, and the filtration pore diameter of the middle fine filter fiber layer 3 The gradient gradually increases from the inside to the outside in the radial direction.
  • the skeleton fiber layer 4 is wound on the outer layer of the medium-fine filter fiber layer 3.
  • the skeleton fiber layer 4 supports the whole filter element, strengthens the stiffness and hardness of the core body, and prevents the filter element from being collapsed and deformed during use, resulting in the filter element being unusable.
  • the use of the skeleton fiber layer 4 eliminates the need for a metal filter, reduces the use of metal, reduces costs, and allows the filter element to be recycled to reduce environmental pollution.
  • an outer coarse filter fiber layer 5 is wound on the outer side of the skeleton fiber layer 4, and the outer coarse filter fiber layer 5 has a filter pore diameter larger than that of the inner fine filter fiber layer 1 and the medium fine filter fiber layer 3, and the outer coarse filter fiber
  • the filter aperture of layer 5 increases in a radial gradient from the inside to the outside.
  • the outer coarse filter fiber layer 5 not only functions as a physical barrier for coarse filtration, but also protects the skeleton fiber layer 4.
  • the inner fine filter fiber layer 1, the middle fine filter fiber layer 3, and the outer coarse filter fiber layer 5 are precisely electronically controlled and wound by providing nozzles and frequency converters with different apertures, and adopting directional and segmented flow guiding technology , so that the shield and filter media can be fully and effectively contacted to ensure 100% filtration, so as to achieve the desired final filtration accuracy and increase the amount of dirt.
  • the filter element is composed of a plurality of layers of fibers 1, 3 and 5, and the filter element has five layers of progressive multi-apertures, respectively intercepting and adsorbing and filtering the mixed shields of different sizes, which not only increases the filtration area. And the amount of dirt, and ensure high filtration precision, good filtration effect and long service life.
  • the adsorptive fibrous layer 2 acts as an adsorption scavenging function, for example, it can filter out the extremely small particles and germs in the filtered medium shield, thereby ensuring that the filtering medium shield is not clean and shieldable.
  • the skeleton fiber layer 4 serves as a support for the skeleton, improves the stiffness and hardness of the filter element, avoids the collapse of the filter element, eliminates the need for a metal mesh, reduces the cost, and improves the economic efficiency of the cycle. Moreover, the various layers of the filter element can be wound and formed at a time by gradient and variable diameter in the whole process, and the production process is simple, and the cost is low.
  • the inner fine filter layer 1, the medium fine filter layer 3 and the outer coarse filter layer 5 may be composed of polyester fibers, or nylon fibers or PP fibers.
  • the inner fine filter fiber layer 1, the middle fine filter fiber layer 3, and the outer coarse filter fiber layer 5 may be formed by hot melt spinning of polyester, nylon, or PP pellets to a predetermined thickness.
  • the adsorptive fibrous layer 2 is composed of carbon fibers or plant fibers, such as cotton fibers, or wood fibers, or coir fibers.
  • the adsorbent fiber layer 2 can be made by using other suitable plant fibers, such as hemp fibers.
  • the adsorptive fibrous layer 2 may be formed by winding high density nanoscale carbon fibers.
  • the skeleton fiber layer 4 may be composed of glass fibers, or polyurethane fibers, or polyhexene fibers. More specifically, the glass fibers are wound into a skeleton fiber to be 4.
  • an active agent may be embedded in the skeleton fiber layer 4 and the outer coarse filter fiber layer 5.
  • the active agent is a mixture of polyene polyamine anion-cation exchange resin particles and zeolite particles in a ratio of 1:1 by weight. The ratio of the weight ratio of the anion exchange resin particles to the cation exchange resin particles is 1:2.
  • the active agent is not limited to being embedded in the skeleton fiber layer 4 and the outer coarse filter fiber layer 5.
  • the oil passing through the respective fiber layers and the active agent are subjected to a physico-chemical action, and the small-molecular alkyl peroxide, sulfide and nitride adsorbed and filtered by the oil during the cooling and cooling are removed by adsorption.
  • the active molecules are slowly introduced into the oil by migration and exchange, and the active molecules consumed by the chemical action of the friction boundary are supplemented, and the non-isotactic polymer compound is added to the oil to prevent the high temperature thinning of the oil, effectively
  • the thickness of the oil film is increased, the wear resistance of the oil is improved, and the service life of the oil is extended.
  • Fig. 3 is a schematic view showing a filter element manufacturing apparatus for carrying out a method of manufacturing a filter element according to an embodiment of the present invention
  • Fig. 4 is a partially enlarged view of the apparatus shown in Fig. 3.
  • the apparatus for manufacturing the filter element sequentially includes a heater 100, an extruder 200, a discharge die 300, a discharge die 301, a receiving device 700, an adsorptive fiber adding device 400, and a skeleton fiber.
  • the device 500 and the cutter 600 are added.
  • the apparatus for manufacturing a filter element includes a discharge die 300 having two discharge dies 301 corresponding to two sets of adsorptive fiber adding devices 400 and a skeleton fiber adding device 500, respectively. And cutter 600. It is to be noted that the apparatus for manufacturing the filter cartridge shown in Figures 3 and 4 can be any suitable manufacturing equipment in the art.
  • the inner fine filter fiber layer 1, the middle fine filter fiber layer 3 and the outer coarse filter fiber layer 5 are made of polyester fiber, and the adsorption fiber is made of carbon fiber, and the skeleton fiber of glass fiber is taken as an example to describe the method for manufacturing the filter element. .
  • polyester pellets are fed from the feed port of the heater 100 to the heater 100, the polyester is melted and then introduced into the extruder 200, and the molten polyester is extruded from the extruder 200 into the discharge die 300, and then from The discharge die 301 ejects the polyester fiber, and the polyester fiber is received by the receiving device 700, whereby the polyester fiber is wound into a cylindrical shape to form the inner fine filter fiber layer 1.
  • the filtration pore size of the inner fine filter fiber layer 1 gradually increases from the inside to the outside.
  • the absorbent fine fiber adding device 400 winds the carbon fibers onto the inner fine filter fiber layer 1 to form the adsorptive fiber layer 2 during the traveling process.
  • the discharge die 301 ejects the polyester fiber and is wound onto the adsorbent fiber layer 2 to form a medium fine filter fiber layer 3.
  • the filter pore diameter of the middle fine filter fiber layer 3 is larger than the filtration pore size of the inner fine filter fiber layer 1 and is fine.
  • the filter pore size of the filter layer 3 gradually increases in a radial direction from the inside to the outside.
  • the skeleton fiber adding device 500 winds the glass fibers onto the medium-fine filter fiber layer 3 to form the skeleton fiber layer 4 during the traveling.
  • the discharge die 301 ejects the polyester fiber to the skeleton fiber 4 to form the outer coarse filter layer 5.
  • the outer coarse filter fiber layer 5 has a filter pore diameter larger than that of the middle fine filter fiber layer 3 and the inner fine filter fiber layer 1, and the filter pore size of the outer filter fiber layer 5 gradually decreases from the inside to the outside in the radial direction. The gradient increases.
  • the cutter 600 cuts the cylindrical filter element into a predetermined length to form a filter element that can be used.
  • the filter element can be continuously manufactured, has a high degree of industrialization, high production efficiency, and adjusts the variable wire diameter and the winding density of the polyester fiber, the carbon fiber, and the glass fiber in the production process.
  • the filter aperture can be easily controlled, i.e., the filtration accuracy of each layer of the filter element is adjusted, and the filtration accuracy of each layer can also vary in the radial direction.
  • different filter aids may be added uniformly during the filament winding, stacking process, depending on the needs of the filtration.
  • an active agent is embedded in the skeleton fiber layer and the outer coarse filter fiber layer, and the active agent is a mixture of polyene polyamine anion-cation exchange resin particles and zeolite particles in a ratio of 1:1 by weight, and anion exchange resin particles. The mixing ratio with the weight of the cation exchange resin particles was 1:2.

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  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Filtering Materials (AREA)

Description

滤芯及其制造方法 技术领域：
本发明涉及一种滤芯及其制造方法， 尤其是涉及一种车用过滤器的滤芯及其制造方法。 背景技术
传统车用过滤器，例如空气滤清器、燃油滤清器和机油滤清器，的滤芯主要有锯末滤芯、 纤维无纺布滤芯、 单一熔喷纤维滤芯、 金属滤网滤芯和纸盾滤芯。
但是， 锯末滤芯透气度小、 阻力大， 当压力大时易破损阻塞通道， 工艺筒单工序繁瑣， 不宜产业化生产。 纤维无纺布滤芯因材料软需附有金属网支撑、 体重， 且工艺繁瑣也不符 合滤芯无金属化发展的要求。 金属网滤芯过滤精度差、 重量大、 成本高。 单一熔喷纤维滤 芯由于由单组分纤维熔融后单一径向缠绕成型， 在高温高压作用下易塌陷变形影响过滤效 果。 广泛使用的纸盾滤芯的孔径单一， 过滤精度低、 纳污量小， 在温度和压力作用时易产 生滤饼效应 , 造成使用寿命短等问题。 发明内容
本发明旨在至少解决现有技术中存在的技术问题之一。
为此， 在本发明的一个方面中， 本发明的一个目的在于提出一种适用范围广、 过滤精度 高、 纳污量大、 具有高挺度、 使用周期长、 能回收循环利用的无金属低碳过滤器滤芯。
在本发明的另一方面中，本发明的另一目的在于提出一种根据本发明第一方面的滤芯的 制造方法。
为了实现上述目的，本发明一个方面的实施例提出一种滤芯，所述滤芯为筒状且沿径向 从内向外依次包括内精滤纤维层、 吸附性纤维层、 中细滤纤维层、 骨架纤维层和外粗滤纤 维层， 其中所述内精滤纤维层、 中细滤纤维层和外粗滤纤维层的过滤孔径沿径向从内向外 渐疏梯度增大。
根据本发明的滤芯， 由多层纤维层复合而成， 内精滤纤维层、 中细滤纤维层和外粗滤纤 维层主要起过滤作用， 且过滤孔径从内向外逐渐增大， 而且滤芯具有五层渐变多孔径， 增 加了过滤面积和纳污量， 过滤精度高、 过滤效果好、 大大延长了使用寿命； 吸附性纤维层 起到吸附作用， 例如能够滤除被过滤介盾中的极小微粒和病菌， 从而保证过滤介盾的洁净 不宜变盾， 提高过滤效果； 骨架纤维层起到骨架支撑作用， 提高了滤芯的挺度和硬度， 避 免了滤芯的塌陷， 无需使用金属网、 降低了成本， 提高了低碳循环经济效益。 根据本发明 实施例的滤芯可以用作空气滤清器、 燃油滤清器和机油滤清器的滤芯。
另外， 根据本发明实施例的滤芯还可以具有如下附加的技术特征：
所述内精滤纤维层、中细滤纤维层和外粗滤纤维层中每一层的过滤孔径沿径向从内向外 渐疏梯度增大。
所述内精滤纤维层、 中细滤纤维层和外粗滤纤维层由聚酯纤维、 或尼龙纤维或 PP纤维 构成。
所述吸附性纤维层由碳纤维或植物纤维构成。
所述骨架纤维层由玻璃纤维、 或聚氨酯纤维、 或聚已烯纤维构成。
所述骨架纤维层与外粗滤纤维层中嵌有活性剂。
所述活性剂为多烯多胺类阴阳离子交换树脂颗粒与沸石颗粒按重量比 1： 1的比例混合 而成， 且阴离子交换树脂颗粒与阳离子交换树脂颗粒的重量混合比例为 1 : 2。
本发明另一方面的实施例提出滤芯的制造方法， 包括以下步骤：
A:将过滤纤维粒料热熔喷丝缠绕成筒状内精滤纤维层；
B:在内精滤纤维层上缠绕吸附性纤维层；
C:在吸附性纤维层上将所述过滤纤维粒料通过热熔喷丝缠绕成中细滤纤维层；
D:在中细滤纤维层上缠绕骨架纤维层；
E:在骨架纤维层上将所述过滤纤维粒料通过热熔喷丝缠绕成外粗滤纤维层， 其中所述内精滤纤维层、中细滤纤维层和外粗滤纤维层的过滤孔径沿径向从内向外渐疏 增大。
根据本发明的滤芯的制造方法，通过将过滤纤维粒料热熔喷丝交织缠绕形成筒状，并且 在熔喷的过程中， 在过滤纤维层中间分别缠绕上吸附纤维和骨架纤维， 因此滤芯的制造筒 单、 能够产业化生产、 效率高， 而且在熔喷缠绕过程中， 通过控制缠绕的丝径和密疏度， 达到人为可控过滤精度。
另外， 根据本发明实施例的滤芯的制造方法还可以具有如下附加的技术特征： 根据本发明的滤芯的制造方法可以进一步包括在骨架纤维层和外粗滤纤维层中嵌入活 性剂。
所述过滤纤维粒料为聚酯纤维、 或尼龙纤维或 PP纤维粒料， 所述吸附性纤维层由碳纤 维或植物纤维构成， 且所述骨架纤维层由玻璃纤维、 或聚氨酯纤维、 或聚已烯纤维构成。
本发明的附加方面和优点将在下面的描述中部分给出， 部分将从下面的描述中变得明 显， 或通过本发明的实践了解到。 附图说明
本发明的上述和 /或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和 容易理解， 其中：
图 1是根据本发明实施例的滤芯的主视剖视示意图；
图 2是图 1所示滤芯的俯视示意图；
图 3是用于制造根据本发明实施例的滤芯的设备的示意图；
图 4是图 3所示用于制造滤芯的设备的局部放大示意图； 和
图 5是根据本发明实施例的制造滤芯的方法的流程示意图。 具体实施方式
下面详细描述本发明的实施例，所述实施例的示例在附图中示出，其中自始至终相同或 类似的标号表示相同或类似的元件或具有相同或类似功能的元件。 下面通过参考附图描述 的实施例是示例性的， 仅用于解释本发明， 而不能理解为对本发明的限制。
在本发明的描述中，需要理解的是，术语"中心"、 "纵向"、 "横向"、 "上"、 "下"、 "前"、 "后"、 "左"、 "右"、 "竖直"、 "水平"、 "顶"、 "底" "内"、 "外" 等指示的方位或位置关系 为基于附图所示的方位或位置关系， 仅是为了便于描述本发明和筒化描述， 而不是指示或 暗示所指的装置或元件必须具有特定的方位、 以特定的方位构造和操作， 因此不能理解为 对本发明的限制。
下面参考附图描述根据本发明实施例的滤芯。在下面的描述中， 以用于车用机油滤清器 的滤芯为例进行描述。 然而， 需要理解的是， 根据本发明实施例的滤芯并不限于用于机油 滤清器， 例如也可以用于空气滤清器或燃油滤清器。
如图 1和图 2所示，根据本发明一个实施例的滤芯为筒状， 例如圆筒状， 且沿径向从内 向外依次包括内精滤纤维层 1、 吸附性纤维层 2、 中细滤纤维层 3、 骨架纤维层 4和外粗滤 纤维层 5 , 其中内精滤纤维层 1、 细过滤纤维层 3和外粗滤纤维层 5的过滤孔径沿径向从内 向外渐疏梯度增大。 换言之， 内精滤纤维层 1的过滤孔径小于中细滤纤维层 3的过滤孔径， 中细滤纤维层 3的过滤孔径小于外粗滤纤维层 5的过滤孔径。 在本发明的一个实施例中， 就内精滤纤维层 1、 中细滤纤维层 3、 和外粗滤纤维层 5中的每个过滤纤维层而言， 过滤孔 径也沿径向从内向外渐疏式增大， 以其独有的 "渐疏式" 内部结构， 内密外疏层层递进的 特别构造， 具有更大纳污能力， 卓越的五层过滤， 将高效吸附与物理拦截过滤完美结合， 由此沿滤芯的径向， 从外向内过滤的杂盾颗粒逐渐减小。
更具体而言， 滤芯的最内层由过滤纤维缠绕成圆筒状， 从而形成内精滤纤维层 1 , 用于 过滤粒度较小的杂盾， 内精滤纤维层 1的过滤孔径沿径向从内向外渐疏梯度增大。
在内精滤纤维层 1上缠绕吸附性纤维层 2 ,例如用高密度纳米级吸附性线型纤维形成吸 附性纤维层 2 , 通过设置吸附性纤维层 2 , 能够滤除被过滤介盾中的病菌， 例如用于空气滤 清器时， 可以吸附滤除空气中的病菌。 在吸附性纤维层 2外面缠绕上中细滤纤维层 3 , 如上 所述， 中细滤纤维层 3的过滤孔径大于内精滤纤维层 1 的过滤孔径， 并且中细滤纤维层 3 的过滤孔径沿径向从内向外渐疏梯度增大。
在中细滤纤维层 3外面缠绕上骨架纤维层 4 , 骨架纤维层 4对整个滤芯起到支撑作用， 加强芯体的挺度和硬度， 避免滤芯在使用中塌陷和变形导致滤芯无法使用， 通过使用骨架 纤维层 4 , 无需使用金属过滤网， 减少了金属的使用， 降低了成本， 并且滤芯可以循环利用， 减少环境污染。
最后， 在骨架纤维层 4的外面缠绕上外粗滤纤维层 5 , 外粗滤纤维层 5的过滤孔径大于 内精滤纤维层 1和中细滤纤维层 3的过滤孔径， 并且外粗滤纤维层 5的过滤孔径沿径向从 内向外渐疏式梯度增大。 外粗滤纤维层 5 不但起到粗滤物理拦截的作用， 而且对骨架纤维 层 4起到保护作用。
由于内精滤纤维层 1、 中细滤纤维层 3、 和外粗滤纤维层 5是通过设置不同孔径的喷头 和变频器而精确电控控制缠绕， 且釆用定向、 分段的导流技术， 令介盾和滤材能充分有效 地接触， 保证 100 %的过滤， 从而达到所需最终的过滤精度并提高纳污量。
才艮据本发明实施例的滤芯， 由多层纤维层 1、 3和 5复合而成， 滤芯具有五层渐变多孔 径， 分别拦截、 吸附过滤大小不一的杂盾， 不但增大了过滤面积和纳污量， 且保证了过滤 精度高、 过滤效果好、 使用周期长。 吸附性纤维层 2 起到吸附清除作用， 例如能够滤除被 过滤介盾中的极小微粒和病菌， 从而保证过滤介盾的洁净不宜变盾。 骨架纤维层 4起到骨 架支撑作用， 提高了滤芯的挺度和硬度， 避免了滤芯的塌陷， 无需使用金属网、 降低了成 本， 提高了循环经济效益。 并且滤芯的各个层可以全过程均以梯度、 变径一次缠绕成型， 生产筒单， 成本低。
在本发明的一些实施例中， 内精滤纤维层 1、 中细滤纤维层 3和外粗滤纤维层 5可以由 聚酯纤维、 或尼龙纤维或 PP纤维构成。 例如， 内精滤纤维层 1、 中细滤纤维层 3和外粗滤 纤维层 5可以由聚酯、 尼龙、 或 PP粒料热熔喷丝缠绕到预定厚度而成。 在本发明的一些实施例中，吸附性纤维层 2由碳纤维或植物纤维构成，所述植物纤维例 如为棉纤维、 或木纤维、 或椰壳纤维， 当然， 本发明并不限于此， 例如也可以釆用其他合 适的植物纤维， 例如麻纤维， 制成吸附性纤维层 2。 在本发明的一个实施例中， 吸附性纤维 层 2可以由高密度纳米级碳纤维缠绕而成。
在本发明的一些实施例中， 骨架纤维层 4可以由玻璃纤维、或聚氨酯纤维、或聚已烯纤 维构成。 更具体地， 用玻璃纤维缠绕成骨架纤维成 4。
为了提高过滤效果，在骨架纤维层 4与外粗滤纤维层 5中可以嵌有活性剂，例如活性剂 为多烯多胺类阴阳离子交换树脂颗粒与沸石颗粒按重量比 1 : 1的比例混合而成， 且阴离子 交换树脂颗粒与阳离子交换树脂颗粒的重量混合比例为 1 : 2。 当然， 活性剂并不限于嵌在 骨架纤维层 4与外粗滤纤维层 5中。
通过嵌入活性剂， 使通过各个纤维层的机油与活性剂发生物理-化学作用， 将机油在润 滑、 冷却时溶解和产生的小分子烷基过氧化物、 硫化物和氮化物吸附过滤清除。 防止因机 油酸化和过氧化物的作用导致的油盾变性和油泥的产生。 同时通过活性剂向机油中緩慢地 以迁移交换的方式引入活性分子， 补充因摩擦边界的化学作用而消耗的活性分子， 向机油 补充非等规高分子化合物， 防止机油的高温稀化， 有效地增加了油膜的厚度， 提高了机油 的抗磨性能， 延长机油使用寿命。
下面参考图 3-5描述根据本发明实施例的滤芯的制造方法。
图 3 示出了用于实施根据本发明一个实施例的滤芯的制造方法的滤芯制造设备的示意 图， 图 4是图 3所示设备的局部放大视图。
如图 3和图 4所示，用于制造滤芯的设备依次包括加热器 100、挤压机 200、出料模 300、 出料模头 301、接收装置 700、吸附性纤维添加装置 400、骨架纤维添加装置 500和切刀 600。 在图 3所示的示例中， 制造滤芯的设备包括出料模 300 , 所述出料模 300具有两个出料模头 301 , 分别对应两套吸附性纤维添加装置 400、 骨架纤维添加装置 500和切刀 600。 需要说 明的是， 图 3和图 4示出的制造滤芯的设备可以是本领域内任何合适的制造设备。
下面以聚酯纤维制成内精滤纤维层 1、 中细滤纤维层 3和外粗滤纤维层 5 , 以碳纤维制 成吸附性纤维， 以玻璃纤维制成骨架纤维为例描述制造滤芯的方法。
首先，将聚酯粒料从加热器 100的加料口加入到加热器 100中，聚酯熔化然后进入挤压 机 200 , 熔融聚酯从挤压机 200挤压到出料模 300内， 接着从出料模头 301喷出聚酯纤维， 聚酯纤维由接收装置 700接收， 从而聚酯纤维缠绕成筒状而形成内精滤纤维层 1。 在一个具 体示例中， 内精滤纤维层 1的过滤孔径从内向外逐渐梯度增大。 在接收装置 700上缠绕成筒状的内精滤纤维层 1在行进的过程中，吸附性纤维添加装置 400将碳纤维缠绕到内精滤纤维层 1上形成吸附性纤维层 2。
接着， 出料模头 301喷出聚酯纤维缠绕到吸附性纤维层 2上形成中细滤纤维层 3 , 中细 滤纤维层 3的过滤孔径大于内精滤纤维层 1的过滤孔径且中细滤纤维层 3的过滤孔径沿径 向从内向外逐渐梯度增大。
形成了中细纤维过滤层 3后，在行进的过程中，骨架纤维添加装置 500将玻璃纤维缠绕 到中细滤纤维层 3上形成骨架纤维层 4。
然后， 出料模头 301喷出聚酯纤维缠绕到骨架纤维成 4上形成外粗滤纤维层 5。 在一个 具体示例中， 外粗滤纤维层 5的过滤孔径大于中细滤纤维层 3和内精滤纤维层 1的过滤孔 径， 且外过滤纤维层 5的过滤孔径沿径向从内向外渐疏梯度增大。
最后， 切刀 600将筒状的滤芯切割成预定的长度， 形成一个个可以使用的滤芯。
根据本发明的制造滤芯的方法， 可以连续地制造滤芯， 工业化程度高， 生产效率高， 且 在生产过程中， 通过调节聚酯纤维、 碳纤维和玻璃纤维的可变丝径、 缠绕密疏度， 可以容 易地控制过滤孔径， 即调节滤芯各层的过滤精度， 并且每层的过滤精度也可以沿径向变化。
在本发明的一些实施例中， 在纤维缠绕、 叠加过程中， 根据过滤的不同需要， 可以均匀 加入不同的助滤活性剂。 例如， 在骨架纤维层和外粗滤纤维层中嵌入活性剂， 活性剂为多 烯多胺类阴阳离子交换树脂颗粒与沸石颗粒按重量比 1 : 1的比例混合而成， 且阴离子交换 树脂颗粒与阳离子交换树脂颗粒的重量混合比例为 1 : 2。
尽管已经示出和描述了本发明的实施例，本领域的普通技术人员可以理解：在不脱离本 发明的原理和宗旨的情况下可以对这些实施例进行多种变化、 修改、 替换和变型， 本发明 的范围由权利要求及其等同物限定。

Claims

权 利 要 求 书
1、 一种滤芯， 其特征在于， 所述滤芯为筒状且沿径向从内向外依次包括内精滤纤维层、 吸附性纤维层、 中细滤纤维层、 骨架纤维层和外粗滤纤维层， 其中所述内精滤纤维层、 中 细滤纤维层和外粗滤纤维层的过滤孔径分别沿径向从内向外渐疏式增大。
2、 根据权利要求 1所述滤芯， 其特征在于， 所述内精滤纤维层、 中细滤纤维层和外粗 滤纤维层中每一层的过滤孔径沿径向从内向外渐疏式梯度增大。
3、 根据权利要求 1所述滤芯， 其特征在于， 所述内精滤纤维层、 中细滤纤维层和外粗 滤纤维层由聚酯纤维、 或尼龙纤维或 PP纤维构成。
4、 根据权利要求 1所述滤芯， 其特征在于， 所述吸附性纤维层由碳纤维或植物纤维构 成。
5、 根据权利要求 1所述滤芯， 其特征在于， 所述骨架纤维层由玻璃纤维、 或聚氨酯纤 维、 或聚已烯纤维构成。
6、 根据权利要求 1所述滤芯， 其特征在于， 所述骨架纤维层与外粗滤纤维层中嵌有活 性剂。
7、 根据权利要求 6所述滤芯， 其特征在于， 所述活性剂为多烯多胺类阴阳离子交换树 脂颗粒与沸石颗粒按重量比 1 : 1的比例混合而成， 且阴离子交换树脂颗粒与阳离子交换树 脂颗粒的重量混合比例为 1 : 2。
8、 一种滤芯的制造方法， 其特征在于， 包括以下步骤：
A:将过滤纤维粒料热熔喷丝缠绕成筒状内精滤纤维层；
B:在内精滤纤维层上缠绕吸附性纤维层；
C:在吸附性纤维层上将所述过滤纤维粒料通过热熔喷丝缠绕成中细滤纤维层；
D:在中细滤纤维层上缠绕骨架纤维层；
E:在骨架纤维层上将所述过滤纤维粒料通过热熔喷丝缠绕成外粗滤纤维层，
其中所述内精滤纤维层、中细滤纤维层和外粗滤纤维层的过滤孔径分别沿径向从内向外 渐疏梯度增大。
9、 根据权利要求 8所述滤芯的制造方法， 其特征在于， 进一步包括在骨架纤维层和外 粗滤纤维层中嵌入活性剂。
10、根据权利要求 8所述滤芯的制造方法，其特征在于，所述过滤纤维粒料为聚酯纤维、 或尼龙纤维或 PP纤维粒料， 所述吸附性纤维层由碳纤维或植物纤维构成， 且所述骨架纤维 层由玻璃纤维、 或聚氨酯纤维、 或聚已烯纤维构成。
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CN116510422A (zh) * 2023-04-17 2023-08-01 山东仁丰特种材料股份有限公司 梯度全合成机油过滤材料及其制备方法
CN117531296A (zh) * 2023-11-23 2024-02-09 江苏舍科科技股份有限公司 一种高效耐污材质的滤芯及其制备方法

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