WO2019097460A1 - 包含多根内置过滤管的无支撑式过滤器及由该过滤器构成的过滤组件 - Google Patents

包含多根内置过滤管的无支撑式过滤器及由该过滤器构成的过滤组件 Download PDF

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Publication number
WO2019097460A1
WO2019097460A1 PCT/IB2018/059024 IB2018059024W WO2019097460A1 WO 2019097460 A1 WO2019097460 A1 WO 2019097460A1 IB 2018059024 W IB2018059024 W IB 2018059024W WO 2019097460 A1 WO2019097460 A1 WO 2019097460A1
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Prior art keywords
filter
unsupported
tubular
fluid
filter media
Prior art date
Application number
PCT/IB2018/059024
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English (en)
French (fr)
Inventor
吴莹旭
Original Assignee
崇鸣投资有限公司
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Application filed by 崇鸣投资有限公司 filed Critical 崇鸣投资有限公司
Publication of WO2019097460A1 publication Critical patent/WO2019097460A1/zh

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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
    • B01D29/31—Self-supporting filtering elements
    • B01D29/33—Self-supporting filtering elements arranged for inward flow filtration
    • 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
    • B01D29/52—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 parallel connection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D35/00—Filtering devices having features not specifically covered by groups B01D24/00 - B01D33/00, or for applications not specifically covered by groups B01D24/00 - B01D33/00; Auxiliary devices for filtration; Filter housing constructions
    • B01D35/30—Filter housing constructions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • 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
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres

Definitions

  • Unsupported filter comprising a plurality of built-in filter tubes and filter assembly comprising the filter
  • the present invention relates to the field of filter technology, and in particular to an unsupported filter comprising a plurality of built-in filter tubes, which generally do not require any supporting structure, are self-supporting and have form retention and A needled nonwoven fabric having good moldability and excellent filterability is molded; and a filter assembly including two or more filters.
  • filters are an important equipment widely used in the chemical, petroleum, coal, pharmaceutical, food and other industries to achieve solid and liquid phase separation as well as solid phase and gas phase separation.
  • Common filters include, for example, a cartridge filter that achieves solid-liquid or solid-gas separation, a High Efficiency particulate air filter (HEPA), and the like.
  • HEPA High Efficiency particulate air filter
  • the cartridge filter includes a cylindrical barrel that is typically made of a filter material or medium. Since existing filter materials or media are generally soft, they need to be installed in the filter by means of support members or structures. However, such a support member or structure on the one hand increases the material cost of the filter and the complexity of the assembly, and on the other hand reduces the filtration performance of the non-woven filter element more or less because of the presence of the support member or structure. It may block the filter material or the medium from coming into contact with the flowing material, or it may accumulate dust or dirt.
  • the cylinder is usually folded into a pleated shape.
  • the height of the pleats should not be too large, otherwise the pleats may collapse or break due to insufficient strength.
  • Chinese Patent Application No. 201580025805.4 proposes a pleated filter cartridge in which a reinforcing structure is provided at the peak of the pleats.
  • a pleated filter cartridge has a complicated structure and high manufacturing and maintenance costs. Therefore, for a cartridge filter of a given size (e.g., a given diameter), the area that is increased by forming a pleated shape in the barrel is always limited.
  • Conventional high efficiency air filters typically include a cubic outer frame, a filter media disposed within the outer frame, and a stack of continuous, forward and backward folded, for example, fiberglass membranes and formed with wavy gaskets for placement and support of the filter media.
  • the filter media of such high efficiency air filters are typically formed into wavy flat sheets. Similarly, since the height of the pleats cannot be too large, measures for increasing the filtration area are limited.
  • Non-woven fabric also known as non-woven fabric, non-woven fabric, is a fabric that does not require spinning and weaving. ⁇ 0 2019/097460 ?01/162018/059024
  • a needle punched nonwoven fabric, a method of producing the same, and a filter formed of the needle punched nonwoven fabric are disclosed.
  • the needle punched nonwoven fabric is made of at least two kinds of short fibers including low-melting short fibers and high-melting short fibers.
  • the invention is characterized in that the low-melting-point fiber layer is a cured material, in particular, has a property of being solidified after being heated and melted, so that the hardness of the needle-punched nonwoven fabric thus formed is sufficient to make the needle-punched nonwoven
  • the cloth is self-supporting and has form retention, and the needle-punched nonwoven fabric has moldability.
  • the needle-punched nonwoven fabric has excellent hardness or rigidity or firmness, excellent moldability, and high compressive strength.
  • the needle weight of the needled nonwoven fabric is generally in the range of 500 to 200 ( ⁇ /111 2 ).
  • Another international patent application filed by the applicant on December 21, 2011? (: 17 ⁇ 011 / 084323 discloses a needle-punched nonwoven fabric, a method of manufacturing the same, and a filter formed from the needle-punched nonwoven fabric.
  • the nonwoven fabric has a single short fiber having the same or close melting point or Made of different kinds of short fibers.
  • the invention is characterized in that about 30-80% of the short fibers are melted and then cured and hardened into a single-melting nonwoven fabric. Also, it has been found through testing that the single-melting needle-punched nonwoven is non-woven.
  • the weight is generally in the range of 250-300 ( ⁇ /111 2 ).
  • needle-punched nonwoven fabric invented by the Applicant has thus far not been known in the prior art to have a high rigidity so that it can be self-supporting, has form retention and moldability, and can be pleated. Needle-punched nonwoven fabric); also not found by needle punched nonwoven fabric A pleated shape filter in which a needle-punched nonwoven fabric can be self-supporting to form a filter medium for a filter without using a support frame
  • the needle punched nonwoven fabric 30 can be molded into a pleated shape.
  • the pleated nonwoven fabric does not require any support frame and has form retention and dimensional stability. Since the above-mentioned needle-punched nonwoven fabric also exhibits excellent filterability, it can be molded into various desired filter elements by a mold, which not only eliminates the support member or structure for supporting the filter element, but also reduces the installation. And the workload of the assembled components greatly reduces labor intensity and reduces operation.
  • the effective filtration area is significantly increased compared to existing filters of the size.
  • Another object of the present invention is to provide an unsupported filter comprising a plurality of built-in filter tubes which are easy to manufacture and low in cost, have no support members inside and outside, and are easy to install and assemble.
  • This gradient configuration allows the filter assembly of the present invention to better filter solid impurities of various sizes without clogging.
  • the present invention provides an unsupported filter, the filter comprising: a brother, a brother, and a brother,
  • the first end and the second end and the plurality of tubular filter media are respectively integrally molded by a needle-punched nonwoven fabric capable of self-supporting and having form retention and moldability, wherein the needle
  • the punctured nonwoven fabric can be molded into a desired shape, and after being molded into a desired shape, can stably maintain the shape of the shape under external pressure in use, so as to be molded by the needle punched nonwoven fabric
  • Each of the tubular filter media made is self-supporting, with no support provided inside or outside, thereby forming an unsupported filter.
  • the unsupported filter of the present invention is suitable for use as a filter medium for gas-solid and liquid-solid separation filters.
  • the filter is a cartridge filter, and the first end and the second end are respectively formed as a first end cover and a second end cover of the cartridge filter, the tube
  • the filter further includes a filter cartridge extending from the first end cap to the second end cap, the filter cartridge being pleated and having a hollow cavity, the filter media array being placed in the In the hollow cavity, wherein the filter cylinder is molded by the needle punched nonwoven fabric to form a self-supporting cylinder, and no support structure is provided.
  • the filter cartridge has an average pore size greater than the average pore size of the tubular filter media.
  • the filter medium array is attached to an inner surface of the first end cap, and the second end cap is provided with an opening corresponding to the number of the plurality of tubular filter media, A plurality of openings are in communication with the plurality of tubular filter media for the filtered fluid to flow out.
  • a space is formed extending upward along the periphery of the end face having the opening to expose a total opening on the end face for the fluid to flow out.
  • the filter media array is attached to the inner surface of the first end cap of the cartridge filter and/or to the second end cap by one of the following methods, or any combination thereof: Adhesive, seam System, heat fusion bonding and plastic ⁇ 0 2019/097460 ?01/162018/059024
  • the filter is a high efficiency air filter (HEPA filter), the high efficiency air filter includes a frame, and the first end and the second end are respectively shaped as a front of the frame On the side and back sides, the array of filter media is placed within the frame, wherein the frame is molded from the needle punched nonwoven into a self-supporting frame without providing any support structure.
  • the filter medium array is attached to an inner surface of a front side of the frame, and a rear side of the frame is provided with an opening corresponding to the number of the plurality of tubular filter media.
  • a plurality of openings are in communication with the plurality of tubular filter media for the filtered fluid to flow out.
  • the front side of the frame is overlapped by a plurality of support strips to form a support end, and the array of filter media is attached to the support end.
  • the filter media array is attached to the inner surface and/or the back side of the front side by one of the following methods, or any combination thereof: adhesive, sewing, and thermal fusion bonding.
  • the filter media array of the present invention further includes a confinement ring having a plurality of through holes corresponding to the number of the plurality of tubular filter media and extending through the confinement ring, the through holes being The size allows the tubular filter medium to pass just to limit the movement of the plurality of tubular filter media in the radial direction.
  • the confinement ring is integrally molded from a needle-punched nonwoven fabric which is self-supporting and has form retention and moldability.
  • the thickness of the selected needle-punched nonwoven fabric is about 0.5 - 2.5 mm, preferably 0.8 - 2.0 mm, more preferably 1.0 - 1.5 mm; the outer diameter of the tubular filter medium is about 1.0 - 3 inches.
  • the height of the crease is about 1 - 2 cm, preferably 1.1 - 1.5 cm.
  • tubular filter media of the present invention can be used in conjunction with activated carbon, such as by coating an activated carbon layer on a tubular filter media or activated carbon as a separate layer.
  • the needle-punched nonwoven fabric used in the present invention can be, for example, a needle-punched nonwoven fabric as disclosed in the International Patent Applications PCT/CN2011/071371 and PCT/CN2011/084323, the entire contents of which are incorporated herein by reference.
  • the needle-punched nonwoven fabric disclosed in the above patent application has excellent hardness, moldability and compressive strength, good good filterability and gas permeability, and is suitable for use in the present invention.
  • Another aspect of the invention relates to a filter assembly comprising two or more unsupported filters of the invention, the two or more unsupported filters being superposed in the direction of flow of the fluid.
  • the filter assembly is configured such that the average pore size of the two or more unsupported filters gradually decreases in the direction of flow of the fluid.
  • a fan is built in the fluid direction of each of the two unsupported filters in the fluid direction of the latter filter to reduce the use of a single high power fan in the large filter assembly. noise.
  • a heater is provided at the fluid inlet of the filter assembly for heating the fluid.
  • the temperature of the heating fluid is 2 - 5 ° higher than the ambient temperature (:.
  • a heater can be used as a heating element.
  • FIG. 1 is a perspective view of a cartridge filter in accordance with a first embodiment of the present invention.
  • Figure 2 is a cross-sectional view taken along line 8 -: 8 of Figure 1.
  • Figure 3 is a cross-sectional view taken along the eight-eight direction of Figure 1.
  • Fig. 4 is a perspective view of a cartridge filter according to a second embodiment of the present invention, which is a modification of the first embodiment of the present invention.
  • Figure 5 is a front perspective view of a high efficiency air filter in accordance with a third embodiment of the present invention.
  • Figure 6 is a rear perspective view of the high efficiency air filter of Figure 5.
  • Figure 7 is a front elevational view of the front side of the high efficiency air filter of Figure 5.
  • Figure 8 is a cross-sectional view taken along line 6 (: (direction).
  • FIG. 9 is a perspective view of a filter assembly in accordance with an embodiment of the present invention.
  • Figure 10 is a perspective exploded view of the filter assembly of Figure 9;
  • Figure 11 is a top perspective view of the first end cap of the intermediate layer filter of the filter assembly of Figure 9.
  • Figure 12 is a top perspective view of the second end cap of the upper filter of the filter assembly of Figure 9.
  • a needle-punched nonwoven fabric can be produced through a specific process, whether it is a short fiber of a single melting point or a short fiber of two melting points or more, and can be referred to the international patent application PCT/CN2011.
  • the entire contents of /071371 and PCT/CN2011/084323 are incorporated herein by reference.
  • the needle-punched nonwoven fabric disclosed in the above application has excellent hardness, rigidity, and firmness in addition to maintaining good filterability, gas permeability, and adsorptivity of the ordinary nonwoven fabric, and can be self-supporting without using a support frame. The compressive strength is very good.
  • the nonwoven fabric is molded into any shape or by a mold. ⁇ 0 2019/097460 ?01/162018/059024
  • the shape or configuration of the molding can be stably maintained, exhibiting excellent moldability and dimensional stability.
  • the needle-punched nonwoven fabric has been widely used in many fields due to its excellent moldability, for example, in the application of a filter device, the nonwoven fabric can be molded into various shapes as needed. Filter component.
  • the present invention is based on the above findings to propose a filter which can significantly increase the filtration area, and can greatly simplify the operation of installation, assembly and maintenance of the filter, wherein the wrinkles on the filter medium of the filter are molded. Formed in a corrugated shape.
  • the various components of the inventive filter are integrally molded by a self-supporting, form-retaining, and moldable nonwoven fabric, such as the needle-punched nonwoven fabric disclosed in the above two patent applications.
  • the filter thus produced not only eliminates the cumbersome steps of installing the support member or structure in the prior art, but also makes the installation process of the filter simpler, and saves the material cost of the filter and the operating cost of the filter. Since the needle punched nonwoven fabric used has dimensional stability, sufficient rigidity, and high compressive strength, the wrinkles molded from the needle punched nonwoven fabric are not easily collapsed.
  • the cartridge filter 100 includes a first end cap 110, a second end cap 120, and a filter media array 130 disposed between the first end cap 110 and the second end cap 120.
  • Two ends of the filter medium array 130 are respectively fixed on the inner surfaces of the first end cover 110 and the second end cover 120, and the fixing method includes using an adhesive, sewing, thermal fusion bonding, plastic-like welding method.
  • the filter media array 130 includes a plurality of filter media 132 in a tubular configuration, the plurality of tubular filter media 132 being generally parallel and perpendicular to the inner surface of the first end cap 110, combined to form a cylindrical shape.
  • the cylindrical array is constructed to replace the existing cartridge filter. In this way, the existing cartridge filter can be replaced with an unsupported filter comprising a plurality of built-in filter tubes without having to modify existing equipment or equipment.
  • the first end cap 110 and the second end cap 120 are made of the above-mentioned needle punched nonwoven fabric and have a ring shape.
  • the first end cap 11 is a closed end cap that closes the open end of all of the tubular filter media 132 at the end of the filter media array 130.
  • the opening of the tubular filter medium 132 that is fixed to the end of the first end cap 110 is closed and attached to the first end cap 110.
  • the second end cap 120 is provided with an opening 122 corresponding to the number of the plurality of tubular filter media 132.
  • the plurality of openings 122 communicate with the plurality of tubular filter media 132, and the fluid is filtered through the tubular filter media 132 and then from the second end.
  • the opening 122 of the cover 120 flows out.
  • Figure 2 is a cross-sectional view taken along line 8 -: 8 of Figure 1. As shown, a portion of the end surface 126 along which the opening 122 is located extends upwardly a certain height 11 to form a space that exposes all of the openings 122 in the end surface 126 for ⁇ 0 2019/097460 ?01/162018/059024
  • the fluid flows out of the second end cap 120.
  • each tubular filter medium 132 is pleated to form a pleated shape 134.
  • the tubular body of the tubular filter medium 132 is formed into a pleated shape 134 by press molding.
  • the filter is formed by a combination of a plurality of tubular filter media 132, and the tubular body of each tubular filter media 132 has pleats 134.
  • the filter thus formed has a filter area that is significantly increased compared to existing cartridge filter media. Big, the filtering effect is superior.
  • each tubular filter media 132 is self-supporting and does not require any support members or frames inside and outside. This saves the material cost of the filter and the operating cost of replacing the filter, and the pleats molded according to the present invention are less likely to collapse, thereby maintaining the filtration area of the cartridge filter.
  • a film polytetrafluoroethylene film; or an acrylic coating to increase the smoothness of the nonwoven fabric. This facilitates dust detachment and cleaning attached to the filter cartridge.
  • the thickness of the selected needle-punched nonwoven fabric is about 0.5 - 2.5111111, preferably 0.8 - 2.0111111, more preferably 1.0 - 1.5111111;
  • the tubular filter medium 132 has an outer diameter of about 1.0 - 3 inches, preferably 1.0 - 1.5. Inches;
  • the height of the pleats 134 is about 1 - 2 ⁇ 111, preferably 1.1
  • the outer diameter of the tubular filter media 132 refers to the diameter ⁇ of the circle defined by the peaks of the pleats of the tubular filter media (see Figure 3).
  • the filter media array 130 further includes a confinement ring 136 in order to limit the radial displacement of the plurality of tubular filter media by the radial impact of the fluid.
  • the restriction ring 136 is provided with a plurality of through holes 135 corresponding to the number of the plurality of tubular filter media and extending through the restriction ring 136.
  • the size of the through hole 135 allows the tubular filter medium 132 to pass therethrough, thereby limiting the movement of the plurality of tubular filter media 132 in the radial direction.
  • the restricting ring 136 is integrally molded by the same needle-punched nonwoven fabric which is self-supporting and has form retention and moldability, and the through hole 135 of the restricting ring 136 is die-cut.
  • the press-formed pleated tubular filter medium 132 can stably maintain the pleated shape and the tubular shape without relying on any supporting structure.
  • the first end cap 110 and the second end cap 120 are also molded from the needle punched nonwoven fabric.
  • the cartridge filter of the present invention eliminates the need to manufacture and mount support members or frames, while greatly increasing the filtration area.
  • the cartridge filter of the present invention has been tested to increase the filtration area by about 70% to 3 times compared to prior art cartridge filter media of the same size. As the filter area increases, the size of the filter can be reduced, reducing the space occupied by the filter. ⁇ 0 2019/097460 ?01/162018/059024
  • Fig. 4 shows a cartridge filter 200 made in accordance with a second embodiment of the present invention, which is a variation of the cartridge filter shown in Figs. For simplicity and clarity, Figure 4 does not show the second end cap.
  • the cartridge filter 200 includes a first end cap 210, a second end cap (omitted for clearly showing the internal structure), and the first in the same manner as the cartridge filter 100 of the first embodiment described above.
  • the structure, manufacture, and function of the first end cover 210, the second end cover, and the filter media array 230 are substantially the same as those of the first embodiment. For reference, refer to the related description of the first embodiment, and no further details are provided herein.
  • the cartridge filter 200 of the present embodiment is different from the cartridge filter 100 of the first embodiment in that it further includes a filter cartridge 240 extending from the first end cap 210 to the second end cap.
  • the filter cartridge 240 is also formed in a pleated shape, and is surrounded by a periphery of the first end cap 210 and the second end cap to form a hollow cavity, and the filter medium array 230 is placed in the hollow cavity of the filter cartridge 240.
  • the filter cartridge 240 is molded from the same needle-punched nonwoven as discussed above into a self-supporting cylinder without providing any support structure.
  • the first end cap 210 is also formed as a closed end cap that closes the open end of all of the tubular filter media 232 at the end of the filter media array 230 and the open end of the filter cartridge 240.
  • the opening of the end of the tubular filter medium fixed to the first end cap 210 and the open end of the filter cartridge 240 are closed and attached to the first end cap 210.
  • the second end cap encloses the other open end of the filter cartridge 240, and is provided with only openings corresponding to the number of the plurality of tubular filter media 232 and communicating with the plurality of tubular filter media 232 such that the fluid passes through the filter cartridge 240 Thereafter, it is filtered through the tubular filter medium 132 to flow out from the opening of the second end cap that communicates with the tubular filter medium 232.
  • the periphery of the open end face of the second end cap extends upwardly to a certain height to form a space exposing all of the openings in the end face for the fluid to flow out of the second end cap.
  • the average diameter of the filter cartridge 240 is greater than the average pore size of each tubular filter media 232 to effect fractional filtration of the fluid.
  • the larger particle size solids contained in the fluid are blocked from the filter cartridge 240, and the smaller particle size solids can pass through the filter cartridge 240 and be trapped on the surface of the tubular filter media 232.
  • the larger particle size solids have been blocked from the filter cartridge 240 and do not block the tubular filter media 232.
  • the high efficiency air filter 300 includes a frame having a quadrangular cross section, the frame being composed of a front side 311, a rear side 312, a left side 313, a right side 314, an upper side 315, and a lower side 316, the front side 311 and the rear side 312 defining the filter 300 depth.
  • the high efficiency air filter 300 also includes a filter media array 330 that follows the shape of the frame in a square shape.
  • the filter media array 330 of the present embodiment includes a plurality of tubular filter media 332 that are generally parallel and perpendicular to the front side 311 and the back side 312. All tubular filter media ⁇ 0 2019/097460 ?01/162018/059024
  • the opening of the end fixed to the front side 311 is closed, and is attached to the support bar 3112 of the front side 311.
  • the entire filter media array 330 is placed along the depth of the filter 300 between the front side 311 and the back side 312 of the frame to form the filter media of the filter 300.
  • the structure, manufacture, and function of the filter media array 330 in the form of a cube can be referred to the cylindrical filter media array 130 of the first embodiment described above, and will not be described herein.
  • the frame is molded from the same needled nonwoven as discussed above into a self-supporting frame without providing any support structure.
  • a frame body composed of a left side 313, a right side 314, an upper side 315, and a lower side 316 of the frame is integrally molded by using a needle punched nonwoven fabric, and molded by the same needle punched nonwoven fabric.
  • the front side 311 of the frame i.e., the inlet end of the fluid
  • the front side 311 of the frame is formed by a plurality of support strips 3112 molded by needle punched nonwoven fabric which are alternately joined to support end faces, and the tubular filter medium 332 is fixed and supported on the support end faces.
  • the rear side 312 of the frame (i.e., the outlet end of the fluid) is provided with an opening 3122 corresponding to the number of tubular filter media 332 that communicates with the plurality of tubular filter media 332.
  • the fluid flows in the direction of the arrow shown in Fig. 5, is filtered by the tubular filter medium 332, and then flows out from the opening 3122 of the rear side 312 in the direction of the arrow shown in Fig. 6.
  • the fixing of the tubular filter medium 332 to the front side 311 and the rear side 312 of the frame, and the fixing of the front side 311 and the rear side 312 of the frame to the frame body, adhesives and seams can be used. Preparation, thermal dissolution bonding, plastic welding or any other suitable method.
  • the thickness of the selected needle-punched nonwoven fabric is about 0.5 - 2.5 mm, preferably 0.8 - 2.0 mm, more preferably 1.0 - 1.5 mm; the outer diameter of the tubular filter medium 332 is about 1.0 - 3 inches, preferably 1.0 - 1.5 inches; the height of the pleats 134 is about 1 - 2 cm, preferably 1.1 - 1.5 cm.
  • Conventional high efficiency air filters typically include a frame and a folded filter paper placed therein.
  • the existing method is to form a dividing strip made of paper or cotton thread in the formed crease inner space to support the space of the filter material crease, and the dynamic folding paper filter is easily deformed to affect the air flow passage. Reduce the filtering effect.
  • the high efficiency air filter 300 of the present invention replaces the folded filter paper with an array of a plurality of tubular filter media 332 made of needle-punched nonwoven fabric and having pleats, which not only increases the filtration area, but also eliminates the conventional high efficiency air filtration.
  • the processing required to handle the folded filter paper greatly reduces labor and reduces the cost of handling, mounting and folding filter paper.
  • the high efficiency air filter 300 of the present invention also avoids deformation of the folded filter paper and affects the filtering effect.
  • the filter assembly 400 includes three unsupported cartridge filters as described in the second embodiment above, the construction of which can be referred to the description of the first and second embodiments above.
  • the three cartridge filters include a lower filter 201, an intermediate filter 202, and an upper filter 203 which are stacked in the flow direction of the fluid, and in the present embodiment, the fluid flows from the bottom to the top.
  • the average pore size of the lower filter 201, the intermediate filter 202, and the upper filter 203 is gradually decreased, that is, the average pore diameter of the lower filter 201 is larger than the average pore diameter of the intermediate filter 202, and the average pore diameter of the intermediate filter 202 is higher than that of the upper filter 203.
  • the average aperture is large. The gradual decreasing configuration of the pore size of the pores enables stratified filtration of the fluid, which can achieve better filtration effect and does not easily block the filter pores.
  • the second end cover of the lower filter 201 and the intermediate filter 202 is provided with a space for fluid to flow from the outlet end of the lower filter 201 to the inlet end of the intermediate filter 202, and from the outlet end of the intermediate layer filter 202 to the upper layer.
  • the inlet end of the filter 203 can be formed in the manner described with reference to the first embodiment above.
  • the tubular filter medium is fixedly connected to the end surface of the second end cover of the lower filter 201, and the circular periphery of the end surface of the second end cover extends upward to a certain height to form the second end cover of the lower filter 201.
  • the end face defines a space with the fluid inlet end of the intermediate filter 202.
  • the second end cap of the intermediate filter 202 has a similar construction defining a space with the fluid inlet end of the upper interlayer filter 203.
  • a power fan 500 is respectively disposed at the fluid inlet end of the intermediate filter 202 and the upper filter 203 and the fluid outlet end of the upper filter 203 to replace a large one set in the existing filter. Power fan, as shown in Figure 10.
  • the fan 500 can be attached to each layer of the filter by various methods known in the art, such as screwing or snapping connections and the like.
  • connection of the two adjacent filters in the lower filter 201, the intermediate filter 202 and the upper filter 203 can also be performed by using an adhesive or a slit. System, hot melt bonding, plastic-like soldering or any other suitable method, such as snap-fit connections.
  • a plurality of through holes 2014 are formed in the second end cap 2012 of the lower filter 201, and the through holes 2014 communicate with the outlet of the tubular filter medium.
  • a fan holder 502 is disposed between the lower filter 201 and the intermediate filter 202, and the lower neck 503 of the fan holder 502 and the second end cap 2012 of the lower filter 201 are fixedly connected by the method listed above, and the fan is maintained
  • the upper neck 504 of the 502 is fixedly coupled to the first end cap 2021 of the intermediate filter 202 by the methods set forth above.
  • FIG. 10 also shows that at the inlet of the filter assembly, that is, the inner surface of the inlet end surface of the lower filter 201 is provided with a heater 600 for heating the fluid, and the filter assembly is reinforced by the principle of hot air rising and cold air sinking. Convection of internal air to improve filtration efficiency.
  • the heater 600 can be electrically heated, directly bonded ⁇ 0 2019/097460 ?01/162018/059024
  • the fluid is heated to a temperature 2 - 5 ° above ambient temperature (:.
  • This embodiment discusses a filter assembly constructed by stacking cartridge filters, and those skilled in the art will appreciate that filter assemblies constructed from other shapes of filter stacks are also possible.
  • the high efficiency air filter of the third embodiment is superposed in the horizontal direction to form a filter assembly in the flow direction of the fluid.
  • the needle-punched nonwoven fabric Since the selected needle-punched nonwoven fabric has the characteristics of light weight, high hardness, high strength, easy molding and form retention, the needle-punched nonwoven fabric having such characteristics is molded into a filter medium and various kinds of materials.
  • the filter parts not only maintain their molded shape, provide sufficient pressure resistance, but also greatly simplify the installation and replacement of the filter, which is more beneficial to reduce labor intensity and save operating costs.
  • the unsupported filter of the present invention comprising a plurality of built-in filter tubes and a filter assembly comprising the filter are described above in a preferred embodiment.
  • a person skilled in the art can make various modifications and/or modifications of the invention in accordance with the teachings in the specification. These modifications and/or modifications are intended to be included within the scope of the appended claims.

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Abstract

一种支撑式过滤器（100），所述过滤器（100）包括第一端（110）、第二端（120）以及置于其间的过滤介质阵列（130）；所述过滤介质阵列（130）包括大致平行排列且垂直于两端的多个呈管状构造的过滤介质（132），该管状过滤介质（132）的管体做成褶皱形状；第一端（110）和第二端（120）以及多个管状过滤介质（132）分别由能够自支撑而具有形态保持性并且具有可模制成型性的针刺无纺布一体模压制成，每个所述管状过滤介质（132）是自支撑的，其内外无需提供支撑体。

Description

\¥0 2019/097460 ?01/162018/059024
包含多根内置过滤管的无支撑式过滤器及由该过滤器构成的过滤组件 技术领域
本发明涉及过滤器技术领域， 具体地说， 涉及一种包含多根内置滤管的无支撑 式过滤器， 所述过滤器总体上不需要任何支撑结构， 由能够自支撑而具有形态保持 性并且具有良好可模制成型性和优异过滤性的针刺无纺布模压形成； 以及涉及包括 两个或以上过滤器的过滤组件。 发明背景
众所周知， 过滤器是一种广泛地使用于化工、 石油、 煤矿、 制药、 食品等行业 实现固相和液相分离以及固相和气相分离的重要设备。 常见的过滤器例如包括实现 固液或固气分离的筒式过滤器、高效空气过滤器（High efficiency particulate air Filter, HEPA）等等。
筒式过滤器包括有一个圆筒形筒体，该筒体通常由一种过滤材料或者介质制成。 由于现有的过滤材料或者介质通常较软， 需要借助于支撑构件或者结构才可以安装 在过滤器中。 但是这种支撑构件或者结构一方面增大了过滤器的材料成本和组装的 复杂程度， 另一方面也或多或少地降低了无纺布过滤元件的过滤性能， 因为支撑构 件或者结构的存在可能会阻挡过滤材料或者介质与流过的物质接触， 或者可能会积 聚灰尘或污物。 更换这些常规的筒式过滤器涉及庞大的人力和时间， 不但需要对固 定支撑构件或者结构的紧固件（例如紧固螺栓和螺母， 或者卡箍带）进行手动操作， 繁琐耗时， 劳动强度大， 而且成本增加， 生产周期延长。
此外， 为了增大筒式过滤器的过滤面积， 通常将筒体折叠成具有褶皱形状。 但 是褶皱的高度不能太大， 否则褶皱由于强度不足容易塌陷或破损。 例如， 中国专利 申请号 201580025805.4提出了一种褶皱式滤筒， 在褶皱的峰部设置了加强结构。 但 是这样的褶皱式滤筒结构复杂， 制造和维护成本高。 因此， 对于给定尺寸 （例如给 定直径） 的筒式过滤器， 通过在筒体形成褶皱形状而增大的面积始终有限。
常规的高效空气过滤器通常包括立方体形外框、 置于外框内的过滤介质和一叠 连续前后折叠的例如玻璃纤维膜构成并形成波浪状垫片用来放置和支撑过滤介质。 这种高效空气过滤器的过滤介质一般做成波浪状的扁平薄片。 同样地， 因为褶皱的 高度不能太大， 故可增大过滤面积的措施也有限。
无纺布， 也称为不织布、 非织造布， 是一种不需要纺纱织布而形成的织物， 它 \¥0 2019/097460 ?01/162018/059024
具有良好的过滤性、 透气性和吸附性， 非常适合用作过滤器的过滤介质。
申请人于
Figure imgf000004_0001
公开了一 种针刺无纺布及其制造方法以及由该针刺无纺布形成的过滤器。 所述针刺无纺布由 包括低熔点短纤维和高熔点短纤维的至少两种短纤维制成。 该发明的特征在于， 所 述低熔点纤维层是固化的材料， 尤其是具有在被加热熔融之后可以固化的性质， 以 致于由此形成的针刺无纺布的硬度足以使该针刺无纺布能够自支撑而具有形态保持 性， 并且所述针刺无纺布具有可模制成型性。 因此， 除了保持普遍无纺布的过滤性、 透气性和吸附性等特性之外， 该针刺无纺布还具有优异的硬度或刚度或坚挺度， 卓 越的成型性， 并且抗压强度非常高。 所述针刺的无纺布的克重一般在 500-200（^/1112 范围内。
申请人于 2011年 12月 21 日提交的另一份国际专利申请？（：17匸 011/084323 公开了一种针刺无纺布及其制造方法以及由该针刺无纺布形成的过滤器。 所述无纺 布由熔点相同或接近的单独一种短纤维或者不同种类的短纤维制成。 该发明的特征 在于， 大约 30-80%的短纤维熔化， 然后使其固化硬化成为单熔点无纺布。 同样， 经 测试发现， 所述单熔点针刺无纺布除了保持普遍无纺布的过滤性、 透气性和吸附性 之外， 它的硬度仍然足以使该无纺布能够自支撑而具有形态保持性， 具有高的刚度 或坚挺度和可模制成型性， 并且克重一般在 250-300（^/1112范围内。
申请人发明的上述针刺无纺布因此，迄今为止，现有技术中还没有公幵一种刚 度较高以使其能够自支撑而具有形态保持性和模制成型性，并且能够打褶的针刺无 纺布 ）；也没有发现由针刺无纺布
Figure imgf000004_0002
做成的褶皱形状过滤器，其中针刺无纺布 可以自支撑而形成过滤器的过滤介质，不需使用支撑框架
利用上述针刺无纺布的独有特性， 尤其是它能够自支撑而具有形态保持性、 良 好可模制成型性， 可以将该针刺无纺布 ^30模制成褶皱形状， 所得到的褶皱无纺布 不需使用任何支撑框架且具有形态保持性和尺寸稳定性。 因为上述针刺无纺布还表 现出优异的过滤性， 可以通过模具将它模制成各种所希望的过滤元件， 不但省去了 用于支承过滤元件的支撑构件或者结构， 而且减轻了安装和组装元件的工作量， 大 大降低了劳动强度和减少了操作。
发明内容
本发明的一个目的是提供一种包含多根内置滤管的无支撑式过滤器， 其与相同 \¥0 2019/097460 ?01/162018/059024
尺寸的现有过滤器相比， 有效的过滤面积明显增大。
本发明的另一个目的是提供一种包含多根内置滤管的无支撑式过滤器， 它易于 制造且成本较低， 其内外没有提供支承件， 安装和组装过程十分简易。
本发明的再一个目的是提供一种多层过滤组件， 由上述无支撑式过滤器层叠构 成， 各层过滤器的孔径不同， 在流体流动方向形成梯度排列而逐渐递减， 实现某种 程度的深度过滤。 这种梯度构造使得本发明的过滤组件能够更好地过滤各种尺寸的 固体杂质而不容易发生堵塞。
为了实现上述目的， 本发明提供了一种无支撑式过滤器， 所述过滤器包括： 弟一¾和弟一¾，
置于所述第一端和所述第二端之间的过滤介质阵列， 所述过滤介质阵列附于所 述第一端的内表面上， 包括多个呈管状构造的过滤介质， 所述多个管状过滤介质大 致平行排列且垂直于所述第一端的内表面， 并且其管体做成褶皱形状；
所述第一端和第二端以及所述多个管状过滤介质分别由能够自支撑而具有形态 保持性并且具有可模制成型性的针刺无纺布一体模压制成， 其中所述针刺无纺布能 够被模压成所需的形状， 且在模压成所需的形状后在使用中能够在外部压力下稳定 地保持所述形状的形态， 以致于由所述针刺无纺布模压制成的每个所述管状过滤介 质是自支撑的， 其内外没有提供支承件， 从而形成无支撑式过滤器。
本发明的无支撑式过滤器适合用作气一固和液一固分离过滤器的过滤介质。 在 本发明一实施例中， 所述过滤器是筒式过滤器， 所述第一端和第二端分别成形为所 述筒式过滤器的第一端盖和第二端盖， 所述筒式过滤器还包括从所述第一端盖延伸 至所述第二端盖的过滤筒体， 所述过滤筒体做成褶皱形状并且具有中空腔体， 所述 过滤介质阵列被放置在所述中空腔体内， 其中所述过滤筒体由所述针刺无纺布模压 制成自支撑的筒体， 没有提供任何支承结构。 较佳地， 所述过滤筒体的平均孔径大 于所述管状过滤介质的平均孔径。
在所述筒式过滤器中， 所述过滤介质阵列附连在所述第一端盖的内表面上， 所 述第二端盖设有与所述多个管状过滤介质数量对应的开口， 所述多个开口与所述多 个管状过滤介质相通， 以供过滤后的流体流出。
在所述筒式过滤器的第二端盖上， 沿着具有所述开口的端面的周边向上延伸一 定的高度形成空间， 露出所述端面上的全部开口， 以供所述流体流出。
根据本发明， 所述过滤介质阵列通过如下方法之一或其任意组合附连在所述筒 式过滤器的第一端盖的内表面上和 /或第二端盖上： 粘胶剂、 缝制、 热熔解结合和塑 \¥0 2019/097460 ?01/162018/059024
料焊接 (plastic welding)。
在本发明另一实施例中， 所述过滤器是高效空气过滤器 (HEPA过滤器)， 所述 高效空气过滤器包括框架，所述第一端和第二端分别成形为所述框架的前侧和后侧， 所述过滤介质阵列被放置在所述框架内， 其中所述框架由所述针刺无纺布模压制成 自支撑的框架， 没有提供任何支承结构。 在所述高效空气过滤器中， 所述过滤介质 阵列附连在所述框架的前侧的内表面上， 所述框架的后侧设有与所述多个管状过滤 介质数量对应的开口， 所述多个开口与所述多个管状过滤介质相通， 以供过滤后的 流体流出。 在一些实施例中， 所述框架的前侧由多根支撑条搭接而成支撑端， 所述 过滤介质阵列附连在所述支撑端上。
在高效空气过滤器中， 所述过滤介质阵列通过如下方法之一或其任意组合附连 在所述前侧的内表面上和 /或后侧上： 粘胶剂、 缝制和热熔解结合。
在一些情况下， 本发明的过滤介质阵列还包括限制环， 所述限制环上设有与所 述多个管状过滤介质的数量对应的且贯穿限制环的多个通孔， 所述通孔的尺寸允许 所述管状过滤介质刚好通过， 用于限制所述多个管状过滤介质在径向上的移动。 较 佳地， 所述限制环由能够自支撑而具有形态保持性并且具有可模制成型性的针刺无 纺布一体模压制成。
在本发明的优选实施例中，选用的针刺无纺布的厚度约是 0.5 - 2.5mm，优选 0.8 - 2.0mm,更优选 1.0 - 1.5mm；管状过滤介质的外直径约是 1.0 - 3英寸，优选 1.0 - 1.5 英寸； 摺皱的高度约是 1 - 2cm, 优选 1.1 - 1.5cm。
本发明的管状过滤介质可以与活性炭联用， 例如在管状过滤介质上涂敷活性炭 层或者活性炭以分离的层提供。
本发明使用的针刺无纺布例如可以采用国际专利申请 PCT/CN2011/071371 和 PCT/CN2011/084323所公开的针刺无纺布， 此处纳入其全部内容作为参考。 上述专 利申请公开的针刺无纺布均具有具有优异的硬度、 可模制成型性和抗压强度、 良好 的良好的过滤性和透气性， 适合用于本发明。
本发明另一方面涉及一种过滤组件， 所述过滤组件包括两个或以上本发明的无 支撑式过滤器， 所述两个或以上无支撑式过滤器沿流体的流动方向叠加而成。 较佳 地， 过滤组件被构造成所述两个或以上无支撑式过滤器的平均孔径沿流体的流动方 向逐渐减少。
在过滤组件中相邻的两个无支撑式过滤器中邻接的两端留有空间， 以供所述流 体从所述两个过滤器中之一流入另一个过滤器。 \¥0 2019/097460 ?01/162018/059024
在一些具体实施例中， 在相邻的每两个无支撑式过滤器中沿流体方向上较后一 个过滤器的流体入口端部内置风机， 以减少大型过滤组件中采用单个大功率风机造 成的噪音。
在另一些具体实施例中， 在所述过滤组件的流体入口处设有加热器， 用于加热 所述流体。 一般的， 加热流体的温度比环境温度高 2 - 5°（:。 加热器例如可选用电热 丝作为加热元件。 附图说明
图 1是根据本发明第一实施例的筒式过滤器的立体图。
图 2是沿图 1中：8-：8方向看的截面图。
图 3是沿图 1中八-八方向看的截面图。
图 4是根据本发明第二实施例的筒式过滤器的立体图， 该筒式过滤器是本发明 第一实施例的一个变型。
图 5是根据本发明第三实施例的高效空气过滤器的前侧立体图。
图 6是根据图 5的高效空气过滤器的后侧立体图。
图 7是根据图 5的高效空气过滤器的前侧的正视图。
图 8是沿图 6中（：（方向看的截面图。
图 9是根据本发明一实施例的过滤组件的立体图。
图 10是图 9的过滤组件的立体图立体分解图
图 11是图 9的过滤组件的中间层过滤器的第一端盖的俯视立体图。
图 12是图 9的过滤组件的上层过滤器的第二端盖的顶视立体图。
附图中相同的部件以相同的附图标记来表示。 具体实施方式
本发明人惊奇地发现， 无论是以单一熔点的短纤维， 还是以两种熔点或以上的 短纤维作为原料， 经过特定的工序可以制成针刺无纺布， 可参阅国际专利申请 PCT/CN2011/071371和 PCT/CN2011/084323的全部内容， 在此引入作为参考。 上述 申请公开的针刺无纺布除了保持普通无纺布的良好的过滤性、透气性和吸附性之外， 还具有优异的硬度或刚度或坚挺度， 可以自支撑而不需使用支撑框架， 抗压强度非 常尚。
上述针刺无纺布的另一个重要特征是， 该无纺布在经过模具模压成任何形状或 \¥0 2019/097460 ?01/162018/059024
构造之后， 能够稳定地保持该模压的形状或构造， 表现出卓越的成型性和尺寸稳定 性。 由于具有非常好的模制成型性，所述针刺无纺布在许多领域都获得广泛的应用， 例如在过滤设备的应用上， 所述无纺布可以根据需要模制成各种不同形状的过滤器 部件。
本发明正是基于上述发现提出一种可以显著地增大过滤面积的过滤器， 并且可 以大大地简化过滤器的安装、 组装和维修等操作， 其中所述过滤器的过滤介质上的 褶皱通过模压形成波纹状。 组成本发明过滤器的各个部件由能够自支撑而具有形态 保持性并且具有可模制成型性的无纺布（例如上述两个专利申请公开的针刺无纺布） 分别一体模压制成。 由此制成的过滤器不但能够省却现有技术中安装支撑构件或者 结构的繁琐步骤， 使过滤器的安装过程更简单， 而且节约了过滤器的材料成本和更 换过滤器的操作成本。 因为所使用的针刺无纺布具有尺寸稳定性、 足够的刚度 和高的抗压强度， 所以由该针刺无纺布模制而成的褶皱不容易塌陷。
现在参看图 1至图 3 ,图中示出了根据本发明第一实施例制成的筒式过滤器 100, 该过滤器 100 的全部零部件均使用国际专利申请 PCT/CN2011/071371 或
Figure imgf000008_0001
所公开的针刺无纺布制成。 如图 1所示， 筒式过滤器 100包括 第一端盖 110、 第二端盖 120以及置于第一端盖 110和第二端盖 120之间的过滤介 质阵列 130。 过滤介质阵列 130的两端分别固定在第一端盖 110和第二端盖 120的 内表面上， 固定的方法包括使用粘胶剂、 缝制、 热熔解结合、 类塑料焊接法
Figure imgf000008_0002
或其他任何合适的方法。 过滤介质阵列 130包括多个呈管状构造的过滤介 质 132, 所述多个管状过滤介质 132大致平行排列且垂直于第一端盖 110的内表面， 组合围绕成一个圆柱形。所述圆柱形阵列被构成它的尺寸能替换现有的筒式过滤器。 这样， 不必对已有的装置或设备进行改动， 即可将现有的筒式过滤器替换成本发明 的包含多根内置过滤管的无支撑式过滤器。
第一端盖 110和第二端盖 120由上述提到的针刺无纺布制成， 呈环形。 第一端 盖 11〇是封闭端盖， 把过滤介质阵列 130—端的所有管状过滤介质 132的开口端封 闭。 或者， 所有管状过滤介质 132中固定于第一端盖 110的那一端的开口封闭， 再 附连固定于第一端盖 110。 第二端盖 120上设有与多个管状过滤介质 132的数量对 应的开口 122, 所述多个开口 122与多个管状过滤介质 132相通， 流体经管状过滤 介质 132过滤后再从第二端盖 120的开口 122流出。
图 2是沿图 1中：8-：8方向看的截面图。 如图所示， 沿开口 122所在的端面 126 的周边向上延伸一定的高度 11， 形成一空间， 露出端面 126上的全部开口 122, 以供 \¥0 2019/097460 ?01/162018/059024
所述流体流出第二端盖 120。
从图 3所示的截面图清晰可见， 每个管状过滤介质 132的管体作打褶处理， 形 成褶皱形状 134。 具体地， 通过模压成型使管状过滤介质 132的管体形成褶皱形状 134。 由多个管状过滤介质 132组合形成过滤器，再加上每个管状过滤介质 132的管 体具有褶皱 134, 这样形成的过滤器具有的过滤面积与现有的筒式过滤介质相比显 著地增大了， 过滤效果更优越。 此外， 每个管状过滤介质 132是自支撑的， 其内外 不需任何支撑构件或框架。 这节约了过滤器的材料成本和更换过滤器的操作成本， 而且根据本发明模制成的褶皱不容易塌陷， 因此能够维持筒式过滤器的过滤面积。
作为一种选择， 可以在制造过滤器的针刺无纺布表面上施加
Figure imgf000009_0001
膜（聚四氟乙 烯膜；或者丙烯酸涂层， 以增大无纺布的光滑度。 这样有利于附着在过滤筒体上的粉 尘脱落和清洁。
在本实施例中， 选用的针刺无纺布的厚度约是 0.5 - 2.5111111， 优选 0.8 - 2.0111111， 更优选 1.0 - 1.5111111; 管状过滤介质 132的外直径约是 1.0 - 3英寸， 优选 1.0 - 1.5英 寸； 褶皱 134的高度约是 1 - 2〇111, 优选 1.1
Figure imgf000009_0002
管状过滤介质 132的外直径指 的是管状过滤介质的褶皱的峰部所限定的圆的直径〇 （见图 3所示）。
当管状过滤介质 132的长度较长时， 为了限制所述多个管状过滤介质受流体的 径向冲击影响在径向上发生位移， 过滤介质阵列 130还包括限制环 136。 如图 1所 示，所述限制环 136上设有与所述多个管状过滤介质的数量对应的且贯穿限制环 136 的多个通孔 135。 通孔 135的尺寸允许管状过滤介质 132刚好通过， 籍此限制所述 多个管状过滤介质 132在径向上的移动。 根据本发明， 限制环 136由能够自支撑而 具有形态保持性并且具有可模制成型性的同一种针刺无纺布一体模压制成， 限制环 136上的通孔 135模切而成。
由于选用的针刺无纺布具有优异的硬度和模制成型性， 所以模压成型的具有褶 皱的管状过滤介质 132不必依靠任何支撑结构就能够稳定地保持褶皱形状和管状形 态。 安装时， 只需要将各个管状过滤介质 132按照所希望的阵列形式排列好， 再通 过合适的固定方法， 例如粘胶剂或类塑料焊接法， 把各个管状过滤介质 132的两端 管口固定在同样由针刺无纺布模制而成的第一端盖 110和第二端盖 120上。
由此可见， 本发明的筒式过滤器省却了制造和安装支撑构件或框架等操作， 同 时大大增大了过滤面积。 经测试， 本发明的筒式过滤器与相同尺寸的现有筒式过滤 介质相比， 其过滤面积增大约 70%至 3倍。 由于过滤面积增大， 过滤器的尺寸可以 缩小， 减少了过滤器占用的空间。 \¥0 2019/097460 ?01/162018/059024
图 4示出了根据本发明第二实施例制成的筒式过滤器 200,所述筒式过滤器 200 是图 1 -图 3所示的筒式过滤器的一个变型。 为了简单和清晰可见， 图 4没有显示第 二端盖。 如图所示， 筒式过滤器 200与上述第一实施例的筒式过滤器 100同样地包 括第一端盖 210、 第二端盖 （为清楚显示内部结构而略去） 以及置于第一端盖 210 和第二端盖之间的过滤介质阵列 230。 第一端盖 210、 第二端盖以及过滤介质阵列 230 的结构、 制造和功能与上述第一实施例的大致相同， 可参看第一实施例的相关 描述， 在此不再赘述。
本实施例的筒式过滤器 200与第一实施例的筒式过滤器 100不同之处在于， 还 包括从所述第一端盖 210延伸至所述第二端盖的过滤筒体 240, 所述过滤筒体 240 也做成褶皱形状， 沿着第一端盖 210和第二端盖的周边围绕成中空腔体， 过滤介质 阵列 230被放置在过滤筒体 240的中空腔体内。 过滤筒体 240由上文讨论的相同针 刺无纺布模压制成自支撑的筒体， 没有提供任何支承结构。
第一端盖 210也做成封闭端盖， 把过滤介质阵列 230—端的所有管状过滤介质 232的开口端以及过滤筒体 240的开口端封闭。 或者， 所有管状过滤介质中固定于 第一端盖 210的那一端的开口以及过滤筒体 240的开口端封闭， 再附连固定于第一 端盖 210。 第二端盖封闭过滤筒体 240的另一个开口端， 其上仅设有与多个管状过 滤介质 232的数量对应的且与多个管状过滤介质 232相通的开口， 使得流体经过滤 筒体 240后再经管状过滤介质 132过滤， 才从第二端盖上与管状过滤介质 232相连 通的开口流出。 同样地， 沿第二端盖的开口端面的周边向上延伸一定的高度， 形成 一空间， 露出该端面上的全部开口， 以供所述流体流出第二端盖。
较佳地， 过滤筒体 240的平均孔径大于各个管状过滤介质 232的平均孔径， 实 现流体的分级过滤。 具体地， 流体中含有的较大颗粒尺寸的固体被阻挡在过滤筒体 240之外， 较小颗粒尺寸的固体能够穿过过滤筒体 240后， 被截留在管状过滤介质 232的表面上。 较大颗粒尺寸的固体已经被阻挡在过滤筒体 240之外， 不会堵塞管 状过滤介质 232。
图 5至图 8示出根据本发明第三实施例制成的高效空气过滤器 300。 高效空气 过滤器 300包括截面为四边形的框架， 框架由前侧 311、 后侧 312、 左侧 313、 右侧 314、 上侧 315和下侧 316组成， 前侧 311和后侧 312限定过滤器 300的深度。 高效 空气过滤器 300还包括跟随框架的形状呈正方体的过滤介质阵列 330。 与上文讨论 的第一和第二实施例的过滤介质阵列一样， 本实施例的过滤介质阵列 330包括多个 大致平行排列且垂直于前侧 311和后侧 312的管状过滤介质 332。 所有管状过滤介 \¥0 2019/097460 ?01/162018/059024
质中固定于前侧 311的那一端的开口封闭，再附连固定于前侧 311的支撑条 3112上。 整个过滤介质阵列 330沿过滤器 300的深度被放置在框架的前侧 311和后侧 312之 间， 构成过滤器 300的过滤介质。 呈正方体的过滤介质阵列 330的结构、 制造和功 能可参看上述第一实施例的圆柱形过滤介质阵列 130, 在此不再赘述。 同样地， 框 架由上文讨论的相同针刺无纺布模压制成自支撑的框架， 没有提供任何支承结构。
如图 5所示， 使用针刺无纺布模压一体制成由框架的左侧 313、右侧 314、上侧 315和下侧 316构成的框架主体， 使用同样的针刺无纺布分别模压制成框架的前侧 311和后侧 312。 框架的前侧 311 （即流体的入口端） 由针刺无纺布模压制成的多根 支撑条 3112交错搭接成支撑端面，管状过滤介质 332固定和被支撑在该支撑端面上。 框架的后侧 312 （即流体的出口端） 设有与多个管状过滤介质 332的数量对应的开 口 3122， 所述多个开口 3122与多个管状过滤介质 332相通。 流体按照图 5所示的 箭头方向流入， 经过管状过滤介质 332过滤后， 再按照图 6所示的箭头方向从后侧 312的开口 3122流出。
由于采用独特的针刺无纺布， 管状过滤介质 332与框架的前侧 311和后侧 312 的固定， 以及框架的前侧 311和后侧 312与框架主体的固定， 可以采用粘胶剂、 缝 制、 热溶解结合、 类塑料焊接法 （plastic welding） 或其他任何合适的方法。
与第一实施例一样， 选用的针刺无纺布的厚度约是是 0.5 - 2.5mm， 优选 0.8 _ 2.0mm, 更优选 1.0 - 1.5mm； 管状过滤介质 332的外直径约是约是 1.0 - 3英寸， 优 选 1.0 - 1.5英； 褶皱 134的高度约是 1 - 2cm， 优选 1.1 - 1.5cm。
传统的高效空气过滤器通常包括框架和置于其内的折叠式滤纸。 对于折叠式滤 纸， 现有的做法是在形成的折缝内垫以纸或棉线等制作的分隔条， 以支撑滤材折缝 的空间， 而且在动态下折叠式滤纸容易变形而影响气流通道， 降低过滤效果。 本发 明的高效空气过滤器 300以包含多根由针刺无纺布制成的且具有褶皱的管状过滤介 质 332的阵列取代折叠式滤纸， 不但增大了过滤面积， 而且省去了常规高效空气过 滤器所必需的对折叠式滤纸进行处理的操作， 大大降低了劳动强度和减少了操作、 安装和折叠式滤纸的成本。 此外， 本发明的高效空气过滤器 300还避免了折叠式滤 纸变形而影响过滤效果。
由于选用的针刺无纺布具有优异的硬度、成型性和尺寸稳定性， 所以模压成型 的管状过滤介质 332、 由框架的左侧 313右侧 314、上侧 315和下侧 316构成的框架 主体、 以及框架的前侧 311和后侧 312都能够在外力作用下在使用中稳定地保持各 自的形态， 不论是管状过滤介质 332还是框架本身， 都不需要任何支撑结构。 \¥0 2019/097460 ?01/162018/059024
图 9至图 12示出了根据本发明一实施例的过滤组件 400。过滤组件 400包括三 个上文第二实施例描述的无支撑筒式过滤器， 其结构可参看上文第一和第二实施例 的描述。 所述三个筒式过滤器包括下层过滤器 201、 中间过滤器 202和上层过滤器 203 , 它们沿流体的流动方向叠加而成， 在本实施例中， 流体由下向上流动。 下层过 滤器 201、 中间过滤器 202和上层过滤器 203的平均孔径逐渐减少， 即下层过滤器 201的平均孔径比中间过滤器 202的平均孔径大， 中间过滤器 202的平均孔径比上 层过滤器 203的平均孔径大。 将滤孔孔径逐渐递减配置实现了流体的分层过滤， 可 以取得较好的过滤效果， 而且不容易阻塞过滤器的滤孔。
在下层过滤器 201和中间过滤器 202的第二端盖设有一空间， 供流体从下层过 滤器 201的出口端流向中间过滤器 202的入口端， 以及从中间层过滤器 202的出口 端流向上层过滤器 203的入口端。 例如， 所述空间可参照上文的第一实施例描述的 方式形成。 具体地， 管状过滤介质与下层过滤器 201的第二端盖的开口所处的端面 固定连接， 第二端盖的端面的圆周边向上延伸一定高度形成由下层过滤器 201的第 二端盖的端面与中间过滤器 202的流体入口端限定的空间。 该空间允许流体从下层 过滤器 201流向中间过滤器 202。 中间过滤器 202的第二端盖具有类似的结构， 与 上层间过滤器 203的流体入口端限定一空间。 为了减少过滤器在工作时的噪音， 在 中间过滤器 202和上层过滤器 203的流体入口端以及上层过滤器 203的流体出口端 分别设置功率风机 500,以取代现有过滤器中设置的一台大功率风机，如图 10所示。 可以采用现有技术中已知的各种方法将风机 500固定在各层过滤器上， 例如螺接或 卡扣连接等等。
由于各层过滤器的端盖同样由针刺无纺布模压成型， 下层过滤器 201、 中间过 滤器 202和上层过滤器 203中相邻的两个过滤器的连接也可以采用粘胶剂、 缝制、 热熔解结合、 类塑料焊接法或其他任何合适的方法， 例如卡扣连接。
如图 10所示， 下层过滤器 201的第二端盖 2012上开有多个通孔 2014, 所述通 孔 2014与管状过滤介质的出口连通。在下层过滤器 201和中间过滤器 202之间设置 风机保持器 502， 风机保持器 502的下颈部 503与下层过滤器 201的第二端盖 2012 通过上文列出的方法固定连接， 风机保持器 502的上颈部 504与与中间过滤器 202 的第一端盖 2021通过上文列出的方法固定连接。
此外， 图 10也显示在过滤组件的入口处， 即下层过滤器 201的入口端面的内表 面上设置了用于加热流体的加热器 600, 利用热空气上升、 冷空气下沉的原理加强 过滤组件内空气的对流， 提高过滤效率。 加热器 600可以选用电加热丝， 直接粘结 \¥0 2019/097460 ?01/162018/059024
在下层过滤器 201的入口端面的内表面上。 一般地， 将流体加热至其温度比环境温 度高 2 - 5° (:。
本实施例讨论了由筒式过滤器叠加构成的过滤组件，本领域技术人员应该懂得， 由其它形状的过滤器叠加构成的过滤组件也是可能的。 例如由第三实施例的高效空 气过滤器在水平方向上沿流体的流动方向叠加形成过滤组件。
由于选用的针刺无纺布具有重量轻、 硬度高、 强度高、 易于成型和形态保持性 等特点， 所以用具有这种特性的针刺无纺布模压成型为过滤介质和各种各样的过滤 器零件， 不但能够保持其模制形状， 提供足够的抗压能力， 而且大大地简化了过滤 器的安装和更换操作， 更有利于减轻劳动强度和节省操作成本。
以上以优选实施例介绍了本发明的包含多根内置过滤管的无支撑式过滤器及由 该过滤器构成的过滤组件。 本领域技术人员可以按照说明书中的教导对本发明进行 各种改进和 /修改， 这些改进和 /或修改都应当被包括在本发明权利要求书的范围中。

Claims

\¥0 2019/097460 ?01/162018/059024 权 利 要 求 书
1. 一种无支撑式过滤器， 所述过滤器包括：
弟一¾和弟一¾，
置于所述第一端和所述第二端之间的过滤介质阵列，所述过滤介质阵列附于 所述第一端的内表面上，包括多个呈管状构造的过滤介质，所述多个管状过 滤介质大致平行排列且垂直于所述第一端的内表面，并且其管体做成褶皱形 状；
所述第一端和第二端以及所述多个管状过滤介质分别由能够自支撑而具有 形态保持性并且具有可模制成型性的针刺无纺布一体模压制成，其中所述针 刺无纺布能够被模压成所需的形状，且在模压成所需的形状后在使用中能够 在外部压力下稳定地保持所述形状的形态，以致于由所述针刺无纺布模压制 成的每个所述管状过滤介质是自支撑的， 其内外没有提供支承件，从而形成 无支撑式过滤器。
2. 根据权利要求 1所述的无支撑式过滤器，特征在于，所述过滤器是筒式过滤 器， 所述第一端和第二端分别成形为所述筒式过滤器的第一端盖和第二端 盖， 所述筒式过滤器还包括从所述第一端盖延伸至所述第二端盖的过滤筒 体，所述过滤筒体做成褶皱形状并且具有中空腔体，所述过滤介质阵列被放 置在所述中空腔体内，其中所述过滤筒体由所述针刺无纺布模压制成自支撑 的筒体， 没有提供任何支承结构
3. 根据权利要求 2所述的无支撑式过滤器，特征在于，所述过滤筒体的平均孔 径大于所述管状过滤介质的平均孔径。
4. 根据权利要求 2所述的无支撑式过滤器，特征在于，所述过滤介质阵列附连 在所述第一端盖的内表面上，所述第二端盖设有与所述多个管状过滤介质数 量对应的开口，所述多个开口与所述多个管状过滤介质相通， 以供过滤后的 流体流出。
5. 根据权利要求 2所述的无支撑式过滤器，特征在于，所述过滤介质阵列通过 如下方法之一或其任意组合附连在所述第一端盖的内表面上:粘胶剂、缝制、 热熔解结合和塑料焊接。
6. 根据权利要求 2所述的无支撑式过滤器， 特征在于， 在所述第二端盖上， 沿 着具有所述开口的端面的周边向上延伸一定的高度形成空间，露出所述端面 \¥0 2019/097460 ?01/162018/059024 上的全部开口， 以供所述流体流出。
7. 根据权利要求 1所述的无支撑式过滤器，特征在于，所述过滤器是高效空气 过滤器，所述高效空气过滤器包括框架，所述第一端和第二端分别成形为所 述框架的前侧和后侧，所述过滤介质阵列被放置在所述框架内，其中所述框 架由所述针刺无纺布模压制成自支撑的框架， 没有提供任何支承结构。
8. 根据权利要求 7所述的无支撑式过滤器，特征在于，所述过滤介质阵列附连 在所述框架的前侧的内表面上，所述框架的后侧设有与所述多个管状过滤介 质数量对应的开口，所述多个开口与所述多个管状过滤介质相通， 以供过滤 后的流体流出。
9. 根据权利要求 7所述的无支撑式过滤器，特征在于，所述过滤介质阵列通过 如下方法之一或其任意组合附连在所述前侧的内表面上： 粘胶剂、缝制和热 熔解结合。
10. 根据权利要求 9所述的无支撑式过滤器， 特征在于， 所述框架的前侧由多 根支撑条搭接而成支撑端， 所述过滤介质阵列附连在所述支撑端上。
11. 根据权利要求 1所述的无支撑式过滤器， 特征在于， 所述过滤介质阵列还 包括限制环，所述限制环上设有与所述多个管状过滤介质的数量对应的且贯 穿限制环的多个通孔，所述通孔的尺寸允许所述管状过滤介质刚好通过，用 于限制所述多个管状过滤介质在径向上的移动。
12. 根据权利要求 12所述的无支撑式过滤器， 特征在于， 所述限制环由能够 自支撑而具有形态保持性并且具有可模制成型性的针刺无纺布一体模压制 成。
13. 根据权利要求 1至 12中任一项所述的无支撑式过滤器， 特征在于， 所述 针刺无纺布的厚度约是 0.5 - 2.5111111,优选 0.8 - 2.0111111,更优选 1.0 - 1.5111111; 所述管状过滤介质的外直径约是 1.0 - 3英寸， 优选 1.0 - 1.5英寸； 所述褶皱 的高度约是 1 - 2〇11, 优选 1.1 - 1.5〇11。
14. 根据权利要求 1至 12中任一项所述的无支撑式过滤器， 特征在于， 所述 管状过滤介质与活性炭联用。
15. 根据权利要求 16所述的无支撑式过滤器， 特征在于， 所述管状过滤介质 上涂敷活性炭层或者活性炭以分离的层提供。
16. 一种过滤组件， 所述过滤组件包括两个或以上如权利要求 1至 15中任一 项所述的无支撑式过滤器，所述两个或以上无支撑式过滤器沿流体的流动方 \¥0 2019/097460 ?01/162018/059024 向叠加而成。
17. 根据权利要求 16所述的过滤组件， 特征在于， 所述两个或以上无支撑式 过滤器的平均孔径沿流体的流动方向逐渐减少。
18. 根据权利要求 16所述的过滤组件， 特征在于， 相邻的两个所述无支撑式 过滤器中邻接的两端留有空间，以供所述流体从所述两个过滤器中之一流入 另一个过滤器。
19. 根据权利要求 16所述的过滤组件， 特征在于， 在相邻的每两个无支撑式 过滤器中沿流体方向上较后一个过滤器的流体入口端部内置风机，以及在所 述过滤组件的流体出口端内置风机。
20. 根据权利要求 16至 19中任一项所述的过滤组件， 特征在于， 在所述过 滤组件的流体入口处设有加热器， 用于加热所述流体。
21. 根据权利要求 20所述的过滤组件， 特征在于， 所述流体被加热后的温度 比环境温度高 2-5° (:。
PCT/IB2018/059024 2017-11-16 2018-11-16 包含多根内置过滤管的无支撑式过滤器及由该过滤器构成的过滤组件 WO2019097460A1 (zh)

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