Carbon fiber filter paper manufacturing method
Carbon fiber filter paper produced through a carbon fiber filter paper production line and hot-cold rolling process solves the problem of insufficient adsorption capacity of folded filter membranes for chemical pollutants, and realizes a high-efficiency, low-cost multi-layer filter element design, which is suitable for compact water purification equipment.
Patent Information
- Application Number
- CN202610136805.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-30
- Publication Date
- 2026-05-15
AI Technical Summary
Existing origami filter membranes perform well in removing suspended particulate matter, but lack effective adsorption capacity for chemical pollutants dissolved in water. Furthermore, composite filters are complex in design, costly, and bulky, making them difficult to apply to compact equipment.
The carbon fiber filter paper production line mixes carbon fiber with activated carbon powder and combines hot and cold rolling processes to produce carbon fiber filter paper with adsorption properties. A PP film is then sprayed onto the surface to form a multi-layer filter element.
It achieves a dual purification effect of simultaneously and efficiently removing particulate impurities and chemical pollutants, simplifies the production process, reduces costs, and is suitable for compact household water purifiers and portable water supply equipment.
Smart Images
Figure CN122039487A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of carbon fiber filter paper manufacturing technology, and particularly to a method for manufacturing carbon fiber filter paper. Background Technology
[0002] Currently, widely used origami filter membranes, with their unique multi-layered folded structure and high-precision pore size design, exhibit excellent interception and removal capabilities for suspended particulate matter in water treatment. Through their precise physical structure, these membrane materials can efficiently filter out silt, rust, algae, and other larger insoluble impurities, significantly reducing water turbidity, improving water transparency and visual appeal, and enhancing the initial purification effect. However, the functional design of these filter membranes is relatively simple, with their main function limited to mechanical physical filtration. For various organic pollutants dissolved in water, such as pesticide residues, industrial chemical solvents, some microbial metabolites, and chemical substances like residual chlorine and odor molecules, since these are not in particulate form, origami membranes have almost no effective adsorption or degradation capacity. Therefore, although they perform excellently in removing suspended solids, they still have significant functional limitations in improving overall water safety and drinking taste.
[0003] To achieve the dual purification goals of simultaneously and efficiently removing particulate impurities and chemical pollutants, a composite integrated design of origami filter membranes and activated carbon filter rods is typically required. This combination allows the system to leverage the synergistic effects of physical interception and chemical adsorption, resulting in a more comprehensive and integrated water treatment effect. Activated carbon, with its highly developed pore structure and large specific surface area, possesses a powerful adsorption capacity, effectively capturing and removing residual chlorine, odors, and various dissolved organic substances, thus compensating for the limitations of origami membranes in chemical purification. However, the design of such composite filters significantly increases the variety and overall quantity of filter materials used, as well as the complexity of the production process and overall manufacturing costs. Furthermore, due to the layered structure and combination requirements of multi-stage filter cartridges, the overall volume and weight of the entire filtration system often increase significantly, imposing more stringent constraints on internal space planning and installation conditions. Therefore, the application and promotion of such composite filtration solutions face certain limitations in specific industrial applications such as compact household water purifiers, portable mobile water supply devices, or space-constrained environments. Summary of the Invention
[0004] This invention aims to at least solve one of the technical problems existing in the prior art. To this end, a first aspect of this invention provides a carbon fiber filter paper production line, specifically including a conveyor belt, a first heating tank, a second heating tank, a first hot roller, a second hot roller, a first cold roller, a second cold roller, and a meltblown equipment. These components cooperate and work together. Along the material conveying direction of the conveyor belt, the equipment is arranged sequentially as a first heating tank, a first hot roller, a second heating tank, a second hot roller, a first cold roller, a meltblown equipment, and a second cold roller, forming a highly efficient, continuous, and automated production line system.
[0005] This layout not only helps to achieve seamless connection between various process links and reduce time wastage during material transfer, but also significantly improves overall production efficiency while ensuring the consistency and stability of product quality.
[0006] According to some embodiments of the present invention, hot roller one and hot roller two, cold roller one and cold roller two are in direct contact with the surface of the conveyor belt, and the material is processed by the rolling action.
[0007] According to some embodiments of the present invention, hot roller one and hot roller two are mainly used to perform hot roller pressing operations on materials, so that different kinds of materials can achieve full thermal fusion under high temperature conditions and enhance the bonding performance between materials.
[0008] According to some embodiments of the present invention, cold roller one and cold roller two are responsible for cold roller pressing the material, thereby rapidly cooling and solidifying the material by reducing its temperature, thus stabilizing the material's structural morphology.
[0009] According to some embodiments of the present invention, the second heating tank is precisely arranged at a key position between the first and second heating rollers to achieve staged heating treatment of the material, ensure uniform heat distribution and improve processing efficiency.
[0010] According to some embodiments of the present invention, the meltblown equipment is arranged between cold roller one and cold roller two to complete the uniform spraying of fibers during the material cooling process. This step further optimizes the surface quality and internal structure uniformity of the product, thereby significantly improving the reliability and consistency of the final product performance.
[0011] A second aspect of the present invention provides a method for manufacturing the carbon fiber filter paper, implemented using the aforementioned production line, and its specific production process includes the following detailed steps:
[0012] Step one involves first thoroughly pulverizing the carbon fiber felt using a high-speed pulverizer. The pulverized carbon fiber raw material is then uniformly mixed with a certain proportion of activated carbon powder to form a mixture with adsorption capabilities. This mixture is then placed into heating tank one and preheated within a strictly controlled temperature range of 100-120℃ to remove some moisture and improve the material's plasticity. After preheating, the material flows out from the outlet at the bottom of heating tank one and falls smoothly onto the conveyor belt directly below, ready for the next process.
[0013] Step 2: Conveyor belt 1 transports the preheated carbon fiber mixture to hot roller station 4 at a constant speed. The hot roller pre-presses the material under certain temperature and pressure conditions. By precisely controlling the roller spacing and pressure parameters, the thickness of the pre-pressed material is strictly controlled within the range of 0.5-1 mm, laying the foundation for subsequent processing.
[0014] Step three: After pre-compression, the carbon fiber mixture is conveyed by conveyor belt 1 to heating tank 2 (3). This heating tank is also maintained at a preheating temperature of 100-120℃, mainly for preheating and softening the resin powder. Then, the molten and softened resin powder is evenly sprayed onto the surface of the carbon fiber carrier using a high-pressure spray system. This aims to utilize the adhesive properties of the resin to tightly bond the originally loose carbon fibers together, thereby forming a carbon fiber base layer with certain mechanical strength and a stable structure.
[0015] Step four: Conveyor belt 1 transports the carbon fiber mixture covered with resin powder to hot roller 5. This roller assembly performs secondary hot pressing on the material under high temperature and high pressure conditions, allowing the resin powder to fully penetrate and be pressed into the internal structure of the carbon fiber, achieving a firm bond between the resin and the fiber, and further enhancing the integrity and functionality of the material.
[0016] Step 5: The hot-pressed carbon fiber material is then conveyed to the cold roller 6. At this stage, it is initially cured and shaped under normal temperature conditions by roller pressing, locking the material structure and preventing deformation and springback.
[0017] Step six: After initial curing, conveyor belt 1 transports the carbon fiber substrate to below meltblown equipment 8. This equipment uses a high-temperature melt-blowing process to coat the carbon fiber surface with a layer of polypropylene (PP) film. This process not only forms a robust support layer on one side of the carbon fiber layer but also further secures the carbon fiber material to prevent it from falling off. Simultaneously, the thickness or density of the PP film can be flexibly adjusted according to actual application needs, enabling it to effectively intercept particulate matter and expanding the applicable scenarios for the filter material.
[0018] Step seven, finally, conveyor belt 1 transports the carbon fiber material covered with PP film to cold roller 7 for final rolling cooling treatment. By precisely controlling the cooling temperature and pressure, the material achieves final shaping and performance stabilization. After cooling, it is wound up by an automatic winding device to obtain the finished carbon fiber filter paper.
[0019] The present invention has at least the following beneficial effects: Innovatively, carbon fiber or a mixture of carbon fiber and powdered activated carbon is made into filter paper and coated with a PP film, enabling it to simultaneously achieve two filtration effects. It can then be made into filter cartridges of different shapes through folding, rolling, and other methods. This design not only improves the adsorption performance and filtration efficiency of the material, but also allows the filter paper to be flexibly folded into different layered structures or rolled into various shapes, making it suitable for applications such as compact household water purifiers, portable mobile water supply equipment, or specific industrial applications with limited space.
[0020] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description
[0021] The first and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of a production line according to an embodiment of the present invention. Detailed Implementation
[0022] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements with the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.
[0023] In the description of this invention, the terms "first," "greater than," "less than," and "exceeding" are understood to exclude the stated number. The use of "first" and "second" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, the quantity of indicated technical features, or the order of the indicated technical features.
[0024] To achieve the dual purification goals of simultaneously and efficiently removing particulate impurities and chemical pollutants, a composite integrated design of origami filter membranes and activated carbon filter rods is typically required. This combination allows the system to leverage the synergistic effects of physical interception and chemical adsorption, resulting in a more comprehensive and integrated water treatment effect. Activated carbon, with its highly developed pore structure and large specific surface area, possesses a powerful adsorption capacity, effectively capturing and removing residual chlorine, odors, and various dissolved organic substances, thus compensating for the limitations of origami membranes in chemical purification. However, this type of composite filter design not only significantly increases the variety and overall quantity of filter materials used but also substantially increases the complexity of the production process and overall manufacturing costs. Furthermore, due to the layered structure and combination requirements of multi-stage filter cartridges, the overall volume and weight of the entire filtration system often increase significantly, imposing more stringent constraints on internal space planning and installation conditions.
[0025] To address the above problems, this invention provides a method for manufacturing carbon fiber filter paper, comprising the following steps: Step 1: First, use a pulverizer to finely pulverize the carbon fiber felt cloth, and preheat the resulting carbon fiber mixture to form a mixture with adsorption function. Step 2: Perform preliminary hot pressing on the preheated carbon fiber mixture from Step 1 to achieve pre-pressing and lay the foundation for subsequent processing. Step 3: After the pre-compression process in Step 2 is completed, the softened resin powder is evenly sprayed onto the surface of the carbon fiber material. Step four: Resin powder is attached to the surface of the carbon fiber after step three. A second hot pre-pressing operation is then performed on it. The pressure causes the resin powder to fully embed into the carbon fiber, achieving a tight bond between the two. The adhesive properties of the resin tightly bind the originally loose carbon fiber together, thus forming a carbon fiber base layer with a certain mechanical strength and stable structure. Step 5: After completing the carbon fiber pressing into the resin in Step 4, perform cold roller pressing to cool the material, promote material curing and shaping, lock the material structure, and prevent deformation and springback. Step six: After the carbon fiber has been cold rolled in step four, a layer of PP film is evenly sprayed onto its surface. The PP film forms a strong support layer, which at the same time enables the carbon fiber filter paper to have an effective particulate matter interception ability, expanding the applicable scenarios of the filter material. Step 7: After completing Step 6, the carbon fiber-coated PP film is subjected to a second cold roll cooling treatment to achieve final shaping and performance stabilization of the material. After cooling, it is uniformly wound up.
[0026] In some embodiments, in step one, the pulverized carbon fiber is mixed with a certain proportion of activated carbon powder to further improve adsorption performance and filtration efficiency.
[0027] In some embodiments, in step one, the temperature range for preheating the carbon fiber mixture is 100 to 120 degrees Celsius to remove some of the moisture from the carbon fiber mixture and improve the plasticity of the material.
[0028] In some embodiments, in step three, the temperature during the softening treatment of the resin powder is controlled between 100 and 120 degrees Celsius, so that the resin powder can be fully preheated and softened, facilitating subsequent spraying.
[0029] In some embodiments, after the carbon fiber mixture is successfully made into carbon fiber filter paper, it is usually necessary to further process it into filter cartridges suitable for filtration systems using various physical forming processes such as folding and winding. Therefore, strict control of the thickness of the carbon fiber filter paper is particularly crucial during the production process. If the filter paper is too thick, it will not only increase the difficulty of folding or winding operations, but may also lead to uneven overall structure of the filter cartridge, and even affect its installation compatibility in equipment. On the other hand, if the filter paper is too thin, although the processing convenience is improved, it may significantly weaken its filtration performance, such as reducing the ability to retain impurities or shortening its service life, which is not in line with the requirements of practical applications. For this reason, in the second step of the process flow, when the carbon fiber mixture is pre-pressed, its pressing thickness must be strictly limited to the range of 0.5 mm to 1 mm. This setting fully considers the feasibility of subsequent processing operations such as folding and winding, and also provides an important guarantee for the final production of a carbon fiber filter cartridge with a reasonable structure and excellent filtration performance.
[0030] This invention provides a carbon fiber filter paper production line to facilitate the implementation of the above-mentioned carbon fiber filter paper production method, such as... Figure 1 As shown, the system includes conveyor belt 1, heating tank 1 2, heating tank 2 3, hot roller 1 4, hot roller 2 5, cold roller 1 6, cold roller 2 7, and meltblown equipment 8. These components work together in coordination. Along the material conveying direction of conveyor belt 1, the equipment is arranged sequentially as heating tank 1 2, hot roller 1 4, heating tank 2 3, hot roller 2 5, cold roller 1 6, meltblown equipment 8, and cold roller 2 7, forming a highly efficient, continuous, and automated production line system.
[0031] This layout not only helps to achieve seamless connection between various process links and reduce time wastage during material transfer, but also significantly improves overall production efficiency while ensuring the consistency and stability of product quality.
[0032] Specifically, hot roller 4 and hot roller 5, cold roller 6 and cold roller 7 are in direct contact with the surface of conveyor belt 1, and the material is processed by the rolling action.
[0033] Specifically, hot roller 4 and hot roller 5, cold roller 6 and cold roller 7 are in direct contact with the surface of conveyor belt 1, and the material is processed by the rolling action.
[0034] Among them, hot roller 4 and hot roller 5 are mainly used to perform hot roller pressing on materials, so that different kinds of materials can achieve full thermal fusion under high temperature conditions and enhance the bonding performance between materials.
[0035] Cold roller 6 and cold roller 7 are responsible for cold rolling the material, which cools and solidifies the material quickly by reducing its temperature, thereby stabilizing the material's structure.
[0036] Heating tank 2 3 is precisely positioned at a critical location between heating roller 1 4 and heating roller 2 5 to achieve staged heating treatment of materials, ensure uniform heat distribution, and improve processing efficiency.
[0037] Meanwhile, the meltblown equipment 8 is set between the first cold roller 6 and the second cold roller 7 to complete the uniform spraying of fibers during the material cooling process. This step further optimizes the surface quality and internal structure uniformity of the product, thereby significantly improving the reliability and consistency of the final product performance.
[0038] To further explain the use of this production line in the aforementioned carbon fiber filter paper manufacturing method: In step one, the carbon fiber mixture is preheated using heating tank 2.
[0039] In step two, the preheated carbon fiber mixture is subjected to hot pre-compression treatment using hot roller 4.
[0040] In step three, heating tank 23 is used to heat and soften the resin powder.
[0041] In step four, the carbon fibers with resin powder adhering to their surface are subjected to a second hot pre-pressing treatment using hot roller 25.
[0042] In step five, cold roller 6 is used to perform cold roller pressing on the resin-impregnated carbon fibers. In step six, PP film is sprayed using meltblown equipment 8. In step seven, cold roller 7 is used to cold roll the carbon fiber covered with PP film.
[0043] Among them, hot roller 4 and hot roller 5 are mainly used to perform hot roller pressing on materials, so that different kinds of materials can achieve full thermal fusion under high temperature conditions and enhance the bonding performance between materials.
[0044] The working principle of this invention is: Step one involves first thoroughly pulverizing the carbon fiber felt using a high-speed pulverizer. The pulverized carbon fiber raw material is then uniformly mixed with a certain proportion of activated carbon powder to form a mixture with adsorption capabilities. This mixture is then placed into heating tank 2 and preheated within a strictly controlled temperature range of 100-120°C to remove some moisture and improve the material's plasticity. After preheating, the material flows out from the outlet at the bottom of heating tank 2 and falls smoothly onto conveyor belt 1 directly below, ready for the next process.
[0045] Step 2: Conveyor belt 1 transports the preheated carbon fiber mixture to the hot roller 4 station at a constant speed. The hot roller 4 pre-presses the material under certain temperature and pressure conditions. Through precise pressure parameters, the thickness of the pre-pressed material is strictly controlled within the range of 0.5-1 mm, laying the foundation for subsequent processing.
[0046] Step three: After pre-compression, the carbon fiber mixture is conveyed by conveyor belt 1 to heating tank 2 (3). Heating tank 2 (3) is also maintained at a preheating temperature of 100-120℃, mainly for preheating and softening the resin powder. Then, the molten and softened resin powder is evenly sprayed onto the surface of the carbon fiber carrier using a high-pressure spraying system. This aims to utilize the adhesive properties of the resin to tightly bond the originally loose carbon fibers together, thereby forming a carbon fiber base layer with certain mechanical strength and a stable structure.
[0047] Step four: Conveyor belt 1 transports the carbon fiber mixture covered with resin powder to hot roller 5. Hot roller 5 performs secondary hot pressing on the material under high temperature and high pressure conditions, so that the resin powder can fully penetrate and be pressed into the internal structure of the carbon fiber, achieving a firm bond between the resin and the fiber, and further enhancing the integrity and functionality of the material.
[0048] Step 5: The hot-pressed carbon fiber material is then conveyed to cold roller 6. At this stage, the cold roller 6 presses the material to initially solidify and shape it at room temperature, locking in the material structure and preventing deformation and springback.
[0049] Step six: After initial curing, conveyor belt 1 transports the carbon fiber substrate to below meltblown equipment 8. This equipment uses a high-temperature melt-blowing process to coat the carbon fiber surface with a layer of polypropylene (PP) film. This process not only forms a robust support layer on one side of the carbon fiber layer but also further secures the carbon fiber material to prevent it from falling off. Simultaneously, the thickness or density of the PP film can be flexibly adjusted according to actual application needs, enabling it to effectively intercept particulate matter and expanding the applicable scenarios for the filter material.
[0050] Step seven, finally, conveyor belt 1 transports the carbon fiber material covered with PP film to cold roller 7 for final rolling cooling treatment. By precisely controlling the cooling temperature and pressure, the material achieves final shaping and performance stabilization. After cooling, it is wound up by an automatic winding device to obtain the finished carbon fiber filter paper.
[0051] Innovatively, carbon fiber or a mixture of carbon fiber and powdered activated carbon is made into filter paper and coated with a PP film, enabling it to simultaneously achieve two filtration effects. It can then be made into filter cartridges of different shapes through folding, rolling, and other methods. This design not only improves the adsorption performance and filtration efficiency of the material, but also allows the filter paper to be flexibly folded into different layered structures or rolled into various shapes, making it suitable for applications such as compact household water purifiers, portable mobile water supply equipment, or specific industrial applications with limited space.
[0052] In the description of this specification, references to terms such as "some embodiments" or "as one might imagine" indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the first-described terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one embodiment or example.
[0053] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the first described embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.
Claims
1. A method for manufacturing carbon fiber filter paper, characterized in that, The production steps include: Step 1: First, use a pulverizer to finely pulverize the carbon fiber felt, and then preheat the resulting carbon fiber mixture. Step 2: Perform preliminary hot pressing on the preheated carbon fiber mixture from Step 1 to achieve pre-pressing. Step 3: After the pre-compression process in Step 2 is completed, the resin powder is heated and softened, and the softened resin powder is evenly sprayed onto the surface of the carbon fiber material. Step four: Resin powder is attached to the surface of the carbon fiber after step three. A second hot pre-pressing operation is then performed on it. The pressure is used to make the resin powder fully embedded in the carbon fiber, so as to achieve a tight bond between the two. Step 5: After pressing the carbon fiber into the resin as in Step 4, perform cold roller pressing to cool it and promote the material to solidify and set. Step six: After the carbon fiber has completed the cold rolling process in step four, a layer of PP film is uniformly sprayed onto its surface. Step 7: After completing Step 6, the carbon fiber-coated PP film undergoes a second cold roll cooling treatment. After cooling, it is then uniformly wound up.
2. The method for producing carbon fiber filter paper according to claim 1, characterized in that, In step one, activated carbon powder is mixed into the carbon fiber mixture obtained by finely pulverizing the carbon fiber felt using a pulverizer.
3. The method for producing carbon fiber filter paper according to claim 1, characterized in that, In step one, the temperature range for preheating the carbon fiber mixture obtained from the pulverization process is controlled between 100 and 120 degrees Celsius.
4. The method for producing carbon fiber filter paper according to claim 1, characterized in that, In step three, the temperature during the heat softening treatment of the resin powder is controlled between 100 and 120 degrees Celsius.
5. The method for producing carbon fiber filter paper according to claim 1, characterized in that, In step two, the preheated carbon fiber mixture undergoes a preliminary hot pressing treatment, with the pressing thickness set between 0.5 mm and 1 mm.
6. The method for producing carbon fiber filter paper according to claim 1, characterized in that, It also includes a conveyor belt (1), and along the conveying direction of the conveyor belt (1) are arranged the heating tank one (2), the hot roller one (4), the heating tank two (3), the hot roller two (5), the cold roller one (6), the meltblown equipment (8), and the cold roller two (7) in sequence. In step one, the carbon fiber mixture obtained by the crushing process is preheated using the heating tank (2); In step two, the carbon fiber mixture that was preheated in step one is subjected to hot pre-pressing treatment using the hot roller (4); In step three, after the pre-compression process in step two is completed, the resin powder is heated and softened using the heating tank two (3); In step four, the carbon fiber surface after step three is coated with resin powder, and the second hot pre-pressing treatment is performed using the hot roller two (5); In step five, the carbon fiber pressing into the resin in step four is completed, and the pressing is cold-pressed using the cold roller (6); In step six, after the carbon fiber has been cold rolled in step four, a PP film is sprayed onto the surface of the carbon fiber using the meltblown equipment (8); In step seven, after completing step six, the carbon fiber is covered with a PP film, and the carbon fiber covered with the PP film is cold-rolled using the second cold roller (7).
7. The method for producing carbon fiber filter paper according to claim 6, characterized in that, The hot roller 1 (4), the hot roller 2 (5), the cold roller 1 (6), and the cold roller 2 (7) are in contact with the surface of the conveyor belt (1).
8. The method for producing carbon fiber filter paper according to claim 6, characterized in that, The second heating tank (3) is located between the first heating roller (4) and the second heating roller (5).
9. The method for producing carbon fiber filter paper according to claim 6, characterized in that, The meltblown equipment (8) is located between the first cold roller (6) and the second cold roller (7).