Filter Rapid Prototyping Method

Abstract

The present invention provides a filter rapid prototyping method, which mainly includes a material preparation step, a mixing step, a spraying step, a preliminary molding step and a molding step, etc.; wherein, in the mixing step, the fiber polymer raw material prepared in the material preparation step is stirred and mixed with a certain proportion of water into a slurry through a stirring unit, and then in the spraying step, the slurry is sprayed into the mold cavities in the upper and lower molds, and during the spraying process, a vacuum unit is used to extract and discharge excess water and gas in the slurry (i.e., the preliminary molding step), so that the slurry is gradually molded into a filter prototype. Finally, the obtained filter prototype is demolded and cured to form a filter (i.e., the molding step). Therefore, the consistent rapid molding process can more effectively improve production efficiency.

Description

Technical Field

[0001] The invention relates to a filter manufacturing process, in particular to a filter rapid prototyping method. Background Art

[0002] It is found that when power plants or large industrial manufacturing plants are in operation, they will generate excessive exhaust gas, and the exhaust gas generated will be rich in many gaseous pollutants. Therefore, in order to avoid the exhaust gas from polluting the environment and causing harm to human health, the environmental protection regulations stipulate that all exhaust gas generated by industrial manufacturing plants must be treated before being discharged. Therefore, when the exhaust gas is discharged from the industrial manufacturing plant, it is treated through a filtration system. At the same time, in order to effectively isolate the dust and dust in the exhaust gas and achieve the purification of the exhaust gas, a fiber filter bag is installed on the existing exhaust gas treatment filtration system. The exhaust gas generated during manufacturing is sucked in by the exhaust device of the filtration system, and then enters the internal filtration through the outside of the fiber filter bag. In this way, the dust and dust in the exhaust gas can be effectively isolated outside the fiber filter bag to achieve the industrial exhaust gas filtration effect.

[0003] However, it was found during use that although the fiber filter bag can be used to filter industrial waste gas, due to the limitations of the thickness and density of the overall structure of the fiber filter bag, it can only effectively isolate the larger dust and powder particles in the industrial waste gas. However, the lighter and smaller dust particles cannot be blocked and filtered by the fiber filter bag. They will still be integrated into the air after filtration. Its filtering effect still needs to be improved. Summary of the Invention

[0004] Therefore, the purpose of the present invention is to provide a filter rapid prototyping method that can simplify the process and quickly produce a filter made of fiber material, thereby effectively improving production efficiency.

[0005] Therefore, the present invention discloses a filter rapid prototyping method, comprising:

[0006] A material preparation step, which includes preparing a fiber polymer raw material;

[0007] A mixing step is provided, wherein water is used as a medium, and a stirring unit is provided, wherein the stirring unit comprises a stirring drum for placing the fiber polymer raw material from the previous step, and a stirrer for stirring in the stirring drum, wherein 2 to 150 times of water is added to the stirring drum based on the fiber polymer raw material, and the stirrer stirs and mixes the water to form a slurry;

[0008] The spraying step comprises a discharge unit connected to the stirring unit, and a forming module corresponding to the discharge unit, wherein the discharge unit comprises a rotating cylinder for receiving the slurry, an output pipe connected to the rotating cylinder and transmitting the slurry, and a plurality of injection holes opened on the output pipe and for outputting the slurry; in addition, the forming module comprises a movable seat, and two upper and lower molds which can be opened and closed and are correspondingly arranged on the movable seat and move with the movable seat, and when the upper and lower molds are covered, a mold cavity for the output pipe to extend into is formed between the upper and lower molds, and a plurality of openings are opened on the inner wall surfaces of the upper and lower molds relative to the mold cavity, so that the slurry can be sprayed into the mold cavity through the output pipe and the plurality of injection holes, and excess water contained in the slurry during spraying can be discharged outside the upper and lower molds through the plurality of openings;

[0009] A preliminary molding step includes a vacuum unit connected between the upper and lower molds. The vacuum unit is capable of extracting moisture and gas in the mold cavity filled with the slurry through the plurality of openings, so that the slurry sprayed between the upper and lower molds is gradually formed into a filter prototype; and

[0010] In the forming step, the filter prototype obtained in the upper and lower molds in the preliminary forming step is separated from the upper and lower molds for curing to form a filter.

[0011] As a further improvement of the present invention, a top pull unit is provided on the side of the upper and lower molds, which can be extended into the mold cavity. The top pull unit has an actuator and a support member that can be acted upon by the actuator and extended into the mold cavity for movement. When the support member is extended, it can support the output pipe to be firmly positioned.

[0012] As a further improvement of the present invention, the fiber polymer raw material is at least one selected from the group consisting of a mixture of ceramic fiber, glass fiber, aluminum silicate fiber, mineral fiber, plant fiber and organic / inorganic adhesive.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] The present invention adopts a consistent rapid continuous process, firstly mixing into a slurry in a mixing step, then using spraying and preliminary molding steps, the slurry is molded in a uniform staggered pattern along the shape of the molding module by spraying, and then the moisture and gas in the slurry are extracted, so that the prototype of the filter can be quickly molded. Then, through the demolding and curing procedures of the molding step, a filter is formed. Not only can molding be achieved quickly, but the production quality of the filter molding can also be effectively improved, and the production efficiency is increased. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1is a block diagram of a process flow of a preferred embodiment of the present invention;

[0016] Figure 2 is a schematic diagram of the process equipment of the preferred embodiment;

[0017] Figures 3A to 4B Schematic diagram of the operation of local components of this preferred embodiment.

[0018] Explanation of symbols:

[0019] 3: Filter rapid prototyping method

[0020] 31: Preparation steps

[0021] 32: Mixing steps

[0022] 33: Spraying steps

[0023] 34: Preliminary molding steps

[0024] 35: Molding steps

[0025] 4: Mixing unit

[0026] 41: Mixing drum

[0027] 42: Blender

[0028] 5: Discharging unit

[0029] 50: Pneumatic pump

[0030] 51: Rotating drum

[0031] 52: Output tube

[0032] 521: End

[0033] 53: Jet hole

[0034] 6: Molding module

[0035] 61: Mobile seat

[0036] 62: Upper mold

[0037] 621: Inner wall of upper mold

[0038] 63: Lower mold

[0039] 631: Inner wall of lower mold

[0040] 64: Mold cavity

[0041] 65: Top switch unit

[0042] 651: Actuator

[0043] 652: Support

[0044] 7: Vacuum unit

[0045] 8: Filter

[0046] A: Fiber polymer raw materials

[0047] B: Water

[0048] C: Opening

[0049] D: Hollow chamber

[0050] E1: one end

[0051] E2: The other end DETAILED DESCRIPTION

[0052] The above and other technical contents, features and effects of the present invention will be clearly understood in the following detailed description of the preferred embodiments with reference to the accompanying drawings.

[0053] See Figure 1In a preferred embodiment of the present invention, the filter rapid prototyping method sequentially comprises the steps of a material preparation step 31, a mixing step 32, a spraying step 33, a preliminary prototyping step 34, and a prototyping step 35; wherein the material preparation step 31 comprises a fiber polymer raw material A, and the fiber polymer raw material A is at least one selected from a group consisting of a mixture of ceramic fiber, glass fiber, aluminum silicate fiber, mineral fiber, plant fiber, and an organic / inorganic adhesive, and the ceramic fiber is a fiber having the characteristics of light weight, high temperature resistance, good thermal stability, low thermal conductivity, high porosity, and not easy to react chemically with chemical substances, good high temperature resistance, and more rigidity, while the glass fiber is an inorganic fiber having the characteristics of high temperature resistance, non-flammability, low hygroscopicity, good electrical insulation performance, and good chemical stability, and the aluminum silicate fiber has the characteristics of light weight, high temperature resistance, good thermal stability, low thermal conductivity, small heat capacity, good resistance to mechanical vibration, small thermal expansion, and good thermal insulation performance, The mineral fiber is a basalt mineral composed of plagioclase, pyroxene and olivine. It is non-flammable, anti-electromagnetic radiation, resistant to acids, alkalis and corrosive chemicals, and has excellent tensile strength. The plant fiber is a fiber extracted from nature. It is light, biodegradable, harmless to the human body, and has high strength, large modulus, hardness, friction resistance, corrosion resistance, and blister resistance. The organic / inorganic adhesive has low toxicity, is not easy to burn, and is durable. , can be cured at room temperature, etc.; in addition, the mixing step 32 is equipped with water B as a medium, and a stirring unit 4 (shown in a simple diagram in the figure), and the stirring unit 4 has a stirring drum 41 for placing the fiber polymer raw material A in the previous step, and a stirrer 42 that can stir in the stirring drum 41, and 2 to 150 times of water B is added to the stirring drum 41 based on the fiber polymer raw material A, and then the stirrer 42 stirs and mixes in the stirring drum 41 to form a slurry.

[0054] Continuing from the above, please refer to Figure 2As shown in FIG3 , the spraying step 33 has a discharging unit 5 connected to the stirring unit 4, and a forming module 6 (shown in a simplified diagram) corresponding to the discharging unit 5, wherein the discharging unit 5 has a rotating cylinder 51 for receiving the slurry, an output pipe 52 connected to the rotating cylinder 51 and transmitting the slurry, and a plurality of injection holes 53 opened on the output pipe 52 for outputting the slurry. The rotating cylinder 51 receives the slurry mixed and stirred by the stirring cylinder 41, and the rotating cylinder 51 continuously rotates to form the slurry. The slurry is stirred by the movement, thereby preventing the slurry from solidifying prematurely. The slurry is then output from the output pipe 52 and ejected outward through the injection holes 53. At the same time, in order to effectively enable the slurry formed by the stirring unit 4 to be completely output to the discharging unit 5, the discharging unit 5 in this embodiment is provided with a pneumatic pump 50 between the rotating drum 51 and the stirring drum 41 (shown in a simplified diagram in the figure). The action of the pneumatic pump 50 allows the slurry to be output smoothly.

[0055] Continuing from the above, the molding module 6 has a movable base 61, and two upper and lower molds 62 and 63 that can be opened and closed and are correspondingly arranged on the movable base 61 and move with the movable base 61. After the upper and lower molds 62 and 63 are covered, a mold cavity 64 for the output tube 52 to extend into is formed between the upper and lower molds 62 and 63, and a plurality of openings C are opened on the inner wall surfaces 621 and 631 of the upper and lower molds 62 and 63 relative to the mold cavity 64. At the same time, the upper mold The upper and lower molds 62 and 63 are provided with a hollow cavity D, so that the openings C are connected to the hollow cavity D. When the upper and lower molds 62 and 63 move toward the output tube 52 along with the movable base 61, the upper and lower molds 62 and 63 gradually become tightly covered with each other, so that the output tube 52 is located between the upper and lower molds 62 and 63. On the contrary, when the upper and lower molds 62 and 63 move away from the output tube 52 along with the movable base 61, the upper and lower molds 62 and 63 gradually become tightly covered with each other, so that the output tube 52 is located between the upper and lower molds 62 and 63. The upper and lower molds 62 and 63 will gradually separate from each other from the covering mode, and the output tube 52 will exit between the upper and lower molds 62 and 63. At the same time, in this embodiment, the upper and lower molds 62 and 63 are provided with a top-pull unit 65 that can be extended into the mold cavity 64 on the side, and the top-pull unit 65 has an actuating member 651 and a supporting member 652 that can be acted upon by the actuating member 651 and extended into the mold cavity 64 for movement, and the supporting member 652 and the actuating member 652 are connected. One end E1 of the support member 652 opposite to 51 extends into the actuating member 651 and is extended or retracted with the movement of the actuating member 651, so that when the support member 652 is extended, the other end E2 of the support member 652 can just extend into the mold cavity 64 and press against the end 521 of the output tube 52, so that the output tube 52 is stably fixed in the mold cavity 64. At the same time, the mold cavity 64 can be set in a tube state, a rectangular state, an irregular state, or according to special customized specifications.

[0056] As for the preliminary molding step 34, there is a vacuum unit 7 (shown in a simplified diagram in the figure) connected to the upper and lower molds 62, 63. The vacuum unit 7 is extended into the hollow chamber D of the upper and lower molds 62, 63, so that the vacuum unit 7 can fill the slurry between the upper and lower molds 62, 63 and the moisture and gas in the mold cavity, and extract them out through the openings C to the hollow chamber D, so that the slurry sprayed between the upper and lower molds 62, 63 is gradually formed into the prototype of the filter 8; finally, in the molding step 35, the prototype of the filter 8 obtained in the upper and lower molds 62, 63 in the preliminary molding step 34 is separated for curing, and in the curing operation, the molded prototype of the filter 8 can be first The filter 8 is then placed in a drying apparatus with different temperatures (not shown), i.e., at least low-temperature, medium-temperature, and high-temperature drying apparatuses, to further perform dehydration and drying on the prototype of the filter 8. Furthermore, the filter 8 may be further subjected to appropriate drying temperatures and times depending on the shape and specifications of the filter 8 to be formed. For example, if the drying temperature of the low-temperature apparatus is at least 100 degrees Celsius, the drying time may be set within 6 to 24 hours; if the drying temperature of the medium-temperature apparatus is at least 100 degrees Celsius to 150 degrees Celsius, the drying time may be set within 24 hours; and if the drying temperature of the high-temperature apparatus is at least 150 degrees Celsius to 1300 degrees Celsius, the drying time may be set within 24 to 96 hours. The filter 8 is dried until the moisture content is less than 10% to form a filter 8.

[0057] See Figures 1 to 2 During the molding process, the prepared fiber polymer raw material A and water B in a certain ratio based on the fiber polymer raw material A are stirred through the mixing drum 41 and the stirrer 42, so that the fiber polymer raw material A is fully integrated with the water B during the mixing and stirring process to form a slurry. The slurry is then received by the rotating drum 51 and continuously stirred during the rotation of the rotating drum 51. Continuous stirring can prevent the slurry from solidifying prematurely. The movable seat 61 is then actuated to move toward the output pipe 52. At this time, during the movement of the movable seat 61, the upper and lower molds 62 and 63 will gradually overlap when approaching the output pipe 52, so that the delivery pipe 52 is located between the mold cavities 64 when the upper and lower molds 62 and 63 are overlapped. Figures 3A to 3B As shown, the support member 652 provided on the side of the upper and lower molds 62 and 63 is also moved by the action of the actuator 651, and is extended into the mold cavity 64 until the upper and lower molds 62 and 63 are tightly covered with each other, and the other end E2 can just press against the end 521 of the conveying tube 52, thereby helping to support the conveying tube 52 to be firmly positioned, that is, Figure 4A shown.

[0058] At this time, the mixing drum 41, with the assistance of the pneumatic pump 50, enables the slurry to be effectively and smoothly output during the process of being output to the rotating drum 51, and appropriately controls the delivery pipe 52 to transport the slurry from the inside of the rotating drum 51 to the outside, so that the slurry is sprayed outward through the spray holes 53 under the output pressure to form on the inner wall surfaces 621 and 631 of the upper and lower molds 62 and 63, and during spraying, the support member 652 is effectively pressed against the support of the end portion 521. The support design can prevent the conveying pipe 52 from deviating and shaking during the spraying operation of the slurry output. It can not only effectively support the conveying pipe 52 to be firmly positioned for the spraying operation, but also facilitate the slurry ejected from the injection holes 53 to be effectively distributed and formed between the mold cavities 64 in a uniform staggered manner until the spraying operation is completed. The vacuum unit 7 is then used to remove the excess water generated by the slurry on the upper and lower molds 62 and 63, and the mixed water during the stirring process. The gas in the cavity is extracted by connecting the openings C to the hollow chamber D, so that the slurry sprayed between the upper and lower molds 62 and 63 is gradually formed into the prototype of the filter 8, so as to avoid excessive moisture affecting the process of forming the filter 8. After a period of molding, the demoulding process can be carried out. By properly controlling the movement of the movable seat 61, the movable seat 61 moves in the direction opposite to the conveying pipe 52. At this time, the upper and lower molds 62 and 63 are moved from the original relative positions during the movement. The tightly covered state is converted into a mutually separated mode, and the support member 652 that extends and pushes on the end portion 521 of the output tube 52 will be retracted under the action of the actuator 651, so that the output tube 52 is no longer pushed by the support member 652, until the delivery tube 52 is completely withdrawn from the mold cavity 64. At this time, the preliminary completed filter 8 prototype will be located on the lower mold 63, and then the filter 8 prototype is removed from the lower mold 63 to form a filter 8, that is, Figure 4B As shown, the prototype of the filter 8 that has been manufactured is subjected to subsequent maintenance operations, that is, a process of drying by static, low temperature, medium temperature and high temperature methods is carried out, and this cycle is repeated. After completion, the filter 8 can be used in the required filtration system (not shown in the figure), so that the filter 8 can not only filter dust and powder in use, but also absorb and isolate harmful nitrogen oxides, organic volatile gases, etc. in the exhaust gas, thereby effectively exerting the filtering effect; therefore, through the manufacturing process of the consistent continuous process of material preparation, mixing, spraying, preliminary molding and molding, not only can the molding be achieved quickly, but the molding quality of the filter can also be effectively improved, as well as the production efficiency.

[0059] To summarize the above, the rapid forming method of the filter of the present invention mainly involves mixing the fiber polymer raw materials with water in a certain proportion in a mixing step to form a slurry, outputting the slurry into the forming module through a spraying step, and forming the slurry in a uniform staggered pattern along the shape of the forming module by spraying. During the spraying process, the vacuum unit (i.e., the preliminary forming step) is used to extract and discharge excess water and gas in the slurry, so that the slurry is gradually formed into a filter prototype. After that, demolding and curing can be performed to form a filter. Not only can the forming be achieved quickly, but the filter forming production quality and production efficiency can also be effectively improved.

[0060] However, the above description is only for the purpose of illustrating the preferred embodiments of the present invention and should not be used to limit the scope of the present invention. In other words, any simple equivalent changes and modifications made according to the scope of the patent application and the contents of the invention description should still fall within the scope of the patent of the present invention.

Claims

1. A filter rapid prototyping method, characterized in that: Includes: A material preparation step, which includes preparing a fiber polymer raw material; A mixing step is provided, wherein water is used as a medium, and a stirring unit is provided, wherein the stirring unit comprises a stirring drum for placing the fiber polymer raw material from the previous step, and a stirrer for stirring in the stirring drum, wherein 2 to 150 times of water is added to the stirring drum based on the fiber polymer raw material, and the stirrer stirs and mixes the water to form a slurry; The spraying step is provided with a discharging unit connected to the stirring unit, and a forming module corresponding to the discharging unit, wherein the discharging unit has a rotating cylinder for receiving the slurry, an output pipe connected to the rotating cylinder and transmitting the slurry, and a plurality of injection holes opened on the output pipe for outputting the slurry. The rotating cylinder continuously rotates to stir the received slurry, thereby avoiding the slurry from solidifying prematurely; in addition, the forming module has a movable seat, and two movable members corresponding to the movable seat and moving with the movable seat can be opened and closed. The upper and lower molds are respectively provided with a mold cavity for the output tube to extend into, and the upper and lower molds are provided with a plurality of openings on inner wall surfaces of the upper and lower molds relative to the mold cavity. When the upper and lower molds move toward the output tube along with the movable base, the upper and lower molds gradually become tightly covered with each other, so that the output tube is located between the upper and lower molds. The slurry is sprayed into the mold cavity through the output tube and the plurality of spray holes. Excess water contained in the slurry during spraying can be discharged outside the upper and lower molds through the plurality of openings. A preliminary molding step includes a vacuum unit connected between the upper and lower molds. The vacuum unit is capable of extracting moisture and gas in the mold cavity filled with the slurry through the plurality of openings, so that the slurry sprayed between the upper and lower molds is gradually formed into a filter prototype; and In the forming step, the filter prototype obtained in the upper and lower molds in the preliminary forming step is separated from the upper and lower molds for curing to form a filter.

2. The filter rapid prototyping method according to claim 1, characterized in that: A top pull unit is provided on the side of the upper and lower molds, which can be extended into the mold cavity. The top pull unit has an actuating member and a supporting member that can be acted upon by the actuating member and extended into the mold cavity for movement. When the supporting member is extended, it can support the output pipe to be firmly positioned.

3. The filter rapid prototyping method according to claim 1, characterized in that: The fiber polymer raw material is at least one selected from the group consisting of a mixture of ceramic fiber, glass fiber, aluminum silicate fiber, mineral fiber, plant fiber and organic / inorganic adhesive.

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