Filter element material, method for producing a filter element material, filter element and vehicle

Abstract

The application discloses a filter element material and a preparation method thereof, a filter element and a vehicle, and relates to the technical field of automobiles. The filter element material comprises a filter layer, a bonding layer and a protective layer. The material of the filter layer comprises glass fiber. The bonding layer is coated on the surface of the filter layer. The protective layer is coated on the surface of the side of the bonding layer away from the filter layer. The material of the protective layer comprises nylon. The filter element material with glass fiber as the filter layer has sufficient strength and rigidity to play a self-supporting role, and does not need to additionally use a fixed-pitch hot melt adhesive, thereby greatly reducing the material and process cost of the filter element assembly, reducing the probability of filter element damage, and improving the ammonia resistance of the filter element material. The nylon protective layer can avoid the breakage of glass fiber during the folding process, and has ammonia resistance, and is more suitable for ammonia engine oil filters.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobiles, in particular to a filter element material and a preparation method thereof, a filter element and a vehicle. BACKGROUND

[0002] Under the condition of not changing the engine structure, it is a more feasible technical solution to use high-activity fuel to ignite the internal combustion engine by combining ammonia fuel with other high-activity fuels.

[0003] Traditional engine oil filter materials are not resistant to ammonia, and the engine oil coarse filter of an ammonia diesel engine is damaged after a performance test of 100 hours of operation, and the substrate leaks out; the engine oil pressure is low, and the engine is disassembled: the top of the cylinder head is distributed with broken fibers; the oil collector filter screen is blocked; the oil pump housing is cracked; and the corrosion caused by the formation of ammonia water or nitration products of ammonia gas on the engine oil filter material. SUMMARY

[0004] The present application provides a filter element material and a preparation method thereof, a filter element and a vehicle to solve the problem that existing filter materials are not resistant to ammonia and are prone to damage and fiber breakage.

[0005] In a first aspect, the present application provides a filter element material, comprising:

[0006] a filter layer, the material of the filter layer comprising glass fiber;

[0007] a bonding layer, the bonding layer being coated on the surface of the filter layer; and

[0008] a protective layer, the protective layer being coated on the surface of the bonding layer away from the filter layer, the material of the protective layer comprising nylon.

[0009] The filter element material with glass fiber as the filter layer has sufficient strength and rigidity to function as self-supporting, does not need to use additional fixed-distance hot melt adhesive, greatly reduces the material and process cost of the filter element assembly, reduces the probability of damage to the filter element, and the glass fiber also has certain ammonia resistance, which can improve the ammonia resistance of the filter element material. The nylon protective layer can avoid the phenomenon of glass fiber breakage during folding, and the broken glass fiber dust can enter the engine through the engine oil filter, causing engine part wear, and the nylon protective layer has ammonia resistance and is more suitable for ammonia engine oil filters.

[0010] It should be noted that nylon is PA (polyamide), and common types include polyamide 6, polyamide 66, polyamide 11, polyamide 12 and polyamide 1010.

[0011] In order to improve the filtering precision of the filter core material, the glass fibers can be composed of superfine fibers with a diameter of 0.5 μm to thick fibers with a diameter of 35 μm.

[0012] In some embodiments, the thickness of the protective layer is 0.2 mm to 0.4 mm. Within this range, the protective layer can improve the protection of the glass fiber layer and improve the ammonia resistance of the filter core material.

[0013] The diameter of the nylon is 1 μm to 10 μm. Within this range, the nylon can be solidified into short and fine fibers on the glass fiber filter material, thereby improving the protection of the glass fiber layer by the protective layer and improving the ammonia resistance of the filter core material.

[0014] In some embodiments, the material of the adhesive layer includes at least one of phenolic resin, acrylic resin and epoxy resin. The use of at least one of the above materials can improve the bonding strength between the protective layer and the filter layer, reduce the peeling between the filter layer and the protective layer, and improve the filtering performance and ammonia resistance of the filter core material.

[0015] The thickness of the adhesive layer is 2 μm to 10 μm. Within this range, the adhesive layer can improve the bonding strength between the protective layer and the filter layer, reduce the peeling between the filter layer and the protective layer, and improve the filtering performance and ammonia resistance of the filter core material.

[0016] The thickness of the filter layer is 0.6 mm to 1.0 mm. Within this range, the filter layer can improve the filtering performance of the filter core material.

[0017] In a second aspect, the application provides a preparation method of a filter core material, which is used to prepare the filter core material of the first aspect, and includes the following steps:

[0018] The glass fiber slurry is prepared into a wet filter layer.

[0019] The wet filter layer is dried to obtain a filter layer.

[0020] The filter layer is immersed in an adhesive layer slurry and dried to obtain a filter layer containing an adhesive layer.

[0021] The nylon is melt-blown on the surface of the filter layer containing the adhesive layer, and is subjected to ultrasonic treatment and welding pressure to obtain the filter core material.

[0022] The nylon fibers are distributed on the surface of the glass fiber filter material by using a melt-blowing process, and the nylon fibers and the glass fiber filter material are welded by using an ultrasonic welding process. When the ultrasonic wave acts on the nylon contact surface, high-frequency vibration of tens of thousands of times per second is generated. The high-frequency vibration of a certain amplitude is transmitted to the interface between the nylon fiber and the glass fiber by the nylon fiber. Because the sound resistance is large at the interface, local high temperature is generated. Because the thermal conductivity of nylon is poor, the heat cannot be dissipated in time, and the heat is accumulated at the contact surface, causing the contact surface of the nylon to melt rapidly. After a certain pressure is applied, the nylon molecules are bonded to the glass fiber filter material under the action of thermal motion and intermolecular force. The filter material after the nylon protective layer is welded by the ultrasonic wave can improve the toughness of the glass fiber filter material and avoid the breakage of the glass fiber during the folding process. At the same time, due to the corrosion resistance of nylon, the filter material can realize the ammonia resistance.

[0023] When the ultrasonic wave stops acting, the welding pressure can make the pressure continue, so that the nylon fiber melted at the interface is immersed into the glass fiber gap and wraps part of the glass fiber to solidify and form, achieving the purpose of welding.

[0024] In some embodiments, the preparation of the glass fiber slurry into a wet filter layer comprises:

[0025] The fibers are dispersed in water to obtain a first glass fiber slurry;

[0026] The pH of the glass fiber slurry is adjusted to 2.5-3.5 to obtain a second glass fiber slurry;

[0027] The second glass fiber slurry is mixed with a dispersing agent to obtain a third glass fiber slurry;

[0028] The third glass fiber slurry is impurity-removed and diluted to obtain a fourth glass fiber slurry;

[0029] The fourth glass fiber slurry is formed into a wet filter layer by wire mesh forming.

[0030] The pH of the glass fiber slurry is adjusted to 2.5-3.5, i.e. an acidic environment. In this way, the SiO2 component in the glass fiber forms a colloidal SiO2 layer on the surface of the fiber under the action of the acid, which promotes the suspension and dispersion of the fiber and also plays a role similar to that of an adhesive to enhance the glass fiber. H2SO4, HNO3 and HCl can be used for pH adjustment.

[0031] The step of impurity-removing and diluting the third glass fiber slurry can be that the mixed fiber slurry is sequentially conveyed to a pressure screen and a slag remover to remove light and heavy impurities; and then the slurry is conveyed to a slurry pump for further dilution.

[0032] The step of forming the fourth glass fiber slurry into a wet filter layer by wire mesh forming can be that the diluted slurry is formed into a wet filter layer by wire mesh forming through a headbox and a former.

[0033] In some embodiments, the dispersant comprises cationic polyacrylamide (CPAM), which has both reinforcing effect and certain suspension dispersion effect on the glass fiber, and the paper uniformity is good; and / or,

[0034] The mass percentage of the glass fiber in the first glass fiber slurry is 0.2% to 5%, and the mass percentage of the glass fiber in the first glass fiber slurry in this range is helpful for the dispersion of the glass fiber; and / or,

[0035] The mass percentage of the glass fiber in the fourth glass fiber slurry is 0.005% to 0.2%, and the mass percentage of the glass fiber in the fourth glass fiber slurry in this range is helpful for the on-line forming.

[0036] In some embodiments, the wet filter layer is dried to obtain a filter layer, and the drying temperature is 130°C to 150°C, and the drying temperature in this range can remove the moisture in the filter layer; and / or,

[0037] The wet filter layer is dried to obtain a filter layer, and the drying time is 1h to 2h, and the drying time in this range can remove the moisture in the filter layer; and / or,

[0038] The filter layer is immersed in the binder layer slurry and dried to obtain a filter layer containing a binder layer, and the drying temperature is 130°C to 150°C, and the drying temperature in this range can remove the solvent in the binder layer slurry; and / or,

[0039] The filter layer is immersed in the binder layer slurry and dried to obtain a filter layer containing a binder layer, and the drying time is 1h to 2h, and the drying time in this range can remove the solvent in the binder layer slurry.

[0040] In some embodiments, the nylon is melt-blown on the surface of the filter layer containing the binder layer, ultrasonic treatment and welding pressure are performed to obtain a filter core material, and the filter core material comprises:

[0041] The melt-blown melting temperature is 200°C to 295°C, and the melt-blown melting temperature in this range can melt the nylon, which is convenient for melt-blown into nylon fibers; and / or,

[0042] The diameter of the melt-blown nylon is 1μm to 10μm, and the diameter of the nylon in this range can be solidified into short and fine fibers on the glass fiber filter material, improve the protection of the glass fiber layer by the protective layer, and improve the ammonia resistance of the filter core material; and / or,

[0043] The melt-blown roller speed is 40m / min to 100m / min, and the melt-blown roller speed in this range can obtain a protective layer of corresponding thickness; and / or,

[0044] The power of the ultrasonic is 30Hz-50Hz. In this range, the nylon fiber and the glass fiber filter material are welded by the ultrasonic welding process. When the ultrasonic acts on the nylon contact surface, high-frequency vibration is generated. The high-frequency vibration transmits the ultrasonic energy to the interface between the nylon fiber and the glass fiber through the nylon fiber. Because the acoustic resistance at the interface is large, local high temperature is generated. Because the thermal conductivity of nylon is poor, the heat cannot be dissipated in time, and the heat is accumulated at the contact surface, so that the contact surface of the nylon is rapidly melted and fused with the filter layer under the welding pressure; and / or,

[0045] The time of the ultrasonic is 0.2s-1s. In this range, the contact surface of the nylon can be rapidly melted and fused with the filter layer under the welding pressure; and / or,

[0046] The pressure of the welding pressure is 0.5MPa-1.6MPa. In this range, the melted nylon can be fused with the filter layer; and / or,

[0047] The time of the welding pressure is 5-10s. In this range, the melted nylon can be fused with the filter layer; and / or,

[0048] The temperature of the welding pressure is 80-120℃. In this range, the melted nylon can be fused with the filter layer.

[0049] The step of melt blowing can be: putting PA particles into an extruder and melting in the extruder. At the melting temperature, the melt passes through a metering pump to a melt blowing die. The metering pump measures the melt flow rate output to the nozzle. The spinneret is a row of capillaries with a spacing of less than 1mm and a diameter of 0.2-0.4mm. Compressed air at 270-300℃ is added through the air inlet holes on both sides. When the polymer extrusion spinneret is just formed, the head of the compressed air acts on the polymer to stretch the hot filament to a diameter of 1-10μm at a speed higher than the speed of sound (550m / s), and the hot filament is attached to the glass fiber filter material to solidify into short and fine fibers. The thickness of the nylon protective layer is 0.2mm-0.4mm. In the glass fiber nylon composite filter material, the glass fiber plays a filtering role, and the nylon plays a role of solidifying and protecting the structure of the glass fiber filter material. The glass fiber filter paper with the melt-blown nylon protective layer is placed in an ultrasonic welding machine, and the nylon fiber and the glass fiber filter material are welded by the ultrasonic welding process. The melted nylon fiber at the interface is immersed into the glass fiber gap and partially wraps the glass fiber to solidify and form, so as to achieve the purpose of welding.

[0050] In a third aspect, the application provides a filter core comprising the filter core material prepared by the preparation method of the filter core material of the second aspect.

[0051] In a fourth aspect, the application provides a vehicle comprising the filter core of the third aspect. DETAILED DESCRIPTION

[0052] In order to make the purpose, technical solutions and advantages of the present application clearer, the technical solutions of the present application will be described clearly and completely below in combination with the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0053] In the case of not changing the engine structure, it is a more feasible technical solution to use high-activity fuel to ignite the internal combustion engine in combination with ammonia fuel and other high-activity fuels.

[0054] The main function of the vehicle oil filter is to remove metal particles, carbon deposits and dust and other pollutants in the oil to prevent the pollutants in the oil from damaging engine parts due to adverse effects on the cooperation between parts. The requirements of heavy-duty engine for oil filtration material are generally higher than those of passenger car, mainly because the material needs different pollution carrying capacity and different aging resistance performance due to different replacement mileage. For example, passenger cars generally recommend replacing oil and oil filter every 5000-10000 kilometers, while commercial vehicles have increased from 50000 kilometers of national four and five to 100000 kilometers of national six, and even 150000 kilometers for oil and oil filter replacement. In addition, due to the higher average working temperature of diesel engine, the oil of high-power diesel engine ages faster than that of gasoline engine, so the aging resistance performance of the filtration material is also higher.

[0055] The filtration precision of the national sixth ammonia diesel engine filter is often up to 4um 99.5% or even higher due to the need to protect the precise gap of 1.5um high-pressure common rail system. At the same time, when the ammonia diesel engine is working, the high-pressure combustible mixture in the combustion chamber and the exhaust gas may leak into the crankcase through the gap between the piston ring and the cylinder, causing blow-by gas. The blow-by gas mixture contains unburned ammonia gas, which enters the engine oil, reduces the performance of the engine oil, accelerates the oxidation of the engine oil, forms sludge, blocks the engine oil circuit, and then the engine oil enters the engine oil filter again. At present, the material of the engine oil filter is generally low-end wood pulp material, medium-end material mixed with synthetic fiber mainly PET and micro glass fiber material, and high-end product without wood pulp material. Not only does the dust holding capacity increase, but the aging resistance also increases. However, these traditional engine oil filter materials are not resistant to ammonia, and there are currently few production engine oil filters that are specifically designed for ammonia diesel engines, especially those that are resistant to ammonia water. In particular, during the ammonia diesel engine bench test, the ammonia diesel engine oil filter broke after 100h performance test, and the nylon liner leaked out; the engine oil pressure was low, and the cylinder head was found to be distributed with broken fibers; the oil collector filter screen was blocked; the oil pump housing was cracked; it was judged that the corrosion of the engine filter material caused by the formation of ammonia water or the nitration product of ammonia gas.

[0056] Therefore, the application provides a filter element material, a preparation method thereof, a filter element and a vehicle to solve the problems of existing filter materials that are not resistant to ammonia and are prone to breakage and fiber breakage.

[0057] In a first aspect, the application provides a filter element material, which comprises a filter layer, a bonding layer and a protective layer. The material of the filter layer comprises glass fiber. The bonding layer is coated on the surface of the filter layer. The protective layer is coated on the surface of the side of the bonding layer away from the filter layer, and the material of the protective layer comprises nylon.

[0058] The filter element material of the application uses glass fiber as the filter layer, which has sufficient strength and rigidity to function as a self-supporting element, eliminating the need for additional fixed-distance hot melt glue, greatly reducing the material and process cost of the filter element assembly, and reducing the probability of filter element breakage. The glass fiber also has certain ammonia resistance, which can improve the ammonia resistance of the filter element material. The nylon protective layer can prevent the glass fiber from breaking during folding, and the broken glass fiber dust can enter the engine through the engine oil filter, causing engine part wear. On the other hand, the nylon protective layer has ammonia resistance and is more suitable for ammonia engine oil filters.

[0059] It should be noted that nylon is PA (polyamide), and common types include polyamide 6, polyamide 66, polyamide 11, polyamide 12 and polyamide 1010.

[0060] In order to improve the filtering precision of the filter material, the glass fibers can be composed of superfine fibers with a diameter of 0.5 μm to thick fibers with a diameter of 35 μm.

[0061] In combination with the first aspect, in some embodiments provided in the application, the thickness of the protective layer is 0.2 mm to 0.4 mm. The thickness of the protective layer in this range can improve the protection of the glass fiber layer by the protective layer, and improve the ammonia resistance of the filter material. The thickness of the protective layer includes but is not limited to 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm or 0.4 mm.

[0062] In combination with the first aspect, in some embodiments provided in the application, the diameter of the nylon is 1 μm to 10 μm. The diameter of the nylon in this range can be consolidated into short and thin fibers on the glass fiber filter material, improve the protection of the glass fiber layer by the protective layer, and improve the ammonia resistance of the filter material. The diameter of the nylon includes but is not limited to 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm or 10 μm.

[0063] In combination with the first aspect, in some embodiments provided in the application, the material of the adhesive layer includes at least one of phenolic resin, acrylic resin and epoxy resin. The material of the adhesive layer includes at least one of the above-mentioned materials, which can improve the bonding strength between the protective layer and the filter layer, reduce the falling off between the filter layer and the protective layer, and improve the filtering performance and ammonia resistance of the filter material.

[0064] In combination with the first aspect, in some embodiments provided in the application, the thickness of the adhesive layer is 2 μm to 10 μm. The thickness of the adhesive layer in this range can improve the bonding strength between the protective layer and the filter layer, reduce the falling off between the filter layer and the protective layer, and improve the filtering performance and ammonia resistance of the filter material. The thickness of the adhesive layer includes but is not limited to 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm or 10 μm.

[0065] In combination with the first aspect, in some embodiments provided in the application, the thickness of the filter layer is 0.6 mm to 1.0 mm. The thickness of the filter layer in this range can improve the filtering performance of the filter material. The thickness of the filter layer includes but is not limited to 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or 1.0 mm.

[0066] The second aspect provides a preparation method of a filter material, which is used to prepare the filter material of the first aspect, and includes the following steps:

[0067] The glass fiber slurry is prepared into a wet filter layer;

[0068] The wet filter layer is dried to obtain a filter layer;

[0069] The filter layer is immersed in a bonding layer slurry, dried to obtain a filter layer containing a bonding layer;

[0070] The nylon is melt-blown on the surface of the filter layer containing the bonding layer, and ultrasonic treatment and welding pressure are performed to obtain a filter core material.

[0071] The nylon fibers are distributed on the surface of the glass fiber filter material by using a melt-blown process, and the nylon fibers and the glass fiber filter material are welded by using an ultrasonic welding process. When the ultrasonic wave acts on the nylon contact surface, high-frequency vibration of tens of thousands of times per second is generated. The high-frequency vibration of a certain amplitude is transmitted to the interface between the nylon fibers and the glass fibers through the nylon fibers, and local high temperature is generated at the interface due to the large acoustic resistance. Since the nylon has poor thermal conductivity, it cannot be dissipated in time and accumulates at the contact surface, causing the nylon contact surface to melt rapidly. After a certain pressure is applied, the nylon is fused into one body. The filter material after the ultrasonic welding of the nylon protective layer can improve the toughness of the glass fiber filter material and avoid the breakage of the glass fiber during the folding process. At the same time, due to the corrosion-resistant properties of the nylon, the filter material can achieve ammonia resistance.

[0072] When the ultrasonic wave stops acting, the welding pressure can make the pressure continue, so that the nylon fibers melted at the interface are immersed into the glass fiber gaps and wrap part of the glass fibers to solidify and form, achieving the purpose of welding.

[0073] In combination with the second aspect, in some embodiments provided in the application, the preparation of the glass fiber slurry into a wet filter layer comprises:

[0074] The fibers are dispersed by beating in water to obtain a first glass fiber slurry;

[0075] The pH of the glass fiber slurry is adjusted to 2.5-3.5 to obtain a second glass fiber slurry;

[0076] The second glass fiber slurry is mixed with a dispersing agent to obtain a third glass fiber slurry;

[0077] The third glass fiber slurry is impurity-removed and diluted to obtain a fourth glass fiber slurry;

[0078] The fourth glass fiber slurry is formed into a wet filter layer by wire meshing.

[0079] The pH of the glass fiber slurry is adjusted to 2.5-3.5, i.e. an acidic environment, so that the SiO2 component in the glass fiber forms a colloidal SiO2 layer on the surface of the fiber under the action of the acid, which promotes the suspension and dispersion of the fiber and also plays a role similar to that of an adhesive to enhance the glass fiber. H2SO4, HNO3 and HCl can be used to adjust the pH. The pH can be adjusted to 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4 or 3.5, but is not limited thereto.

[0080] The step of removing impurities and diluting the third glass fiber slurry can be to sequentially deliver the mixed fiber slurry to a pressure screen and a slag remover to remove light and heavy impurities therefrom, and then deliver the slurry to a pulp pump for further dilution.

[0081] The step of forming the fourth glass fiber slurry into a wet filter layer can be to form the diluted slurry into a wet filter layer by a headbox and a former.

[0082] In combination with the second aspect, in some embodiments provided in the present application, the dispersant comprises cationic polyacrylamide (CPAM), which has both reinforcing effect and certain suspension and dispersion effect on the glass fiber, and the paper uniformity is good.

[0083] In combination with the second aspect, in some embodiments provided in the present application, the mass percentage of the glass fiber in the first glass fiber slurry is 0.2%-5%, and the mass percentage of the glass fiber in the first glass fiber slurry within this range is helpful for the dispersion of the glass fiber. The mass percentage of the glass fiber in the first glass fiber slurry includes but is not limited to 0.2%, 0.5%, 1%, 1.5%, 2.0%, 2.5%, 3.0%, 3.5%, 4.0%, 4.5% or 5.0%.

[0084] In combination with the second aspect, in some embodiments provided in the present application, the mass percentage of the glass fiber in the fourth glass fiber slurry is 0.005%-0.2%, and the mass percentage of the glass fiber in the fourth glass fiber slurry within this range is helpful for the forming of the wet filter layer. The mass percentage of the glass fiber in the fourth glass fiber slurry includes but is not limited to 0.005%, 0.01%, 0.03%, 0.05%, 0.08%, 0.1%, 0.12%, 0.15%, 0.18% or 0.2%.

[0085] In combination with the second aspect, in some embodiments provided in the present application, the drying temperature of the wet filter layer is 130-150°C, and the drying temperature within this range can remove the moisture in the filter layer. The drying temperature includes but is not limited to 130°C, 132°C, 135°C, 138°C, 140°C, 142°C, 145°C, 147°C or 150°C.

[0086] With reference to the second aspect, in some embodiments of the present application, the drying the wet filter layer to obtain a filter layer, the drying time is 1h-2h, and the drying time in this range can remove the moisture in the filter layer. The drying time includes but is not limited to 1h, 1.1h, 1.2h, 1.3h, 1.4h, 1.5h, 1.6h, 1.7h, 1.8h, 1.9h or 2.0h.

[0087] With reference to the second aspect, in some embodiments of the present application, the dipping the filter layer into the adhesive layer slurry and drying to obtain an adhesive layer-containing filter layer, the drying temperature is 130℃-150℃, and the drying temperature in this range can remove the solvent in the adhesive layer slurry. The drying temperature includes but is not limited to 130℃, 132℃, 135℃, 138℃, 140℃, 142℃, 145℃, 147℃ or 150℃.

[0088] With reference to the second aspect, in some embodiments of the present application, the dipping the filter layer into the adhesive layer slurry and drying to obtain an adhesive layer-containing filter layer, the drying time is 1h-2h, and the drying time in this range can remove the solvent in the adhesive layer slurry. The drying time includes but is not limited to 1h, 1.1h, 1.2h, 1.3h, 1.4h, 1.5h, 1.6h, 1.7h, 1.8h, 1.9h or 2.0h.

[0089] With reference to the second aspect, in some embodiments of the present application, the melt-blowing the nylon on the surface of the adhesive layer-containing filter layer and ultrasonic treatment and welding pressure to obtain a filter core material, the melt-blowing melt temperature of the melt-blowing is 200℃-295℃, and the melt-blowing melt temperature in this range can melt the nylon, which is convenient for melt-blowing into nylon fibers. The melt-blowing melt temperature includes but is not limited to 200℃, 205℃, 210℃, 215℃, 220℃, 225℃, 230℃, 235℃, 240℃, 245℃, 250℃, 255℃, 260℃, 265℃, 270℃, 275℃, 280℃, 285℃, 290℃ or 295℃.

[0090] With reference to the second aspect, in some embodiments of the present application, the melt-blowing the nylon on the surface of the adhesive layer-containing filter layer and ultrasonic treatment and welding pressure to obtain a filter core material, the diameter of the melt-blowing nylon is 1μm-10μm, and the diameter of the nylon in this range can be solidified into short and fine fibers on the glass fiber filter material, which improves the protection of the glass fiber layer by the protective layer and improves the ammonia resistance of the filter core material. The diameter of the melt-blowing nylon includes but is not limited to 1μm, 2μm, 3μm, 4μm, 5μm, 6μm, 7μm, 8μm, 9μm or 10μm.

[0091] In some embodiments of the second aspect, the nylon melt-blown is applied to the surface of the filter layer with the adhesive layer, and ultrasonic treatment and welding pressure are performed to obtain the filter element material, wherein the rotation speed of the melt-blown roller is 40 m / min to 100 m / min. The rotation speed of the melt-blown roller includes, but is not limited to, 40 m / min, 50 m / min, 60 m / min, 70 m / min, 80 m / min, 90 m / min, or 100 m / min.

[0092] In some embodiments of the second aspect, the nylon melt-blown is applied to the surface of the filter layer with the adhesive layer, and ultrasonic treatment and welding pressure are performed to obtain the filter element material, wherein the power of the ultrasonic treatment is 30 Hz to 50 Hz. The power of the ultrasonic treatment in this range can weld the nylon fiber and the glass fiber filter material by using the ultrasonic welding process. When the ultrasonic treatment acts on the nylon contact surface, high-frequency vibration is generated. The high-frequency vibration transmits the ultrasonic energy to the interface between the nylon fiber and the glass fiber through the nylon fiber. Due to the large acoustic resistance at the interface, local high temperature is generated. Since the nylon has poor thermal conductivity, the heat cannot be dissipated in time, and is accumulated at the contact surface, so that the contact surface of the nylon is rapidly melted and integrated with the filter layer under the welding pressure. The power of the ultrasonic treatment includes, but is not limited to, 30 Hz, 32 Hz, 35 Hz, 37 Hz, 40 Hz, 42 Hz, 45 Hz, 48 Hz, or 50 Hz.

[0093] In some embodiments of the second aspect, the nylon melt-blown is applied to the surface of the filter layer with the adhesive layer, and ultrasonic treatment and welding pressure are performed to obtain the filter element material, wherein the ultrasonic treatment time is 0.2 s to 1 s. The ultrasonic treatment time in this range can make the contact surface of the nylon rapidly melt and integrate with the filter layer under the welding pressure. The ultrasonic treatment time includes, but is not limited to, 0.2 s, 0.3 s, 0.35 s, 0.4 s, 0.45 s, 0.5 s, 0.55 s, 0.6 s, 0.65 s, 0.7 s, 0.75 s, 0.8 s, 0.9 s, or 1 s.

[0094] In some embodiments of the second aspect, the nylon melt-blown is applied to the surface of the filter layer with the adhesive layer, and ultrasonic treatment and welding pressure are performed to obtain the filter element material, wherein the welding pressure is 0.5 MPa to 1.6 MPa. The welding pressure in this range can make the molten nylon integrate with the filter layer. The welding pressure includes, but is not limited to, 0.5 MPa, 0.6 MPa, 0.7 MPa, 0.8 MPa, 0.9 MPa, 1.0 MPa, 1.1 MPa, 1.2 MPa, 1.3 MPa, 1.4 MPa, 1.5 MPa, or 1.6 MPa.

[0095] With reference to the second aspect, in some embodiments provided in the present application, the step of ultrasonic treatment and welding pressure to obtain the filter core material, the welding pressure time is 5-10s. The welding pressure time in this range can make the molten nylon and the filter layer into one. The welding pressure time includes but is not limited to 5s, 5.5s, 6s, 6.5s, 7s, 7.5s, 8s, 8.5s, 9s, 9.5s or 10s.

[0096] With reference to the second aspect, in some embodiments provided in the present application, the step of ultrasonic treatment and welding pressure to obtain the filter core material, the welding pressure temperature is 80-120℃. The welding pressure temperature in this range can make the molten nylon and the filter layer into one. The welding pressure temperature includes but is not limited to 80℃, 85℃, 90℃, 95℃, 100℃, 105℃, 110℃, 115℃ or 120℃.

[0097] The step of melt blowing can be: putting PA granules into an extruder and melting in the extruder. At the melting temperature, the melt passes through a metering pump to a melt blowing die. The metering pump measures the melt flow rate output to the nozzle. The spinneret is a row of capillaries with a spacing of less than 1mm and a diameter of 0.2-0.4mm. Compressed air at 270-300℃ is added through the air inlet holes on both sides. At the moment the polymer extrusion spinneret is formed, the head end of the compressed air acts on the polymer to stretch the hot filament to a diameter of 1-10μm at a gas flow rate higher than the speed of sound (550m / s), and to adhere to the glass fiber filter material to solidify into short and fine fibers. The thickness of the nylon protective layer is 0.2mm-0.4mm. In the glass fiber nylon composite filter material, the glass fiber plays a filtering role, and the nylon plays a role of solidifying and protecting the structure of the glass fiber filter material. The glass fiber filter paper with the melt blown nylon protective layer is placed in an ultrasonic welding machine to weld the nylon fiber and the glass fiber filter material by using ultrasonic welding process. The molten nylon fiber at the junction is immersed in the glass fiber gap and wraps part of the glass fiber to solidify and form, achieving the purpose of welding.

[0098] In a third aspect, the present application provides a filter core comprising the filter core material of the first aspect or the filter core material prepared by the method of the second aspect.

[0099] In a fourth aspect, the present application provides a vehicle comprising the filter core of the third aspect.

[0100] The technical solutions provided in the present application will be described in detail below with reference to the embodiments.

[0101] Embodiment 1

[0102] The embodiment 1 of the present application provides a filter core material, comprising:

[0103] a filter layer, a material of the filter layer includes glass fiber, a diameter ratio of the glass fiber is (0.5-1 μm):(1-10 μm):(10-35 μm)=2:3:1, a thickness of the filter layer is 0.6 mm;

[0104] a bonding layer, the bonding layer is coated on a surface of the filter layer, a material of the bonding layer includes phenolic resin, a thickness of the bonding layer is 2 μm; and

[0105] a protective layer, the protective layer is coated on a surface of the bonding layer away from the filter layer, a material of the protective layer includes nylon 6, a diameter of the nylon 6 is 1 μm, a thickness of the protective layer is 0.2 mm.

[0106] Embodiment 2

[0107] The embodiment 2 of the application provides a filter core material, which comprises:

[0108] a filter layer, a material of the filter layer includes glass fiber, a diameter ratio of the glass fiber is (0.5-1 μm):(1-10 μm):(10-35 μm)=1:4:2, a thickness of the filter layer is 1.0 mm;

[0109] a bonding layer, the bonding layer is coated on a surface of the filter layer, a material of the bonding layer includes acrylic resin, a thickness of the bonding layer is 5 μm; and

[0110] a protective layer, the protective layer is coated on a surface of the bonding layer away from the filter layer, a material of the protective layer includes nylon 11, a diameter of the nylon 11 is 10 μm, a thickness of the protective layer is 0.4 mm.

[0111] Embodiment 3

[0112] The embodiment 3 of the application provides a filter core material, which comprises:

[0113] a filter layer, a material of the filter layer includes glass fiber, a diameter ratio of the glass fiber is (0.5-1 μm):(1-10 μm):(10-35 μm)=1:4:1, a thickness of the filter layer is 0.8 mm;

[0114] a bonding layer, the bonding layer is coated on a surface of the filter layer, a material of the bonding layer includes epoxy resin, a thickness of the bonding layer is 10 μm; and

[0115] a protective layer, the protective layer is coated on a surface of the bonding layer away from the filter layer, a material of the protective layer includes nylon 12, a diameter of the nylon 12 is 5 μm, a thickness of the protective layer is 0.3 mm.

[0116] Embodiment 4

[0117] Embodiment 4 of the present application provides a filter core material preparation method, comprising the following steps:

[0118] Water is injected into a pulper, and glass fibers with a diameter of 20 μm are put into the pulper, the pulper uniformly disperses the fibers to form a glass fiber slurry with a mass concentration of 0.2%;

[0119] The pH value of the glass fiber slurry is adjusted to 3 by adding HCl;

[0120] Cationic polyacrylamide (CPAM) is added to the fiber slurry, so that the mass fraction of the cationic polyacrylamide (CPAM) in the mixed solution is 1%;

[0121] The mixed fiber slurry is sequentially conveyed to a pressure screen and a deslagger to remove light and heavy impurities therein, and then the slurry is conveyed to a slurry pump for further dilution to a slurry concentration of 0.1%;

[0122] The diluted slurry is formed into a wet filter paper web, i.e. a wet filter layer, by a headbox and a former on a wire;

[0123] The wet filter layer is dried in a first drying section at a drying temperature of 130°C for 2h to form a dry filter layer 0.8mm thick;

[0124] The dry protective layer is coated by immersion coating, and the coating is a phenolic resin;

[0125] After coating, drying is performed at a drying temperature of 130°C for 2h, and the thickness of the adhesive layer after drying is 10 μm;

[0126] The nylon (PA12) protective layer is attached to the surface of the glass fiber filter material by melt blowing, and the specific steps are as follows: PA12 granules are put into an extruder and melted in the extruder at a melting temperature of 250°C; 300°C compressed air is added to the air inlet holes on both sides; when the polymer extrusion spinneret is just formed, the head end of the compressed air acts on the polymer to stretch the hot filament to a diameter of 5 μm at an air flow of 550 m / s, and the hot filament is attached to the glass fiber filter material to solidify into ultra-fine fibers;

[0127] The glass fiber filter paper with the attached nylon protective layer is placed in an ultrasonic welding machine, and the nylon fiber and the glass fiber filter material are welded by ultrasonic welding process. The working frequency of the ultrasonic welding machine is 40 KHZ, the welding time is 0.35s, and the welding pressure is 0.66MPa. After the ultrasonic wave stops acting, the pressure is maintained at 0.66MPa and 100°C for 5s, so that the melted nylon fiber at the junction is immersed into the glass fiber gap and wraps part of the glass fiber to solidify and form, achieving the purpose of welding. The thickness of the protective layer is 0.3mm, and the filter core material is obtained.

[0128] Comparative Example 1

[0129] The comparative example 1 of the present application provides a filter core material, comprising:

[0130] a filter layer, the material of the filter layer comprises glass fiber, the diameter ratio of the glass fiber ranges from (0.5-1 μm):(1-10 μm):(10-35 μm) = 2:2:1, and the thickness of the filter layer is 0.6 mm;

[0131] a bonding layer, the material of the bonding layer comprises phenolic resin, and the thickness of the bonding layer is 2 μm; and

[0132] a protective layer, the material of the protective layer comprises PET, the diameter of the PET is 5 μm, and the thickness of the protective layer is 0.2 mm.

[0133] Comparative example 2

[0134] The comparative example 2 of the present application provides a filter core material, comprising:

[0135] a filter layer, the material of the filter layer comprises wood pulp fiber, the diameter ratio of the wood pulp fiber ranges from (0.5-1 μm):(1-10 μm):(10-35 μm) = 1:1:2;

[0136] a bonding layer, the material of the bonding layer comprises phenolic resin, and the thickness of the bonding layer is 2 μm;

[0137] no protective layer.

[0138] Comparative example 3

[0139] The comparative example 3 of the present application provides a filter core material, comprising:

[0140] a filter layer, the material of the filter layer comprises full-synthetic PET fiber, the diameter ratio of the full-synthetic PET fiber ranges from (0.5-1 μm):(1-10 μm):(10-35 μm) = 2:2:1;

[0141] a bonding layer, the material of the bonding layer comprises acrylic resin, and the thickness of the bonding layer is 2 μm;

[0142] no protective layer.

[0143] Performance test

[0144] The filter core materials of examples 1-4 and comparative examples 1-3 are subjected to performance test, and the filtration performance, air permeability, MD tensile strength and CD tensile strength are tested, and the results are shown in Table 1, wherein:

[0145] The measurement method of the filtration performance is ISO 16889.

[0146] The measurement method of the air permeability is TAPPI.

[0147] The measurement method of MD tensile strength is TAPPI.

[0148] The measurement method of CD tensile strength is TAPPI.

[0149] The ammonia resistance performance test method is as follows:

[0150] The ammonia resistance performance test uses engine oil containing 2.5% ammonia, the test temperature is 120°C, and the test time is 50h, 100h, 200h, 400h, and 500h respectively.

[0151] After the ammonia resistance test, the tensile strength of the filter paper is tested by a tensile testing machine, and when the tensile strength is lower than 50% of the initial strength, the filter material is determined to be invalid.

[0152] Table 1 Performance of filter core materials of examples 1 to 4 and comparative examples 1 to 2

[0153]

[0154] As can be seen from Table 1, the filter core materials of examples 1 to 4 have high dust holding capacity, high stiffness and burst resistance, which can effectively prolong the service life and reduce the replacement frequency.

[0155] Comparative example 1 has poor ammonia resistance because PET will decompose in an ammonia environment, and the PET protective layer is not resistant to ammonia.

[0156] Comparative example 2 has poor ammonia resistance because wood pulp fiber is not resistant to ammonia.

[0157] Comparative example 3 has poor ammonia resistance because PET fiber is not resistant to ammonia.

[0158] In summary, the filter core material with glass fiber as the filter layer has sufficient strength and stiffness to function as a self-supporting structure, and does not need to use additional fixed-distance hot melt glue, greatly reducing the material and process cost of the filter core assembly, and also reducing the probability of filter core damage. Glass fiber also has certain ammonia resistance, which can improve the ammonia resistance of the filter core material. The nylon protective layer can prevent the glass fiber from breaking during folding, and the broken glass fiber dust can enter the engine through the oil filter, causing engine part wear. On the other hand, the nylon protective layer has ammonia resistance and is more suitable for ammonia engine oil filters.

[0159] In the description of the specification, the description of the terms "one embodiment / way", "some embodiments / ways", "an example", "a specific example" or "some examples" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment / way or example are included in at least one embodiment / way or example of the present application. In the specification, the illustrative description of the above terms does not necessarily refer to the same embodiment / way or example. Also, the specific features, structures, materials or characteristics described can be combined in any appropriate manner in one or more embodiments / ways or examples. In addition, the person skilled in the art can combine and combine the different embodiments / ways or examples described in the specification and the features of the different embodiments / ways or examples, without contradiction.

[0160] It should be noted that in the present application, the relationship terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between the entities or operations. Moreover, the terms "include", "contain" or any other variant thereof are intended to cover non-exclusive inclusion, so that the process, method, article or device including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or device. Without more limitations, the element defined by the statement "including a" does not exclude the presence of another identical element in the process, method, article or device including the element. In the present application, the meaning of "a plurality of" is at least two, for example two, three, etc., unless otherwise explicitly specified.

[0161] The above is only a specific embodiment of the present application, which enables those skilled in the art to understand or implement the present application. Various modifications of these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to these embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features applied herein.

Claims

1. A filter element material, characterized by The filter core material comprises: a filter layer, a material of the filter layer comprising glass fibers; a bonding layer, the bonding layer being coated on a surface of the filter layer; and a protective layer, the protective layer being coated on a surface of the bonding layer away from the filter layer, a material of the protective layer comprising nylon. The filter core material is prepared by the following method: preparing a wet filter layer from a glass fiber slurry; drying the wet filter layer to obtain the filter layer; immersing the filter layer in a bonding layer slurry and drying to obtain a filter layer with a bonding layer; melt-blowing nylon on a surface of the filter layer with the bonding layer, ultrasonic treatment and welding pressure to obtain the filter core material. The ultrasonic treatment is performed for 0.2s-1s. The welding pressure is performed at a pressure of 0.5MPa-1.6MPa. The welding pressure is performed for 5-10s. The welding pressure is performed at a temperature of 80-120℃. The protective layer has a thickness of 0.2mm-0.4mm. The diameter of the nylon is 1μm-10μm. The bonding layer comprises at least one of phenolic resin, acrylic resin and epoxy resin. The bonding layer has a thickness of 2μm-10μm. The filter layer has a thickness of 0.6mm-1.0mm. The glass fibers have a diameter of 0.5μm-35μm.

2. The filter element material of claim 1, wherein, The preparing of the wet filter layer from the glass fiber slurry comprises: beating and dispersing the fibers in water to obtain a first glass fiber slurry; adjusting the pH of the glass fiber slurry to 2.5-3.5 to obtain a second glass fiber slurry; mixing the second glass fiber slurry with a dispersant to obtain a third glass fiber slurry; removing impurities and diluting the third glass fiber slurry to obtain a fourth glass fiber slurry; forming the fourth glass fiber slurry into a wet filter layer.

3. The filter core material of claim 2, wherein: the dispersant comprises cationic polyacrylamide; and / or the mass percentage of the glass fibers in the first glass fiber slurry is 0.2%-5%; and / or the mass percentage of the glass fibers in the fourth glass fiber slurry is 0.005%-0.2%.

4. The filter core material of claim 1, wherein: in the drying of the wet filter layer to obtain the filter layer, the drying temperature is 130℃-150℃; and / or in the drying of the wet filter layer to obtain the filter layer, the drying time is 1h-2h; and / or in the immersing of the filter layer in the bonding layer slurry and drying to obtain the filter layer with the bonding layer, the drying temperature is 130℃-150℃; and / or in the immersing of the filter layer in the bonding layer slurry and drying to obtain the filter layer with the bonding layer, the drying time is 1h-2h.

5. The filter element material of claim 1, wherein, in the melt-blowing of the nylon on the surface of the filter layer with the bonding layer, the melt-blowing melt temperature is 200℃-295℃; and / or the diameter of the nylon is 1μm-10μm; and / or the melt-blowing roller rotation speed is 40m / min-100m / min. The filter core material of any one of claims 1-5.

6. A filter cartridge characterized by, The filter core of claim 6.

7. A vehicle characterized by comprising: ​

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