A novel laminated honeycomb air filter element, air filter and manufacturing method thereof

Abstract

The present invention discloses a novel stacked honeycomb air filter element, which belongs to the field of air filtration technology and solves the problem of insufficient structural strength of existing large-area air filter elements. It includes a supporting frame and multiple filter element packages, each of which includes a lower guard plate and multiple composite filter materials, each of which includes a corrugated filter material and a flat filter material, the corrugated filter material is placed on top of the flat filter material, and one end of the corrugated filter material and one end of the flat filter material are coated with a first end sealant, multiple composite filter materials are stacked on the lower guard plate along the wave height direction of the corrugated filter material, and the other end of the corrugated filter material corresponding to two adjacent composite filter materials and the other end of the flat filter material are coated with a second end sealant, and multiple filter element packages are stacked in the supporting frame along the wave height direction of the corrugated filter material. The stacked honeycomb air filter element of the present invention can effectively improve the structural strength of the filter element.

Description

Technical Field

[0001] The invention relates to the technical field of air filtration, and more specifically, to a novel laminated honeycomb air filter element, an air filter and a manufacturing method thereof. Background Art

[0002] An air filter is a device that captures dust from a gas-solid two-phase flow and purifies the gas through the action of a porous filter material. The filtration efficiency requirements for air filtration in different fields are not the same. For example, the filtration efficiency of air filters for engineering machinery is relatively low, while the filtration efficiency requirements for filters in the medical field are generally H13 and above. To achieve this ultra-high efficiency filtration level, the filter material of the filter must be made of glass fiber filter material or ultra-fine synthetic fiber filter material with ultra-high filtration efficiency. However, since such ultra-high efficiency filter materials are relatively soft and the strength of the filter material is poor, the size of the filter element made by stacking should not be made larger. The cross-section of the filter element is generally 300mmX300mm, otherwise the filter element will collapse its own waveform due to its own excessive weight. However, in most applications, the inflow cross-section size of the square stacked honeycomb filter element needs to be relatively large, such as being larger than 600mmx600mm, and the existing stacked honeycomb filter element is difficult to meet the use requirements. Therefore, a new type of stacked honeycomb air filter element, air filter and its manufacturing method are designed. Summary of the invention

[0003] The technical problem to be solved by the present invention is to address the above-mentioned deficiencies in the prior art. One purpose of the present invention is to provide a new type of laminated honeycomb air filter element, which can effectively improve the structural strength of the filter element.

[0004] The second purpose of the present invention is to provide a new type of laminated honeycomb air filter that can meet the needs of a larger filtering area.

[0005] The third purpose of the present invention is to provide a novel method for manufacturing a laminated honeycomb air filter element.

[0006] In order to achieve the above-mentioned purpose one, the present invention provides a new type of stacked honeycomb air filter element, including a supporting frame and multiple filter element packages, each of the filter element packages includes a lower guard plate and multiple composite filter materials, each of the composite filter materials includes a corrugated filter material and a flat filter material, the corrugated filter material is placed on the top of the flat filter material, and one end of the corrugated filter material and one end of the flat filter material are coated with a first end sealing glue, multiple composite filter materials are stacked on the lower guard plate along the wave height direction of the corrugated filter material, and the other end of the corrugated filter material corresponding to two adjacent composite filter materials and the other end of the flat filter material are coated with a second end sealing glue, and multiple filter element packages are stacked in the supporting frame along the wave height direction of the corrugated filter material.

[0007] As a further improvement, the support frame and filter element package are both square structures. The support frame includes an upper guard plate, a left end cover plate and a right end cover plate. The upper guard plate is installed on the top of the topmost filter element package by glue sealing. The flat filter material and the lower guard plate, between two adjacent filter element packages, between the filter element package and the left end cover plate, right end cover plate, and between the upper guard plate and the left end cover plate, right end cover plate are all connected by glue sealing.

[0008] Furthermore, both ends of the upper guard plate and the lower guard plate corresponding to each filter element package have plug-in plates, and the left end cover plate and the right end cover plate are both grooved plates with bent plates around them, and the plug-in plates corresponding to the upper guard plate and the lower guard plate are respectively plugged into the left end cover plate and the right end cover plate.

[0009] Furthermore, an anti-drop structure is provided between each of the plug-in boards and the left end cover plate and the right end cover plate.

[0010] Furthermore, the upper guard plate and the lower guard plate corresponding to the filter element package located at the bottom layer are provided with flanges on one side or both sides along the airflow direction.

[0011] Furthermore, a coarse filter structure is provided on one side of the support frame located on the inlet surface.

[0012] Furthermore, protective nets are provided on both sides of the support frame, and the coarse filtration structure is located on the inner side of the protective nets.

[0013] In order to achieve the above-mentioned second objective, the present invention provides a novel laminated honeycomb air filter, comprising at least one of the above-mentioned air filter elements.

[0014] In order to achieve the third objective, the present invention provides a novel method for manufacturing a laminated honeycomb air filter element, including the above-mentioned air filter element, the method comprising the following steps:

[0015] S1: Prepare multiple composite filter materials with the same length and width;

[0016] S2: Apply glue on the top of the lower guard plate, and then place and stick a layer of composite filter material on top of it;

[0017] S3: Apply a second end sealant to the top of the composite filter material at the opposite end of the first end sealant, and then place and stick a layer of composite filter material on the top;

[0018] S4: repeat step S3 until the required height of the filter element package is reached to obtain a single filter element package;

[0019] S5: Repeat steps S2-S4 to obtain multiple filter element packages;

[0020] S6: Apply glue on the top of the composite filter material of one of the filter element packages, and place and stick the lower guard plate corresponding to the other filter element package on the top of the composite filter material of one of the filter element packages;

[0021] S7: Repeat step S6 until the required height dimension of the air filter element is reached;

[0022] S8: Install a coarse filter structure on the support frame on one side of the inlet surface of the air filter element;

[0023] S9: Install protective nets on both sides of the support frame;

[0024] S10: Apply glue on the top of the composite filter material of the top filter element pack, and then place and stick the upper guard plate on top of it to obtain a full-size filter element pack;

[0025] S11: Apply glue to the left end cover and the right end cover respectively, then insert the left end cover and the right end cover into and stick them to the left and right ends of the full-size filter element package respectively to obtain a complete air filter element.

[0026] Furthermore, in step S4, the height dimension required for the filter element package refers to the number of layers n of the composite filter material conforming to the following formula:

[0027] H = nh - Δd;

[0028] Wherein, m is the weight of a single-layer composite filter material, n is the total number of composite filter material stacking layers, h is the height of a single-layer composite filter material, H is the total height of a single filter element package, Δd is the cumulative deformation after n layers of composite filter material are stacked, k is the elastic coefficient of the composite filter material in the stacking direction, and g is the acceleration of gravity.

[0029] Beneficial Effects

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] 1. The laminated honeycomb air filter element of the present invention adopts a honeycomb structure, which has higher space utilization and more compact structure compared with the traditional folded air filter.

[0032] 2. The stacked honeycomb air filter element of the present invention adopts a block structure, and each filter element package corresponds to a lower guard plate, thereby forming a support structure between two adjacent filter element packages, thereby improving the strength of the filter element, and can effectively solve the problem that the strength of glass fiber filter materials or composite filter materials is low and cannot be made into large-sized stacked filter elements.

[0033] 3. The laminated honeycomb air filter element of the present invention adopts a block structure and can be manufactured in a modular manner first, which can effectively reduce the difficulty of manufacturing and improve the efficiency of the manufacturing process; at the same time, it can also better realize the serialization of product sizes and the standardization of parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the main structure of the present invention;

[0035] Figure 2 It is a schematic diagram of the three-dimensional structure of the filter element package of the present invention;

[0036] Figure 3 for Figure 2 A schematic diagram of the structure enlargement at the center A;

[0037] Figure 4 It is a schematic diagram of the three-dimensional structure of the lower guard plate in the present invention;

[0038] Figure 5 It is a schematic diagram of the three-dimensional structure of the left end cover plate in the present invention;

[0039] Figure 6 It is a schematic diagram of the partial structure of the composite filter material in the present invention;

[0040] Figure 7 It is a schematic diagram of the partial structure enlargement of the composite filter material stacking in the present invention;

[0041] Figure 8 It is a schematic diagram of the three-dimensional structure of the present invention;

[0042] Fig. 9 for Figure 8 A schematic diagram of the structure in which the right end cover is removed;

[0043] Fig.10 for Fig. 9 A magnified schematic diagram of the structure at point B in the middle.

[0044] Among them, 1-support frame, 2-filter element package, 3-plug-in board, 4-anti-slip structure, 5-flange, 6-coarse filtration structure, 7-protective net, 11-upper guard plate, 12-left end cover plate, 13-right end cover plate, 21-lower guard plate, 22-composite filter material, 23-second end sealing, 221-corrugated filter material, 222-flat filter material, 223-first end sealing. DETAILED DESCRIPTION

[0045] The present invention will be further described below with reference to the specific embodiments in the accompanying drawings.

[0046] See also Figures 1 to 10A novel laminated honeycomb air filter element comprises a supporting frame 1 and a plurality of filter element packages 2, each filter element package 2 comprises a lower guard plate 21 and a plurality of composite filter materials 22, each composite filter material 22 comprises a corrugated filter material 221 and a flat filter material 222, wherein the corrugated filter material 221 is placed on top of the flat filter material 222, and one end of the corrugated filter material 221 and one end of the flat filter material 222 are coated with a first end sealing glue 223 to form a layer of composite filter material 22, and a plurality of composite filter materials 22 are laminated on the lower guard plate 21 along the wave height direction of the corrugated filter material 221, and the other end of the corrugated filter material 221 corresponding to two adjacent composite filter materials 22 and the other end of the flat filter material 222 are coated with a first end sealing glue 223. There is a second end sealant 23 to form a multi-layer composite filter material 22, an inlet channel is formed between the corrugated filter material 221 and the flat filter material 222 in the single layer, the inlet channel is connected to the inlet surface of the air filter element, an outflow channel is formed between the corrugated filter material 221 and the flat filter material 222 in two adjacent layers, the outflow channel is connected to the outflow surface of the air filter element to form a honeycomb flow channel, air enters the outflow channel from the inlet channel to achieve the purpose of filtering, and it adopts a honeycomb structure, compared with the traditional folded air filter, it has higher space utilization and more compact structure; multiple filter element packs 2 are stacked and installed in the support frame 1 along the wave height direction of the corrugated filter material 221 to form a stacked honeycomb air filter element.

[0047] The stacked honeycomb air filter element of the present invention adopts a block structure, and each filter element package 2 is supported by a corresponding lower guard plate 21. During the manufacturing process, the lower guard plate 21 can effectively support the multi-layer composite filter material 22, which is convenient for handling and transfer, and further avoids the problem of damage during the manufacturing process. At the same time, after the air filter element is assembled, a supporting structure is formed between two adjacent filter element packages 2, which improves the strength of the filter element and can effectively solve the problem that the glass fiber filter material or the composite filter material has low strength and cannot be made into a large-sized stacked filter element.

[0048] Furthermore, the laminated honeycomb air filter element of the present invention adopts a block structure and can be manufactured in a modular manner, which can effectively reduce the difficulty of manufacturing and improve the efficiency of the manufacturing process; at the same time, it can also better realize the serialization of product sizes and the commonality of parts.

[0049] In this embodiment, the support frame 1 and the filter element package 2 are both square structures, that is, the entire air filter element is square in shape, wherein the support frame 1 includes an upper guard plate 11, a left end cover plate 12 and a right end cover plate 13, the upper guard plate 11 is installed on the top of the topmost filter element package 2 by glue sealing, and the flat filter material 222 and the lower guard plate 21, between two adjacent filter element packages 2 (that is, between the flat filter material 222 corresponding to the two adjacent filter element packages 2 and the lower guard plate 21), and between the filter element package 2 and the left end cover plate 12, the right end cover plate 13, and between the upper guard plate 11 and the left end cover plate 12, the right end cover plate 13 are all connected by glue sealing, so that the air can only flow from the inlet channel to the outlet channel, forming a unique air flow channel, thereby achieving the filtering effect. The square-shaped air filter element of this embodiment is convenient for transportation and assembly, and can also improve the structural strength of the filter element.

[0050] Preferably, both ends of the upper guard plate 11 and the lower guard plate 21 corresponding to each filter element package 2 are provided with a plug-in plate 3, that is, the upper guard plate 11, the lower guard plate 21 and the ends corresponding to the left end cover plate 12 and the right end cover plate 13 are all integrally formed with a plug-in plate 3, the left end cover plate 12 and the right end cover plate 13 are both groove-type plates with flanged bending plates around them, and the plug-in plates 3 corresponding to the upper guard plate 11 and the lower guard plate 21 are respectively plugged into the left end cover plate 12 and the right end cover plate 13. When glue is used for sealing, the glue can be gathered in the left end cover plate 12 and the right end cover plate 13, and the plug-in plate 3 is located in the left end cover plate 12 and the right end cover plate 13, which can better contact with the glue, thereby improving the connection reliability of the upper guard plate 11, the lower guard plate 21 and the left end cover plate 12, the right end cover plate 13, while ensuring the sealing, further improving the structural strength of the filter element.

[0051] Preferably, an anti-slip structure 4 is provided between each plug-in board 3 and the left end cover plate 12 and the right end cover plate 13. The anti-slip structure 4 can be a plurality of through holes opened on the plug-in board 3, or a raised portion integrally formed on the plug-in board 3, or a groove integrally formed on the plug-in board 3, or a raised block protruding from the bottom of the inner wall of the left end cover plate 12 or the right end cover plate 13, etc. The anti-slip structure 4 is utilized to increase the adhesion between the plug-in board 3 and the glue or between the glue and the left end cover plate 12 and the right end cover plate 13, thereby improving the connection reliability of the upper guard plate 11 and the lower guard plate 21, and further improving the structural strength of the filter element.

[0052] Preferably, flanges 5 are provided on one or both sides of the upper guard plate 11 and the lower guard plate 21 corresponding to the filter element package 2 located at the bottom layer along the airflow direction, that is, the flanges 5 are located on the inlet surface and / or the outlet surface of the air filter element. By providing flanges 5 in the upper guard plate 11 and the lower guard plate 21, on the one hand, it is convenient to position the composite filter material 22 during production, and when the filter element is assembled, the positioning of two adjacent filter element packages 2 makes the multiple filter element packages 2 in the entire filter element flush; on the other hand, it can improve the structural strength of the filter element and avoid the problem of lateral displacement of the composite filter material during the later transportation or use of the filter element. Furthermore, the lower guard plate 21 corresponding to each filter element package 2 can also be provided with flanges 5, which has a better effect. It should be noted that the height of the flange 5 should be less than the height of the corrugated filter material 221 to avoid blocking the inlet channel or the outlet channel.

[0053] Preferably, a coarse filter structure 6 is provided on one side of the inlet surface of the support frame 1. The coarse filter structure 6 may be a non-woven fabric, a sponge, or steel wool, etc., which plays a role in coarse filtering of the air. The air is first coarsely filtered and then enters the composite filter material for filtration. The two-stage filtration effect is better and the loss of the composite filter material can be slowed down.

[0054] Preferably, protective nets 7 are provided on both sides of the support frame 1 , and the coarse filter structure 6 is located on the inner side of the protective nets 7 . The protective nets 7 can protect the composite filter material and the coarse filter structure 6 .

[0055] This embodiment also provides a novel laminated honeycomb air filter, which includes at least one of the above-mentioned air filter elements. In practical applications, multiple air filter elements can be combined and spliced ​​according to the filtering area, and the support frame between two adjacent air filter elements can be sealed and connected with glue, which can meet the use of a larger filtering area.

[0056] This embodiment also provides a novel method for manufacturing a laminated honeycomb air filter element, including the above-mentioned air filter element, the method comprising the following steps:

[0057] S1: preparing a plurality of composite filter materials 22 with the same length and width, wherein the specific operation is: preparing square flat filter materials 222 and corrugated filter materials 221 respectively according to the sizes, then applying a first end sealant 23 on one end of the flat filter material 222, then placing the corrugated filter material 221 on the flat filter material 222 to obtain a single composite filter material 22, and repeating the operation to prepare a plurality of composite filter materials 22;

[0058] S2: Apply glue on the top of the lower guard plate 21, and then place and stick a layer of composite filter material 22 on the top;

[0059] S3: Apply the second end sealant 23 to the top of the composite filter material 22 at the opposite end to the first end sealant 223, and then place and stick a layer of composite filter material 22 on the top;

[0060] S4: repeat step S3 until the required height of the filter element package is reached, and a single filter element package 2 is obtained;

[0061] S5: Repeat steps S2-S4 to obtain multiple filter element packages 2;

[0062] S6: Apply glue on the top of the composite filter material 22 of one of the filter element packages 2, and place and stick the lower guard plate 21 corresponding to the other filter element package 2 on the top of the composite filter material 22 of one of the filter element packages 2;

[0063] S7: Repeat step S6 until the required height dimension of the air filter element is reached;

[0064] S8: Installing a coarse filter structure 6 on the support frame 1 on one side of the inflow surface of the air filter element;

[0065] S9: Install the protective net 7 on both sides of the supporting frame 1;

[0066] S10: Apply glue on the top of the composite filter material 22 of the uppermost filter element package 2, and then place and stick the upper guard plate 11 on the top to obtain a full-size filter element package;

[0067] S11: Glue is applied to the left end cover plate 12 and the right end cover plate 13 respectively, and then the left end cover plate 12 and the right end cover plate 13 are respectively inserted and pasted to the left and right ends of the full-size filter element package to obtain a complete air filter element.

[0068] In step S4 of this embodiment, the height dimension required for the filter element package refers to the number of layers n of the composite filter material 22 conforming to the following formula:

[0069] H = nh - Δd;

[0070] Wherein, m is the weight of a single-layer composite filter material, n is the total number of composite filter material stacking layers, h is the height of a single-layer composite filter material, H is the total height of a single filter element package, Δd is the cumulative deformation after n layers of composite filter material are stacked, k is the elastic coefficient of the composite filter material in the stacking direction, and g is the acceleration of gravity.

[0071] Specifically, the calculation process of the cumulative deformation Δd after the composite filter material is stacked with n layers is:

[0072]

[0073]

[0074] Δd i It is the deformation of the i-th layer of composite filter material when stacking and bonding from bottom to top.

[0075] The air filter element of the present invention, wherein the multiple filter element packages 2 are split up by evenly dividing them according to the height dimension of the air filter element. During the design process, evenly dividing them is performed based on the basis that the cumulative deformation Δd of the composite filter material of a single filter element package 2 after stacking n layers does not exceed 1.5 h (the height of a single-layer composite filter material).

[0076] During the manufacturing process of the air filter element of the present invention, the cumulative deformation Δd of a single filter element package 2 is strictly controlled, thereby ensuring the height of each filter element package 2, so that the height of the air filter element obtained after assembling multiple filter element packages 2 meets the height required by the design, effectively ensuring the assembly accuracy of the air filter element.

[0077] Preferably, the fluidity of the glue used in step S9 is greater than the fluidity of the glue used in steps S2, S3, S6, and S8. The fluidity of the glue associated with the filtering surface of the composite filter material 22 is poor, which avoids the glue affecting the filtering area and ensures the filtering effect of the filter element. At the same time, the fluidity of the glue corresponding to the left end cover plate 12 and the right end cover plate 13 is relatively good, so that the glue can flow to the edges of the composite filter material 22 and the upper guard plate 11, further improving the connection reliability.

[0078] The above are only preferred embodiments of the present invention. It should be pointed out that for those skilled in the art, several modifications and improvements can be made without departing from the structure of the present invention, which will not affect the effect of the implementation of the present invention and the practicality of the patent.

Claims

1. A new type of laminated honeycomb air filter element, characterized in that: The invention comprises a support frame (1) and a plurality of filter element packages (2), each of the filter element packages (2) comprising a lower guard plate (21) and a plurality of composite filter materials (22), each of the composite filter materials (22) comprising a corrugated filter material (221) and a flat filter material (222), the corrugated filter material (221) being placed on top of the flat filter material (222), and one end of the corrugated filter material (221) and one end of the flat filter material (222) being coated with a first end sealing glue (223), the plurality of composite filter materials (22) being stacked and installed on the lower guard plate (21) along the wave height direction of the corrugated filter material (221), and the other end of the corrugated filter material (221) corresponding to two adjacent composite filter materials (22) and the other end of the flat filter material (222) being coated with a second end sealing glue (23), and the plurality of filter element packages (2) being stacked and installed in the support frame (1) along the wave height direction of the corrugated filter material (221).

2. A novel laminated honeycomb air filter element according to claim 1, characterized in that: The support frame (1) and the filter element package (2) are both square structures. The support frame (1) comprises an upper guard plate (11), a left end cover plate (12) and a right end cover plate (13). The upper guard plate (11) is installed on the top of the topmost filter element package (2) by means of glue sealing. The flat filter material (222) and the lower guard plate (21), between two adjacent filter element packages (2), between the filter element package (2) and the left end cover plate (12), the right end cover plate (13), and between the upper guard plate (11) and the left end cover plate (12), the right end cover plate (13) are all connected by means of glue sealing.

3. A novel laminated honeycomb air filter element according to claim 2, characterized in that: Both ends of the upper guard plate (11) and the lower guard plate (21) corresponding to each filter element package (2) are provided with plug-in plates (3); the left end cover plate (12) and the right end cover plate (13) are both groove-type plates with a bent plate around them; the plug-in plates (3) corresponding to the upper guard plate (11) and the lower guard plate (21) are respectively plugged into the left end cover plate (12) and the right end cover plate (13).

4. A novel laminated honeycomb air filter element according to claim 3, characterized in that: An anti-drop structure (4) is provided between each of the plug-in boards (3) and the left end cover plate (12) and the right end cover plate (13).

5. A novel laminated honeycomb air filter element according to claim 2, characterized in that: The upper guard plate (11) and the lower guard plate (21) corresponding to the filter element package (2) at the bottom layer are provided with flanges (5) on one side or both sides along the airflow direction.

6. A novel laminated honeycomb air filter element according to claim 1, characterized in that: A coarse filter structure (6) is provided on one side of the support frame (1) located on the inlet surface.

7. A novel laminated honeycomb air filter element according to claim 6, characterized in that: Protective nets (7) are also provided on both sides of the support frame (1), and the coarse filtering structure (6) is located on the inner side of the protective net (7).

8. A novel laminated honeycomb air filter, characterized in that: An air filter element comprising at least one of claims 1 to 7.

9. A novel method for manufacturing a laminated honeycomb air filter element, characterized in that: The air filter element comprising any one of claims 1 to 7 above, the method comprising the following steps: S1: preparing a plurality of composite filter materials (22) having the same length and width; S2: Apply glue on the top of the lower guard plate (21), and then place and stick a layer of composite filter material (22) on the top; S3: applying a second end sealant (23) on the top of the composite filter material (22) at the opposite end to the first end sealant (223), and then placing and pasting a layer of composite filter material (22) on the top; S4: Repeat step S3 until the required height of the filter element package is reached, thereby obtaining a single filter element package (2); S5: repeating steps S2-S4 to obtain a plurality of filter element packages (2); S6: applying glue to the top of the composite filter material (22) of one of the filter element packages (2), and placing and sticking the lower guard plate (21) corresponding to the other filter element package (2) on the top of the composite filter material (22) of one of the filter element packages (2); S7: Repeat step S6 until the required height dimension of the air filter element is reached; S8: Installing a coarse filter structure (6) on the support frame (1) on one side of the inflow surface of the air filter element; S9: Installing a protective net (7) on both sides of the supporting frame (1); S10: Apply glue on the top of the composite filter material (22) of the uppermost filter element package (2), and then place and stick the upper protective plate (11) on the top to obtain a full-size filter element package; S11: Glue is applied to the left end cover plate (12) and the right end cover plate (13) respectively, and then the left end cover plate (12) and the right end cover plate (13) are respectively inserted and pasted to the left and right ends of the full-size filter element package to obtain a complete air filter element.

10. A novel laminated honeycomb air filter manufacturing method according to claim 9, characterized in that: In the step S4, the height dimension required for the filter element package refers to the number of layers n of the composite filter material (22) conforming to the following formula: Wherein, m is the weight of a single-layer composite filter material, n is the total number of composite filter material stacking layers, h is the height of a single-layer composite filter material, H is the total height of a single filter element package, Δd is the cumulative deformation after n layers of composite filter material are stacked, k is the elastic coefficient of the composite filter material in the stacking direction, and g is the acceleration of gravity.

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