A manufacturing process and portable assembly / disassembly device for a high-capture-efficiency fiberglass filter.

Abstract

This invention provides a manufacturing process and portable assembly / disassembly device for a high-capture-efficiency fiberglass filter, comprising the following steps: S1: Precisely controlling the composition of the raw materials for manufacturing the fiberglass filter, and then calcining it in a crucible to form a molten fiberglass material; S2: Cooling the molten fiberglass material in S1 and then performing centrifugal spinning, while precisely controlling the temperature and humidity during the spinning process. Compared with the prior art, this invention has the following beneficial effects: The manufacturing process of the high-capture-efficiency fiberglass filter begins with the precise proportioning of raw materials. High-purity quartz sand, calcined aluminum carbide, and calcium borate are mixed according to a formula of 52±0.5% silicon dioxide and 15±0.5% alumina. After hot pressing and shaping, the edges are sealed with two-component polyurethane slit coating. The curing process is monitored by infrared thermal imaging. The finished product is cured in an FFU+HEPA clean environment, and the filtration efficiency, air permeability, and other indicators are monitored by SPC control chart. Waste fibers are crushed, air-separated, and then incinerated at high temperature for recycling, and are recycled by re-mixing raw materials at a ratio of 1:8.

Description

Technical Field

[0001] This invention belongs to the field of glass fiber filter technology, and relates to a manufacturing process and portable assembly / disassembly device for a high-capture-efficiency glass fiber filter. Background Technology

[0002] Fiberglass filters are widely used in air conditioners, air purifiers, and range hoods, primarily to capture airborne particulate matter for air purification. However, their manufacturing process is complex, resulting in drawbacks such as low capture efficiency and inconvenience in disassembly and replacement. The manufacture of fiberglass filters involves steps such as high-temperature melting, fiber drawing, weaving, or non-woven fabric forming. These processes are not only technically demanding but also energy-intensive, causing environmental impact. Fiberglass itself is brittle, making the filters prone to breakage during use, affecting their lifespan and particulate matter capture efficiency. Furthermore, with increasing usage time, the filter surface gradually becomes clogged, leading to increased airflow resistance, higher energy consumption, and potentially decreased filtration efficiency.

[0003] During use, the low efficiency of fiberglass filters in capturing airborne particles is mainly due to their relatively large pore structure, which makes them unable to effectively intercept tiny particles. Furthermore, the surface properties of fiberglass allow particles to easily penetrate or bypass the fibers, reducing filtration effectiveness. The difficulty in disassembling and replacing these filters stems from their size and shape design, as well as their mounting method. These filters often require specialized tools or skills for proper installation and replacement, making them challenging for ordinary users. Common solutions include increasing the number of filter layers or using finer fiberglass to improve filtration efficiency, and redesigning the filter's mounting structure for easier disassembly and replacement. However, increasing the number of layers or using finer fiberglass increases filter resistance, leading to increased energy consumption and potentially reduced airflow. Moreover, finer fiberglass may pose greater health and environmental risks. While improving the mounting structure can enhance user convenience, it may increase manufacturing costs and complexity, and a design that balances filtration efficiency and ease of use may be difficult to achieve. In summary, although fiberglass filters have a wide range of applications in the field of air filtration, their main drawbacks are the complexity of their manufacturing process, low collection efficiency during use, and inconvenience in disassembly and replacement. Therefore, our organization urgently needs a manufacturing process for high-efficiency fiberglass filters and a portable disassembly and assembly device to solve the above problems. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a manufacturing process and a portable disassembly and assembly device for high-capture-efficiency glass fiber filter, thereby solving the problems mentioned in the background technology.

[0005] This invention is achieved through the following technical solution: a manufacturing process and portable assembly / disassembly device for a high-capture-efficiency fiberglass filter, comprising the following steps:

[0006] S1: The raw material composition for manufacturing glass fiber filter mesh is precisely controlled, and then calcined in a crucible to form glass fiber melt. The internal composition of the melt is then monitored in real time using an XRF spectrometer to ensure the accuracy of the composition during the glass raw material pretreatment process.

[0007] S2: After cooling the glass fiber melt in S1, centrifugal spinning is performed, and the temperature and humidity during the spinning process are precisely controlled. Then, the fiber diameter distribution of the glass fiber spinning is analyzed by a CCD image processing system to ensure that the spinning material in the glass fiber filter meets the requirements. Then, the mesh is laid and woven according to the specific method.

[0008] S3: After the glass fiber melt spinning and weaving process in S2 is completed, the initially formed glass fiber filter is ultrasonically impregnated to improve the penetration rate of the coupling agent. At the same time, the flame retardant and coupling agent are mixed and configured into a composite agent. Ultrasonic vibration is used to achieve uniform penetration into the gaps of the glass fiber, forming a combined modification effect of flame retardancy and coupling. Then it is dried. After drying, bipolar corona treatment technology is used to optimize the electret properties of the glass fiber filter.

[0009] S4: Use a servo hydraulic hot press to hot press and shape the fiberglass filter, then use a two-component polyurethane to seal the outer surface of the fiberglass filter. Apply the polyurethane to the outer surface of the fiberglass filter through slit extrusion, and then use an infrared thermal imager to monitor the curing of the outer adhesive layer in real time.

[0010] S5: Place it in the drying area and use FFU+HEPA combination air supply for air circulation. At the same time, establish an SPC control chart and conduct testing procedures such as filtration efficiency, air permeability, charge density and electrostatic analysis. Once the relevant standards are met, it can be used.

[0011] As a preferred embodiment, firstly, quartz sand with a silica content ≥99.9%, calcined aluminum carbide with an alumina content ≥99.0%, and calcium borate are used as the main raw materials, with a formula ratio of silica 52±0.5%, alumina 15±0.5%, and total alkali metal oxides <1.2%. Then, the glass fiber raw materials are dynamically compensated by using a loss-in-weight feeder, with each batch of raw materials weighing 5±0.2KG. After the process is completed, a SYH series three-dimensional motion mixer is used to mix at a speed of 10r / min for 30min, and the mixing uniformity CV value must be ≤8%. After mixing, an infrared dryer is used to reduce the moisture content of the raw materials to below 0.1% before proceeding to the next process.

[0012] In a preferred embodiment, the dried fiberglass raw material is ground and then fed into a furnace. The furnace is divided into three zones: a preheating zone, a melting zone, and a clarification zone, based on the specific usage steps of the fiberglass raw material. The temperatures of the three zones are controlled as follows: 900°C for the preheating zone, 1600°C for the melting zone, and 1400°C for the clarification zone. The materials are added in the following order: quartz sand, alumina, and calcium carbonate spraying, with a ten-minute interval between each layer. The fiberglass material is then melted. During the melting stage, a variable frequency electromagnetic stirrer is used to promote the uniform distribution of the fiberglass material. During the clarification process, sulfur dioxide gas is introduced to promote the uniform distribution of the composition within the fiberglass.

[0013] In a preferred embodiment, during the melting stage of the furnace, a laser particle size analyzer is used to detect microbubbles in the melt, requiring that the microbubble b90 ≤ 10 μm to prevent fiber forming defects. During the drawing process of the glass fiber melt, a laser detection module is integrated and installed below the drawing die to dynamically feed back the fiber diameter fluctuations and adjust the drawing machine speed and temperature parameters in a linked manner, thereby controlling the diameter of the glass fiber filaments.

[0014] In a preferred embodiment, the glass fiber melt flows out through a platinum-rhodium alloy spinneret. The traction tension is dynamically adjusted by a servo motor, and the glass fiber melt is drawn into fibers at a speed maintained at 3000-4000 m / min. During the weaving process, a composite weaving technique is used, with alternating layers of plain and twill weaves. Laser detection technology is used to monitor the weaving density, and the fiber feeding tension is adjusted in conjunction with the weaving equipment to ensure the uniformity of the multi-layer structure of the glass fiber filter mesh. After weaving, the glass fiber filter material is cleaned with high-frequency ultrasonic waves. A composite solution of flame retardant and coupling agent is prepared and uniformly penetrated into the fiber gaps through ultrasonic vibration to complete the flame retardant coating. Subsequently, a stepped drying method is used: first, pre-drying at 75°C for 60 minutes to remove surface solvents, and then curing at 120°C for 90 minutes to form a film of flame retardant on the outer surface of the glass fiber material.

[0015] In a preferred embodiment, waste filaments generated during the glass fiber drawing process are conveyed by a plate chain conveyor into a crusher. The waste filament particles are then crushed to a cross-sectional inner diameter of less than 5mm, and further crushed using an air classifier to form glass fiber powder ≤0.5mm in size. The waste filaments are then incinerated in an 800-1000℃ incinerator to completely decompose residual wetting agents, producing clean glass powder. This powder is then returned to process S1 and mixed with pretreated raw materials in a 1:8 ratio in a tank furnace for remelting and drawing. In actual use, the manufacturing process of high-capture-efficiency glass fiber filter screens begins with precise raw material proportioning. High-purity quartz sand, calcined aluminum carbide, and calcium borate are mixed according to a formula of 52±0.5% silica and 15±0.5% alumina, and the mixture is stirred using a three-dimensional motion mixer to ensure a uniformity CV value ≤8%. The raw materials are melted in a gradient in three zones of the furnace (preheating zone 900℃, melting zone 1600℃, and clarifying zone 1400℃). Variable frequency electromagnetic stirring and sulfur dioxide gas injection promote component homogeneity. The melt is drawn into fibers at a speed of 3000-4000 m / min through a platinum-rhodium alloy spinneret. A laser detection module controls the fiber diameter in real time. A composite weaving process with alternating plain and twill weaves is used to form the substrate. After ultrasonic impregnation to improve the coupling agent penetration rate, bipolar corona treatment optimizes the electret performance. After hot pressing and shaping, a two-component polyurethane slot coating is used to seal the edges. Infrared thermal imaging monitors the curing process. The finished product is cured in an FFU+HEPA clean environment, and filtration efficiency, air permeability, and other indicators are monitored using SPC control charts. Waste fibers are crushed, air-separated, and then incinerated at high temperature for recycling. They are then mixed back into the raw materials at a ratio of 1:8 to achieve recycling.

[0016] A high-efficiency fiberglass filter and a portable assembly / disassembly device are disclosed, comprising: a housing and a filter body; the housing contains a set of front guide louvers for airflow guidance; a set of front latches for positioning and engaging with an inner liner at the center of the housing; and a set of rotating shafts for movably supporting the inner liner at the rear upper end of the housing. The inner liner has two sets of limiting shaft housings at its upper end for limiting engagement with the rotating shafts, each limiting shaft housing being movably engaged with the rotating shaft, and the outer side of the rotating shaft being fixedly connected to the housing. The inner liner shell has a set of rear shells for placing the filter body. The rear shell has a set of rear air louvers for air circulation. The rear shell has a set of rear fixing holes for connecting and fixing with external air conditioners, air purifiers and range hoods. The connection between the rear shell and the inner liner plate has several sets of rear buckles for fastening and positioning. The rear shell has a set of filter chambers for placing the filter body. The filter chamber has a rectangular cross-section when viewed from above. The filter chamber is sealed and fitted with the filter body on all sides.

[0017] In a preferred embodiment, the filter body includes a front layer, a middle layer, and an inner resistance cotton mesh. The outer surface of the front layer is provided with a set of limiting grids for protecting the inner resistance cotton mesh. These limiting grids are arranged in a diamond-shaped cross structure. Inside the limiting grids is a set of inner resistance cotton meshes for flexibly bonding the middle layer. The inner resistance cotton meshes and the inner side of the limiting grids are interlocked and bonded. Behind the front layer is a middle layer with high dust particle capture efficiency, and behind the middle layer is a rear layer. When actually using this high-efficiency fiberglass filter and portable disassembly / removal device, first, the outer shell is... Afterwards, the fixing holes are installed at the air inlet of equipment such as air conditioners, air purifiers, or range hoods. During installation, ensure that the front guide louvers face the airflow direction and the rear guide louvers are aligned with the air outlet of the equipment. When it is necessary to replace the filter body, press the rear buckle at the connection between the rear shell and the inner liner to separate the rear shell from the inner liner. At the same time, rotate the inner liner through the cooperation of the rotating shaft and the limiting shaft housing to vertically remove the old filter body from the rectangular filter cavity. Align the middle layer of glass fiber filter material with the rear layer inward in sequence, and completely embed the filter around the filter cavity to achieve a sealed fit, thereby ensuring that the air in the pipeline of equipment such as air conditioners, air purifiers, or range hoods can be completely filtered.

[0018] In a preferred embodiment, the middle layer includes an outer permeable cotton layer, an outer air-permeable layer, an inner permeable cotton layer, an inner filter core layer, an inner bonding layer, and an outer permeable cotton layer. The inner side of the outer permeable cotton layer is provided with a set of outer air-permeable layers for guiding airflow. The outer air-permeable layer has several sets of pores for air circulation. At the lower end of the outer air-permeable layer is a set of inner permeable cotton layers for permeable separation within the inner filter core layer. The inner filter core layer has several sets of core rods for adsorbing particulate matter within the air. The outer permeable cotton layer, outer air-permeable layer, inner permeable layer, inner filter core layer, and inner bonding layer constitute an inner filter core mesh for filtering air from external air conditioners, air purifiers, and range hoods. Two sets of inner filter core meshes are provided, arranged symmetrically.

[0019] In a preferred embodiment, the inner filter core layer contains several sets of filter cores, each including an outer core cotton, an adhesive layer, and an inner core column. The filter core has a columnar structure, and the sets of filter cores are tightly fitted together. Inside the outer core cotton, there is an inner permeation mesh for permeating airborne particles and grease. Inside the inner permeation mesh, there is an inner core cotton covering the outer side of the adhesive layer. Inside the inner core cotton, there is an adhesive layer for adhering airborne particles and grease. Inside the adhesive layer, there is an inner core column for positioning. In actual use, when using this fiberglass filter, it is necessary to ensure the correct installation direction of the middle composite filter element; the outer permeation cotton layer should face the air intake. On the side, when airflow passes through the pores of the outer permeable layer, it is first pre-filtered by the outer cotton layer. Then, the airflow is evenly distributed to the inner filter core layer through the inner cotton layer. After the filter core is pre-filtered by the outer core cotton, the inner permeable mesh performs gradient permeation of grease and particulate matter. The adhesion layer then adsorbs fine pollutants. The two sets of symmetrically arranged inner filter core meshes can form a dual-channel purification structure, which increases the dust holding capacity. When replacing the filter, the middle layer assembly must be removed as a whole. During installation, the inner bonding layer must be accurately aligned with the adjacent filter layer to ensure that the airflow flows through the designed filtration path. When obvious oil stains are visible on the inner core column, the entire middle layer filter core assembly must be replaced. This structure achieves high capture efficiency while ensuring air permeability through the synergistic effect of multi-layer gradient filtration and dual core mesh.

[0020] The beneficial effects of this invention after adopting the above technical solution are as follows: By using a high-efficiency fiberglass filter with precise proportions, high-purity quartz sand, calcined aluminum carbide, and calcium borate are mixed according to a formula of 52±0.5% silicon dioxide and 15±0.5% alumina. The uniformity (CV value) is ensured to be ≤8% using a three-dimensional motion mixer. The raw materials are melted in a gradient within three zones of a furnace (preheating zone 900℃, melting zone 1600℃, and refining zone 1400℃). Variable frequency electromagnetic stirring and sulfur dioxide gas injection promote component uniformity. The melt is then passed through a platinum-rhodium alloy perforator at 3000-4000℃. The fiber is drawn at a speed of 0m / min, and the laser detection module adjusts the fiber diameter in real time. The substrate is formed by a composite weaving process of alternating plain and twill weaves. After ultrasonic impregnation to improve the penetration rate of coupling agent, the electret performance is optimized by bipolar corona treatment. After hot pressing and shaping, the edges are sealed with two-component polyurethane slit coating. The curing process is monitored by infrared thermal imaging. The finished product is cured in an FFU+HEPA clean environment, and the filtration efficiency, air permeability and other indicators are monitored by SPC control chart. Waste fibers are crushed, air-separated and then incinerated at high temperature for recycling. They are then mixed with raw materials at a ratio of 1:8 to achieve recycling.

[0021] First, install the outer casing through the rear fixing hole at the air inlet of the air conditioner, air purifier, or range hood. During installation, ensure that the front guide louvers face the airflow direction and the rear guide louvers are aligned with the air outlet of the device. When it is necessary to replace the filter body, press the rear buckle at the connection between the rear casing and the inner liner to separate the rear casing from the inner liner. At the same time, rotate the inner liner through the cooperation of the rotating shaft and the limiting shaft housing to vertically remove the old filter body from the rectangular filter chamber. Align the middle layer of glass fiber filter material with the rear layer inward in sequence, and completely embed the filter around the filter chamber to achieve a sealed fit, thereby ensuring that the air in the pipes of the air conditioner, air purifier, or range hood can be completely filtered.

[0022] When using this fiberglass filter, ensure the correct installation orientation of the middle layer composite filter element. The outer permeable cotton layer should face the air inlet side. When the airflow passes through the pores of the outer permeable layer, it first undergoes preliminary filtration by the outer permeable cotton layer. Subsequently, the airflow is evenly distributed to the inner filter core layer through the inner permeable cotton layer. After the filter core is pre-filtered by the outer core cotton, the inner permeable mesh performs gradient permeation of grease and particulate matter. The adhesion layer then performs final adsorption of fine pollutants. The two sets of symmetrically arranged inner filter core meshes can form a dual-channel purification structure, increasing dust holding capacity. When replacing the filter element, the entire middle layer assembly must be removed. During installation, the inner bonding layer must be accurately aligned with the adjacent filter layer to ensure that the airflow flows entirely through the designed filtration path. When obvious oil stains are visible on the inner core column, the entire middle layer filter core assembly must be replaced. This structure achieves high capture efficiency while ensuring air permeability through the synergistic effect of multi-layer gradient filtration and dual-core mesh. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a technical flow diagram of the manufacturing process of a high-capture-efficiency glass fiber filter screen according to the present invention;

[0025] Figure 2 This is a front view structural diagram of a high-capture-efficiency fiberglass filter and a portable disassembly and assembly device of the present invention.

[0026] Figure 3 This is a schematic diagram of the rear side structure of the rear shell in the high-capture-efficiency glass fiber filter and portable disassembly and assembly device of the present invention.

[0027] Figure 4 This is a front view of the filter chamber structure in a high-capture-efficiency fiberglass filter and portable disassembly and assembly device of the present invention.

[0028] Figure 5 This is a front view of the filter body in the high-capture-efficiency fiberglass filter and portable disassembly and assembly device of the present invention.

[0029] Figure 6 This is a top view of the structure of the middle layer of a high-capture-efficiency fiberglass filter and portable disassembly and assembly device of the present invention during internal separation.

[0030] Figure 7 This is a top view of the inner filter core layer of the high-capture-efficiency glass fiber filter and portable disassembly and assembly device of the present invention.

[0031] In the diagram: 1-outer shell, 2-front guide louver, 3-front buckle, 4-rotating shaft, 5-inner liner, 6-rear shell, 7-rear guide louver, 8-rear buckle, 9-rear fixing hole, 10-limiting shaft shell, 11-filter chamber, 12-filter screen body;

[0032] 12a - Front layer, 12b - Middle layer, 12c - Rear layer, 12d - Limiting grid mesh, 12e - Internal resistance cotton wire mesh;

[0033] b1-Outer cotton permeable layer 1, b2-Outer air-permeable layer 1, b3-Inner cotton permeable layer 1, b4-Inner filter rod core layer 1, b5-Inner bonding layer 1, b6-Inner bonding layer 2, b7-Inner filter rod core layer 2, b8-Inner cotton permeable layer 2, b9-Outer air-permeable layer 2, b10-Outer cotton permeable layer 2;

[0034] 7a-Outer core cotton, 7b-Inner permeable mesh, 7c-Inner core cotton, 7d-Adhesive layer, 7e-Inner core column. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Please see Figure 1 A manufacturing process and portable assembly / disassembly device for a high-capture-efficiency fiberglass filter includes the following steps:

[0037] S1: The raw material composition for manufacturing glass fiber filter mesh is precisely controlled, and then calcined in a crucible to form glass fiber melt. The internal composition of the melt is then monitored in real time using an XRF spectrometer to ensure the accuracy of the composition during the glass raw material pretreatment process.

[0038] S2: After cooling the glass fiber melt in S1, centrifugal spinning is performed, and the temperature and humidity during the spinning process are precisely controlled. Then, the fiber diameter distribution of the glass fiber spinning is analyzed by a CCD image processing system to ensure that the spinning material in the glass fiber filter meets the requirements. Then, the mesh is laid and woven according to the specific method.

[0039] S3: After the glass fiber melt spinning and weaving process in S2 is completed, the initially formed glass fiber filter is ultrasonically impregnated to improve the penetration rate of the coupling agent. At the same time, the flame retardant and coupling agent are mixed and configured into a composite agent. Ultrasonic vibration is used to achieve uniform penetration into the gaps of the glass fiber, forming a combined modification effect of flame retardancy and coupling. Then it is dried. After drying, bipolar corona treatment technology is used to optimize the electret properties of the glass fiber filter.

[0040] S4: Use a servo hydraulic hot press to hot press and shape the fiberglass filter, then use a two-component polyurethane to seal the outer surface of the fiberglass filter. Apply the polyurethane to the outer surface of the fiberglass filter through slit extrusion, and then use an infrared thermal imager to monitor the curing of the outer adhesive layer in real time.

[0041] S5: Place it in the drying area and use FFU+HEPA combination air supply for air circulation. At the same time, establish an SPC control chart and conduct testing procedures such as filtration efficiency, air permeability, charge density and electrostatic analysis. Once the relevant standards are met, it can be used.

[0042] First, quartz sand with a silica content ≥99.9%, calcined aluminum carbide with an alumina content ≥99.0%, and calcium borate are used as the main raw materials, with a formula ratio of silica 52±0.5%, alumina 15±0.5%, and total alkali metal oxides <1.2%. Then, a loss-in-weight feeder is used to dynamically compensate the glass fiber raw materials, with each batch of raw materials weighing 5±0.2KG. After the process is completed, a SYH series three-dimensional motion mixer is used to mix at a speed of 10r / min for 30min, and the mixing uniformity CV value must be ≤8%. After mixing, an infrared dryer is used to reduce the moisture content of the raw materials to below 0.1% before proceeding to the next process.

[0043] After drying, the fiberglass raw material is ground and fed into a furnace. The furnace is divided into three zones: a preheating zone, a melting zone, and a clarification zone, based on the specific usage steps of the fiberglass raw material. The temperatures of the three zones are controlled as follows: 900℃ for the preheating zone, 1600℃ for the melting zone, and 1400℃ for the clarification zone. The materials are added in the following order: quartz sand, alumina, and calcium carbonate spraying, with a ten-minute interval between each layer. The fiberglass material is then melted. During the melting stage, a variable frequency electromagnetic stirrer is used to promote the uniform distribution of the fiberglass material. During the clarification process, sulfur dioxide gas is introduced to promote the uniform distribution of the composition within the fiberglass.

[0044] During the melting stage in the furnace, a laser particle size analyzer is used to detect microbubbles in the melt, requiring that the microbubble b90≤10μm to prevent fiber forming defects. During the fiber drawing process, a laser detection module is integrated and installed below the drawing die to dynamically feed back fiber diameter fluctuations and adjust the drawing machine speed and temperature parameters accordingly, thereby controlling the diameter of the fiber filaments.

[0045] The glass fiber melt flows out through a platinum-rhodium alloy spinneret. The traction tension is dynamically adjusted by a servo motor, and the glass fiber melt is drawn into fibers at a speed maintained at 3000-4000 m / min. During the weaving process, a composite weaving technique is used, with alternating layers of plain and twill weaves. Laser detection technology is used to monitor the weaving density and to adjust the fiber feeding tension in conjunction with the weaving equipment to ensure the uniformity of the multi-layer structure of the glass fiber filter mesh. After weaving, the glass fiber filter material is cleaned with high-frequency ultrasonic waves. A composite solution of flame retardant and coupling agent is prepared and uniformly penetrated into the fiber gaps through ultrasonic vibration to complete the flame retardant coating. Subsequently, a stepped drying method is used: first, pre-drying at 75℃ for 60 minutes to remove surface solvents, and then curing at 120℃ for 90 minutes to form a film of flame retardant on the outer surface of the glass fiber material.

[0046] Please see Figure 1 As a first embodiment of the present invention:

[0047] When waste fibers are generated during the fiberglass drawing process, they are conveyed by a plate chain conveyor into the crusher, where the cross-sectional inner diameter of the crushed particles is reduced to less than 5mm. Then, combined with an air classifier, the crushed particles are further crushed to form fiberglass powder ≤0.5mm in size. The waste fibers are then incinerated in an 800-1000℃ incinerator to completely decompose residual sizing agents, producing clean glass powder. This powder is then returned to the S1 process and mixed with pretreated raw materials in a 1:8 ratio in a tank furnace for remelting and drawing. In actual use, the manufacturing process of high-capture-efficiency fiberglass filters begins with precise raw material proportioning. High-purity quartz sand, calcined aluminum carbide, and calcium borate are mixed according to a formula of 52±0.5% silica and 15±0.5% alumina. A three-dimensional motion mixer ensures a uniformity CV value ≤8%. The raw materials are then processed in the tank furnace. The process involves gradient melting in three zones (preheating zone 900℃, melting zone 1600℃, and clarifying zone 1400℃). Component homogeneity is promoted through variable frequency electromagnetic stirring and sulfur dioxide gas injection. The melt is drawn into fibers at a speed of 3000-4000 m / min using a platinum-rhodium alloy spinneret. A laser detection module controls the fiber diameter in real time. A composite weaving process alternating between plain and twill weaves is used to form the substrate. After ultrasonic impregnation to improve the coupling agent penetration, bipolar corona treatment optimizes electret performance. After hot pressing and shaping, a two-component polyurethane slot coating is used to seal the edges. Infrared thermal imaging monitors the curing process. The finished product is cured in an FFU+HEPA clean environment, and filtration efficiency and air permeability are monitored using SPC control charts. Waste fibers are crushed, air-separated, and then incinerated at high temperatures for recycling, with the fibers being re-blended with raw materials at a 1:8 ratio for reuse.

[0048] Please see Figures 2-7 As a second embodiment of the present invention: a high-efficiency fiberglass filter and a portable assembly / disassembly device, comprising: a housing 1 and a filter body 12, wherein the housing 1 is provided with a set of front guide louvers 2 for airflow guidance, a set of front buckles 3 for positioning and engaging with an inner liner 5 at the center of the housing 1, a set of rotating shafts 4 for movable support of the inner liner 5 at the upper rear side of the housing 1, and two sets of limiting shaft housings 10 for limiting and engaging with the rotating shafts 4 at the upper end of the inner liner 5, wherein the interior of each limiting shaft housing 10 is movably engaged with the interior of the rotating shaft 4, and the outer side of the rotating shaft 4 is connected to the housing 1. The inner liner shell has a set of rear shells 6 for placing the filter body 12. The rear shell 6 has a set of rear air louvers 7 for air circulation. The rear shell 6 has a set of rear fixing holes 9 for connecting and fixing with external air conditioners, air purifiers and range hoods. The connection between the rear shell 6 and the inner liner plate 5 has several sets of rear buckles 8 for fastening and positioning. The rear shell 6 has a set of filter chambers 11 for placing the filter body 12. The filter chamber 11 has a rectangular cross-section when viewed from above. The filter chamber 11 is sealed and fitted with the filter body 12 on all sides.

[0049] The filter body 12 includes a front layer 12a, a middle layer 12b, a limiting grid 12d, and an inner resistance cotton wire mesh 12e. The outer surface of the front layer 12a is provided with a set of limiting grids 12d for protecting the inner resistance cotton wire mesh 12e. The limiting grids 12d are arranged in a diamond-shaped cross structure. Inside the limiting grids 12d is a set of inner resistance cotton wire mesh 12e for flexibly bonding the middle layer 12b. The inner resistance cotton wire mesh 12e and the inner side of the limiting grids 12d are interlocked and bonded. Behind the front layer 12a is a middle layer 12b with high dust particle capture efficiency. Behind the middle layer 12b is a rear layer 12c. When actually using this high-efficiency fiberglass filter and portable disassembly / removal device, first... The outer casing 1 is installed at the air inlet of equipment such as air conditioners, air purifiers, or range hoods through the rear fixing hole 9. During installation, ensure that the front guide louvers 2 face the airflow direction and the rear guide louvers 7 are aligned with the air outlet of the equipment. When it is necessary to replace the filter body 12, press the rear buckle 8 at the connection between the rear casing 6 and the inner liner 5 to separate the rear casing 6 from the inner liner 5. At the same time, rotate the inner liner 5 by cooperating with the rotating shaft 4 and the limiting shaft housing 10 to vertically remove the old filter body 12 from the rectangular filter cavity 11. Align the middle layer 12b glass fiber filter material and the rear layer 12c inward in sequence, and completely embed the filter around the filter cavity 11 to achieve a sealed fit, thereby ensuring that the air in the pipeline of equipment such as air conditioners, air purifiers, or range hoods can be completely filtered.

[0050] Please see Figures 2-7 As a third embodiment of the present invention: based on the description in the second embodiment, further: the middle layer 12b includes an outer permeable cotton layer b1, an outer air-guiding and breathable layer b2, an inner permeable cotton layer b3, an inner filter core layer b4, an inner bonding layer b5, and an outer permeable cotton layer b10. The inner side of the outer permeable cotton layer b1 is provided with a set of outer air-guiding and breathable layers b2 for guiding airflow. The outer air-guiding and breathable layer b2 has several sets of air holes for air circulation inside. The lower end of the outer air-guiding and breathable layer b2 is provided with a set of... The inner filter core layer b4 is divided into an inner permeable cotton layer b3, which is used to separate the inner filter rod core layer b4. The inner filter core layer b4 contains several sets of core rods for adsorbing particulate matter inside the air. The outer permeable cotton layer b1, the outer air guiding layer b2, the inner permeable cotton layer b3, the inner filter core layer b4, and the inner bonding layer b5 constitute an inner filter core mesh for filtering the air of external air conditioners, air purifiers, and range hoods. There are two sets of inner filter core meshes, which are arranged symmetrically.

[0051] The inner filter core layer (b4) contains several sets of filter cores, each including an outer core cotton 7a, an adhesive layer 7d, and an inner core column 7e. The filter cores have a columnar structure, with the sets of filter cores tightly fitted together. Inside the outer core cotton 7a is an inner permeation mesh 7b for permeating airborne particles and grease. Inside the inner permeation mesh 7b is an inner core cotton 7c for covering the outer side of the adhesive layer 7d. Inside the inner core cotton 7c is an adhesive layer 7d for adhering airborne particles and grease. Inside the adhesive layer 7d is an inner core column 7e for positioning. In actual use, when using this fiberglass filter, it is necessary to ensure the correct installation direction of the middle layer (12b) composite filter element. The outer permeation cotton layer should face the air inlet side. When airflow... When the air passes through the pores of the outer permeable layer, it first undergoes preliminary filtration by the outer cotton layer. Then, the airflow is evenly distributed to the inner filter core layer through the inner cotton layer. After the filter core is pre-filtered by the outer core cotton 7a, the inner permeable mesh 7b performs gradient permeation of grease and particulate matter. The adhesion layer 7d then performs final adsorption of fine pollutants. The two sets of symmetrically arranged inner filter core meshes can form a dual-channel purification structure, which increases the dust holding capacity. When replacing the filter element, the entire middle layer 12b assembly needs to be removed. During installation, the inner bonding layer must be accurately aligned with the adjacent filter layer to ensure that the airflow flows through the designed filtration path. When obvious oil stains are visible on the inner core column 7e, the entire middle layer 12b filter core assembly needs to be replaced. This structure achieves high capture efficiency while ensuring air permeability through the synergistic effect of multi-layer gradient filtration and dual core mesh.

Claims

1. A manufacturing process for a high-capture-efficiency fiberglass filter, characterized in that, Includes the following steps: S1: The raw material composition for manufacturing glass fiber filter mesh is precisely controlled, and then calcined in a crucible to form glass fiber melt. The internal composition of the melt is then monitored in real time using an XRF spectrometer to ensure the accuracy of the composition during the glass raw material pretreatment process. S2: After cooling the glass fiber melt in S1, centrifugal spinning is performed, and the temperature and humidity during the spinning process are precisely controlled. Then, the fiber diameter distribution of the glass fiber spinning is analyzed by a CCD image processing system to ensure that the spinning material in the glass fiber filter meets the requirements. Then, the mesh is laid and woven according to the specific method. S3: After the glass fiber melt spinning and weaving process in S2 is completed, the initially formed glass fiber filter is ultrasonically impregnated to improve the penetration rate of the coupling agent. At the same time, the flame retardant and coupling agent are mixed and configured into a composite agent. Ultrasonic vibration is used to achieve uniform penetration into the gaps of the glass fiber, forming a combined modification effect of flame retardancy and coupling. Then it is dried. After drying, bipolar corona treatment technology is used to optimize the electret properties of the glass fiber filter. S4: Use a servo hydraulic hot press to hot press and shape the fiberglass filter, then use a two-component polyurethane to seal the outer surface of the fiberglass filter. Apply the polyurethane to the outer surface of the fiberglass filter through slit extrusion, and then use an infrared thermal imager to monitor the curing of the outer adhesive layer in real time. S5: Place it in the drying area and supply air through the combination of FFU+HEPA and circulate the air. At the same time, establish an SPC control chart and carry out the testing process of filtration efficiency, air permeability, charge density and electrostatic analysis. Once the relevant standards are met, it can be used. First, quartz sand with a silica content ≥99.9%, calcined aluminum carbide with an alumina content ≥99.0%, and calcium borate are used as the main raw materials, with a formula ratio of silica 52±0.5%, alumina 15±0.5%, and total alkali metal oxides <1.2%. Then, a loss-in-weight feeder is used to dynamically compensate the glass fiber raw materials, with each batch of raw materials weighing 5±0.2KG. After the process is completed, a SYH series three-dimensional motion mixer is used to mix at a speed of 10r / min for 30min, and the mixing uniformity CV value must be ≤8%. After mixing, an infrared dryer is used to reduce the moisture content of the raw materials to below 0.1% before proceeding to the next process.

2. The manufacturing process of a high-capture-efficiency fiberglass filter according to claim 1, characterized in that: After drying, the fiberglass raw material is ground and fed into a furnace. The furnace is divided into three zones: a preheating zone, a melting zone, and a clarification zone, based on the specific usage steps of the fiberglass raw material. The temperatures of the three zones are controlled as follows: 900℃ for the preheating zone, 1600℃ for the melting zone, and 1400℃ for the clarification zone. The materials are added in the following order: quartz sand, alumina, and calcium carbonate spraying, with a ten-minute interval between each layer. The fiberglass material is then melted. During the melting stage, a variable frequency electromagnetic stirrer is used to promote the uniform distribution of the fiberglass material. During the clarification process, sulfur dioxide gas is introduced to promote the uniform distribution of the composition within the fiberglass.

3. The manufacturing process of a high-capture-efficiency glass fiber filter according to claim 2, characterized in that: During the melting stage in the furnace, a laser particle size analyzer is used to detect microbubbles in the melt, requiring that the microbubble b90≤10μm to prevent fiber forming defects. During the fiber drawing process, a laser detection module is integrated and installed below the drawing die to dynamically feed back fiber diameter fluctuations and adjust the drawing machine speed and temperature parameters accordingly, thereby controlling the diameter of the fiber filaments.

4. The manufacturing process of a high-capture-efficiency fiberglass filter according to claim 1, characterized in that: The glass fiber melt flows out through a platinum-rhodium alloy spinneret. The traction tension is dynamically adjusted by a servo motor, and the glass fiber melt is drawn into fibers at a speed maintained at 3000-4000 m / min. During the weaving process, a composite weaving technique is used, with alternating layers of plain and twill weaves. Laser detection technology is used to monitor the weaving density and to adjust the fiber feeding tension in conjunction with the weaving equipment to ensure the uniformity of the multi-layer structure of the glass fiber filter mesh. After weaving, the glass fiber filter material is cleaned with high-frequency ultrasonic waves. A composite solution of flame retardant and coupling agent is prepared and uniformly penetrated into the fiber gaps through ultrasonic vibration to complete the flame retardant coating. Subsequently, a stepped drying method is used: first, pre-drying at 75℃ for 60 minutes to remove surface solvents, and then curing at 120℃ for 90 minutes to form a film of flame retardant on the outer surface of the glass fiber material.

5. The manufacturing process of a high-capture-efficiency glass fiber filter according to claim 1, characterized in that: When waste filaments are generated during the glass fiber drawing process, they are conveyed by a plate chain conveyor into the crusher. The cross-sectional inner diameter of the waste filament particles is reduced to less than 5mm. Then, the waste filament particles are further crushed by an air classifier to form glass fiber powder with a size of ≤0.5mm. Subsequently, the waste filaments are incinerated in an 800-1000℃ incinerator to completely decompose the residual sizing agent and produce clean glass powder. This powder is then returned to the S1 process and mixed with the pretreated raw materials in a 1:8 ratio in the tank furnace for remelting and drawing.

6. A high-efficiency fiberglass filter and a portable assembly / disassembly device, comprising: The outer shell (1) and the filter body (12) are provided. The outer shell (1) is provided with a set of front guide louvers (2) for air guidance. The center of the outer shell (1) is provided with a set of front buckles (3) for positioning and fastening with the inner lining plate (5). The upper rear side of the outer shell (1) is provided with a set of rotating shafts (4) for movable support with the inner lining plate (5). The inner lining plate (5) is provided with two sets of limiting shaft shells (10) for limiting and fitting with the rotating shafts (4). The inner lining plate (5) is provided with two sets of limiting shaft shells (10) for limiting and fitting with the rotating shafts (4). The inner lining plate (10) is movably fitted with the rotating shaft (4) inside. The outer side of the rotating shaft (4) is fixedly connected to the outer shell (1). The rear side of the inner lining shell is provided with A set of rear shells (6) for placing the filter body (12), the rear shell (6) is provided with a set of rear guide louvers (7) for air circulation, the rear shell (6) is provided with a set of rear fixing holes (9) for connecting and fixing with external air conditioners, purifiers and range hoods, the connection between the rear shell (6) and the inner lining plate (5) is provided with several sets of rear buckles (8) for fastening and positioning, the rear shell (6) is provided with a set of filter chambers (11) for placing the filter body (12), the filter chamber (11) has a rectangular cross-section when viewed from above, and the filter chamber (11) is sealed and fitted with the filter body (12) around its perimeter; The filter body (12) includes a front layer (12a), a middle layer (12b), and an inner cotton fiber mesh (12e). The outer surface of the front layer (12a) is provided with a set of limiting grid mesh (12d) for protecting the inner cotton fiber mesh (12e). The limiting grid mesh (12d) is arranged in a diamond cross structure. The inner side of the limiting grid mesh (12d) is provided with a set of inner cotton fiber mesh (12e) for flexibly bonding the middle layer (12b). The inner cotton fiber mesh (12e) and the inner side of the limiting grid mesh (12d) are interlocked and bonded. The rear side of the front layer (12a) is provided with a set of middle layer (12b) with high dust particle capture efficiency. The rear side of the middle layer (12b) is provided with a set of rear layer (12c). The middle layer (12b) includes an outer permeable cotton layer (b1), an outer air-permeable layer (b2), an inner permeable cotton layer (b3), an inner filter core layer (b4), an inner bonding layer (b5), and an outer permeable cotton layer (b10). The inner side of the outer permeable cotton layer (b1) is provided with a set of outer air-permeable layers (b2) for guiding airflow. The outer air-permeable layer (b2) has several sets of air vents for air circulation. The lower end of the outer air-permeable layer (b2) is provided with a set of vents for guiding the inner filter core layer (b4). The inner cotton layer (b3) is internally permeable and separated. The inner filter core layer (b4) has several sets of core rods for adsorbing particulate matter inside the air. The outer cotton layer (b1), the outer air guiding layer (b2), the inner cotton layer (b3), the inner filter core layer (b4), and the inner bonding layer (b5) constitute an inner filter core mesh for filtering the air of external air conditioners, air purifiers, and range hoods. There are two sets of inner filter core meshes, which are arranged symmetrically.

7. The high-efficiency fiberglass filter and portable assembly / disassembly device according to claim 6, characterized in that: The inner filter core layer (b4) is provided with several sets of filter cores. The filter core includes an outer core cotton (7a), an adhesive layer (7d), and an inner core column (7e). The filter core is a columnar structure. The several sets of filter cores are closely attached. The inner side of the outer core cotton (7a) is provided with an inner permeation mesh (7b) for permeating particulate matter and grease in the air. The inner side of the inner permeation mesh (7b) is provided with an inner core cotton (7c) for covering the outer side of the adhesive layer (7d). The inner side of the inner core cotton (7c) is provided with an adhesive layer (7d) for adhering particulate matter and grease inside the air. The inner side of the adhesive layer (7d) is provided with an inner core column (7e) for positioning it.

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