Special filter element for removing oil sludge and paint film colloids

Abstract

The utility model provides a special filter element for removing oil sludge and paint film colloid, which comprises an upper end cover, a lower end cover and a filter element body adhered between the upper end cover and the lower end cover, and the filter element body comprises an outer support tube, a filter layer and an inner support tube which are coaxially arranged from outside to inside at equal height, the outer supporting pipe and the inner supporting pipe are stainless steel pipes with the side faces in a uniform mesh shape, oil inlet cavities are formed between the inner supporting pipe and the upper end cover and between the inner supporting pipe and the lower end cover, and an oil inlet allowing hydraulic oil to enter is formed in the lower end cover. The end faces, corresponding to the filtering layer, of the upper end cover and the lower end cover are each provided with a conductive column extending to be inserted into the filtering layer. The filter layer is arranged in a cylindrical layered mode and sequentially comprises a polypropylene superfine fiber filter material, a glass fiber filter material and an electrostatic filter material from outside to inside, and the electrostatic filter material is close to one side of the inner supporting pipe.

Description

Technical Field

[0001] This utility model belongs to the field of hydraulic oil filtration technology, and relates to a special filter element, especially a special filter element for removing oil sludge and varnish. Background Technology

[0002] An excessively high MPC (Modulation Propensity) value in hydraulic oil testing can negatively impact equipment operation in several ways. For example, it can increase oil degradation rates, reducing oil lifespan. The varnish degrades lubricant through autocatalytic reactions; this degradation accelerates with increasing free radicals and temperature, while simultaneously reducing the hydraulic oil's heat dissipation capacity. Furthermore, the varnish can form an insulating layer on heat exchangers and tank walls, preventing proper heat transfer. This further increases hydraulic oil temperature and leads to further lubricant degradation, reduces heat transfer to critical components (such as bearings), and causes premature failure. It can also reduce clearances in critical areas such as shafts, bearings, servo valves, and last-chance filters, causing filter clogging.

[0003] The solubility of varnish in turbine oil is temperature-dependent. When the temperature in the turbine's hydraulic control section falls below a certain threshold, deposits will form on the control valves, potentially leading to sticking and malfunctions in tightly spaced moving parts. Varnish can obstruct the flow of critical oil passages, causing metal-to-metal contact, interfering with proper lubrication, and thus exacerbating wear. Furthermore, it can attract abrasive dirt and solid particles, further increasing wear.

[0004] Currently, the main method for addressing varnish buildup in China is the use of balanced charge oil filters. These filters install a device to balance the charge, removing static electricity before filtering the oil to reduce the varnish tendency index. However, these balanced charge oil filters have low flow rates and are expensive, with a single filter element costing several thousand yuan, making them unsuitable for larger and more complex hydraulic systems.

[0005] Therefore, it is necessary to provide a treatment element for sludge, varnish, and gum-like substances that can be applied in large hydraulic systems to intercept and adsorb solid particles, gum, asphalt, and other sludge components in hydraulic oil, thereby improving oil cleanliness and ensuring the normal operation of equipment. Utility Model Content

[0006] The purpose of this utility model is to provide a special filter element for removing sludge and varnish, so as to solve the technical problems of existing balanced charge oil filters having small flow rates and being unable to effectively intercept and adsorb solid particles, colloids, asphalt and other greasy components in hydraulic oil in large hydraulic systems.

[0007] To achieve the above objectives, the specific technical solution of this utility model is as follows:

[0008] A special filter element for removing sludge and varnish, comprising an upper end cap, a lower end cap, and a filter element body bonded between the two. The filter element body includes an outer support tube, a filter layer, and an inner support tube arranged coaxially and at the same height from the outside to the inside. The outer support tube and the inner support tube are stainless steel tubes with uniform mesh-like patterns on their sides. The inner support tube, the upper end cap, and the lower end cap form an oil inlet chamber. The lower end cap is provided with an oil inlet for hydraulic oil to enter.

[0009] The upper end cap, the lower end cap and the end face corresponding to the filter layer are respectively provided with conductive posts that extend into the filter layer.

[0010] The filter layer is arranged in a cylindrical layered manner, including polypropylene microfiber filter material, glass fiber filter material and electrostatic filter material from the outside to the inside. The electrostatic filter material is located near the inner support tube.

[0011] An intermediate tube, coaxial with and at the same height as the outer and inner support tubes, is provided between the outer support tube and the inner support tube. The intermediate tube is a stainless steel tube with a uniform mesh pattern on its side. A primary filtration chamber is formed between the inner support tube and the intermediate tube, and a secondary filtration chamber is formed between the intermediate tube and the outer support tube. There are two sets of filter layers, which are adapted to the inner and outer diameters of the primary and secondary filtration chambers, respectively, and are filled in the primary and secondary filtration chambers. Multiple conductive pillars are uniformly provided on the end faces of the upper and lower end caps corresponding to the primary and secondary filtration chambers, respectively.

[0012] The filter layers are stacked and arranged in a corrugated shape with the same axial extension direction as the filter element body. After stacking, the two sides of the filter layers are bonded together in a barrel shape.

[0013] The inner surface of the electrostatic filter material and the outer surface of the polypropylene microfiber filter material are respectively provided with filter material support layers. The filter material support layer is a nylon woven mesh filter material protective layer. The filter material support layer, polypropylene microfiber filter material, glass fiber filter material and electrostatic filter material are stacked together to form a corrugated shape.

[0014] A coarse fiber filter material is also provided between the inner surface of the electrostatic filter material and the filter material support layer located inside it. The coarse fiber filter material, the filter material support layer, the polypropylene microfiber filter material, the glass fiber filter material, and the electrostatic filter material are stacked together to form a corrugated shape.

[0015] After the outer support tube, middle tube, filter layer and inner support tube are assembled, they are respectively bonded to the upper end cover and the lower end cover.

[0016] The upper end cover seals the upper end of the filter element body, and a handle for easy filter element replacement is welded on the outer end face of the upper end cover.

[0017] The beneficial effects of this utility model are as follows: This utility model provides a special filter element for removing oil sludge and varnish. By using electrostatic filter material, glass fiber filter material, and polypropylene ultrafine fiber filter material as the filter layer, the adsorption capacity of the filter layer can be significantly improved. The electrostatic filter material electrostatically adsorbs small particles smaller than 1μm in the oil into larger particles, which are then filtered deeply by the glass fiber filter material and polypropylene ultrafine fiber filter material to remove oil sludge and varnish. When used together with traditional coarse fiber filter material, the filtration accuracy of the traditional filter layer can be increased from tens of micrometers to tens of micrometers, significantly improving the overall filtration accuracy and filtration effect of the filter layer.

[0018] In addition, this filter layer filters from the inside out, allowing the oil to pass through the mesh on the inner support tube, middle tube, and outer support tube in sequence before seeping out from the filter element body. This effectively increases the flow rate of the filtered oil and is suitable for use in large hydraulic systems.

[0019] In addition, the technical solution of this utility model also provides conductive posts extending into the filter layer on the upper and lower end caps, which can release the static charge generated by the filter material, prevent the static electricity generated by the filter material from damaging the filter element and causing local spark discharge, thereby providing effective protection for the filter layer and extending the service life of the filter layer.

[0020] The technical solution provided by this utility model effectively improves filtration performance and service life of the filter layer by removing oil, sludge, paint film and colloidal substances, and is easy to maintain. It is not only suitable for application in small hydraulic systems, but also meets the high flow requirements of large hydraulic systems. It is suitable for promotion and application in multiple industries such as steam turbines and gas turbines, and has significant advantages and market prospects. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the main structure of this utility model;

[0022] Figure 2 This is a schematic diagram of the main structure of this utility model from another perspective;

[0023] Figure 3 This is a cross-sectional view of the present invention after the filter layer has been removed;

[0024] Figure 4 This is a schematic diagram of the main structure of the filter layer in this utility model;

[0025] Figure 5 This is a cross-sectional view of the filter layer in the thickness direction of this utility model;

[0026] Figure 6 for Figure 3 A magnified view of a portion of point A in the middle.

[0027] The markings in the diagram are as follows: 1. Filter element body, 2. Upper end cap, 3. Lower end cap, 4. Outer support tube, 5. Filter layer, 6. Inner support tube, 7. Middle tube, 8. Oil inlet chamber, 9. Oil inlet, 10. Conductive column, 11. Polypropylene microfiber filter media, 12. Glass fiber filter media, 13. Electrostatic filter media, 14. Filter media support layer, 15. Coarse fiber filter media, 16. Handle, 17. Rubber pad. Detailed Implementation

[0028] To better understand the purpose, structure, and function of this utility model, a more detailed description of this utility model is provided below with reference to the accompanying drawings.

[0029] like Figures 1 to 6 As shown, this utility model provides a special filter element for removing oil sludge and paint film adhesives. It includes an upper end cap 2, a lower end cap 3, and a filter element body 1 bonded between the two. The filter element body 1 includes an outer support tube 4, a filter layer 5, and an inner support tube 6 arranged coaxially and at the same height from the outside to the inside. The outer support tube 4 and the inner support tube 6 are stainless steel tubes with uniform mesh on the sides, which are used to provide placement space and support for the filter layer 5. The inner support tube 6, the upper end cap 2, and the lower end cap 3 form an oil inlet chamber 8. The lower end cap 3 is provided with an oil inlet 9 for hydraulic oil to enter. The hydraulic oil enters the oil inlet chamber 8 through the oil inlet 9, passes through the mesh of the inner support tube 6, and is filtered by the filter layer 5. After filtration, it seeps out from the filter element body 1 through the mesh of the outer support tube 4.

[0030] In order to prevent the static electricity generated in the filter layer 5 from causing local spark discharge and damaging the filter element, in this embodiment, conductive posts 10 extending into the filter layer 5 are respectively provided on the end faces of the upper end cover 2 and the lower end cover 3 corresponding to the filter layer 5.

[0031] It is important to note that the filter layer 5 in this embodiment is arranged in a cylindrical layered configuration, comprising, from the outermost layer to the innermost layer, chemical fiber filter material, glass fiber filter material 12, and electrostatic filter material 13. In this embodiment, the chemical fiber filter material is preferably polypropylene microfiber filter material 11. The electrostatic filter material 13, located near the inner support tube 6, has electrostatic adsorption properties, which adsorb tiny particles in the filter material, causing them to aggregate into larger particles. These larger particles are then deeply filtered out by the glass fiber filter material 12 and the polypropylene microfiber filter material 11 through physical filtration. When fluid containing sludge, varnish, and colloids passes through the filter element, these tiny impurities are first adsorbed by the particles of the electrostatic filter material 13, and then deeply filtered by the polypropylene microfiber filter material 11 and the glass fiber filter material 12, which can significantly improve the filtration effect of sludge and varnish in the engine oil.

[0032] Furthermore, to further improve the filtration effect of the filter element body 1, in this embodiment, an intermediate pipe 7, coaxial and at the same height as the outer support pipe 4 and the inner support pipe 6, is provided between them. The intermediate pipe 7 is a stainless steel pipe with a uniform mesh pattern on its side. A primary filtration chamber is formed between the inner support pipe 6 and the intermediate pipe 7, and a secondary filtration chamber is formed between the intermediate pipe 7 and the outer support pipe 4. The number of filter layers 5 is two sets, which are adapted to the inner and outer diameters of the primary and secondary filtration chambers, respectively, and are filled in the primary and secondary filtration chambers. Four conductive pillars 10 are uniformly provided on the end faces of the upper end cap 2 and the lower end cap 3 corresponding to the primary and secondary filtration chambers, respectively. After the oil enters the oil inlet chamber 8 through the oil inlet 9, it first enters the primary filtration chamber for primary filtration and then enters the secondary filtration chamber for secondary filtration, which can further improve the purity of the hydraulic oil, reduce the sludge content, and reduce the hydraulic paint film tendency index (MPC).

[0033] Furthermore, in this embodiment, the filter layer 5 is arranged in a stacked manner, and is folded into a corrugated shape with the same axial extension direction as the filter element body 1 using a folding machine, such as... Figure 4 As shown, by bonding the two sides of the stacked filter layer 5 into a barrel shape and placing it into the primary and secondary filter chambers, the filtration area of ​​the filter layer 5 can be significantly increased, thereby further improving the filtration effect.

[0034] To provide support for the stacked filter layers 5 and ensure that they maintain their shape and are not easily deformed after stacking, in this embodiment, filter material support layers 14 are respectively provided on the inner side of the electrostatic filter material 13 and the outer side of the polypropylene microfiber filter material 11. The filter material support layer 14 is a nylon woven mesh filter material protective layer, which is stacked together with the polypropylene microfiber filter material 11, glass fiber filter material 12 and electrostatic filter material 13 in a corrugated shape. After stacking, the nylon woven mesh filter material protective layer has a certain strength and toughness, which can provide the required support for the filter layers 5.

[0035] Furthermore, in order to filter out large particulate impurities in the hydraulic oil before filtering out sludge and paint film, thereby fully utilizing the particle adsorption and deep filtration functions of the electrostatic filter material 13, glass fiber filter material 12, and polypropylene microfiber filter material 11, this embodiment also provides a coarse fiber filter material 15 between the inner surface of the electrostatic filter material 13 and the filter material support layer 14 located inside it. The coarse fiber filter material 15, the filter material support layer 14, the polypropylene microfiber filter material 11, the glass fiber filter material 12, and the electrostatic filter material 13 are stacked together in a corrugated shape. This embodiment has undergone multiple tests, installing the above-mentioned filter layer on the system circulation filter of a large hydraulic system, allowing the system to filter naturally during operation. This reduced the hydraulic paint film tendency index (MPC) from over 80 to around 10, demonstrating excellent and sustained filtration performance.

[0036] Furthermore, such as Figure 3 , Figure 6 As shown, after the outer support tube 4, the middle tube 7, the filter layer 5 and the inner support tube 6 are assembled, they are respectively bonded to the upper end cover 2 and the lower end cover 3. In order to facilitate the sealing and docking of the lower end cover 3 with external parts, in this embodiment, a rubber pad 17 is also bonded to the outer surface of the lower end cover 3.

[0037] In order to prevent hydraulic oil from overflowing from the upper cover 2, in this embodiment, the upper cover 2 is sealed at the upper end of the filter element body 1 by adhesive bonding. To facilitate filter element replacement, a handle 16 for easy lifting is welded on the outer end face of the upper cover 2.

[0038] It is understood that this utility model has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this utility model. Furthermore, under the teachings of this utility model, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this utility model.

Claims

1. A special filter element for removing oil sludge and paint film adhesives, characterized in that: It includes an upper end cap (2), a lower end cap (3), and a filter element body (1) bonded between the two. The filter element body (1) includes an outer support tube (4), a filter layer (5), and an inner support tube (6) arranged coaxially and at the same height from the outside to the inside. The outer support tube (4) and the inner support tube (6) are stainless steel tubes with uniform mesh on the side. The inner support tube (6) forms an oil inlet chamber (8) with the upper end cap (2) and the lower end cap (3). The lower end cap (3) is provided with an oil inlet (9) for hydraulic oil to enter. The upper end cap (2), the lower end cap (3) and the filter layer (5) are respectively provided with conductive posts (10) extending into the filter layer (5); The filter layer (5) is arranged in a cylindrical layered manner, and from the outside to the inside, it includes polypropylene microfiber filter material (11), glass fiber filter material (12) and electrostatic filter material (13). The electrostatic filter material (13) is located on the side close to the inner support tube (6).

2. The special filter element for removing sludge and varnish as described in claim 1, characterized in that: An intermediate tube (7) is provided between the outer support tube (4) and the inner support tube (6), and is coaxial and at the same height as the two. The intermediate tube (7) is a stainless steel tube with a uniform mesh pattern on the side. A primary filter chamber is formed between the inner support tube (6) and the intermediate tube (7). A secondary filter chamber is formed between the intermediate tube (7) and the outer support tube (4). There are two sets of filter layers (5), which are adapted to the inner and outer diameters of the primary filter chamber and the secondary filter chamber, respectively, and are filled in the primary filter chamber and the secondary filter chamber. Multiple conductive pillars (10) are uniformly provided on the end faces of the upper end cap (2) and the lower end cap (3) corresponding to the primary filter chamber and the secondary filter chamber, respectively.

3. The special filter element for removing sludge and varnish as described in claim 1, characterized in that: The filter layers (5) are stacked and arranged in a corrugated shape with the same axial extension direction as the filter body (1). After stacking, the two sides of the filter layers (5) are bonded together in a barrel shape.

4. The special filter element for removing sludge and varnish as described in claim 1, characterized in that: The inner surface of the electrostatic filter material (13) and the outer surface of the polypropylene microfiber filter material (11) are respectively provided with filter material support layers (14). The filter material support layer (14) is a nylon woven mesh filter material protective layer. The filter material support layer (14), polypropylene microfiber filter material (11), glass fiber filter material (12) and electrostatic filter material (13) are stacked together to form a corrugated shape.

5. A special filter element for removing sludge and varnish as described in claim 4, characterized in that: A coarse fiber filter material (15) is also provided between the inner side of the electrostatic filter material (13) and the filter material support layer (14) located inside it. The coarse fiber filter material (15), the filter material support layer (14), the polypropylene microfiber filter material (11), the glass fiber filter material (12), and the electrostatic filter material (13) are stacked together in a corrugated shape.

6. A special filter element for removing sludge and varnish as described in claim 1, characterized in that: After the outer support tube (4), the middle tube (7), the filter layer (5) and the inner support tube (6) are assembled, they are respectively bonded to the upper end cap (2) and the lower end cap (3).

7. A special filter element for removing sludge and varnish as described in claim 1, characterized in that: The upper end cover (2) seals the upper end of the filter element body (1), and a handle (16) for easy replacement of the filter element is welded on the outer end face of the upper end cover (2).

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