Dimensionally stable filter element, filter cartridge and brake dust particle filter, as well as method and tool for manufacturing the filter element.

Abstract

The invention relates to a dimensionally stable filter element (28) for a brake dust particle filter (16) comprising a high-temperature filter medium (76) forming at least one filtration section (46) and at least one mounting section (48) with a heat-resistant filter layer (78). The mounting section (68) surrounds the filtration section (46), which has at least one protrusion (52) and / or a recess for increasing the surface area, in a frame-like manner and forms a flange area (68) that is designed as a mechanically compacted section of the high-temperature filter medium (76) for connecting the filter element (28) to a housing component of a brake dust particle filter (16). The invention also relates to a filter cartridge (24) with such a filter element (28). Furthermore, the invention relates to a brake dust particle filter (16) with such a filter element (28).Furthermore, the invention relates to a tool (86) and a method for manufacturing the filter element (28).

Description

Technical field

[0001] The invention relates to a filter element for a brake dust particle filter with a high-temperature filter medium. The invention further relates to a filter cartridge for a brake dust particle filter with a filter element, a brake dust particle filter with a filter cartridge, and a tool and a method for manufacturing the filter element. State of the art

[0002] A filter element of the type mentioned above is generally known from the prior art. In particular, such filter elements are used on disc brakes to separate the brake dust generated by the braking process and carried along in the airflow.

[0003] Conventional filter elements, or brake dust particle filters, consist of a filtering layer and a supporting layer. The filter medium is usually flat or smooth and, for use in a brake dust particle filter, is positioned around the brake disc without contact with it. However, the flat shape of the filter medium significantly restricts the available flow cross-section, so that, due to the high dynamic pressure in front of the filter medium, air often flows around it. Furthermore, flat filter media have the disadvantage that no ventilation or clearly defined flow cross-section can be provided on the downstream side. This allows brake dust-laden air to escape unfiltered into the environment.

[0004] To increase the cross-sectional area of ​​the filter medium, the filtering layer is typically pleated. However, common filter materials are dimensionally unstable and tend to return to their original shape. Therefore, in this case, the filter medium must be painstakingly attached – often manually – to the supporting layer at the base of each pleat, either by hand or by welding. This represents a considerable manufacturing effort. Furthermore, even with this manufacturing method, the dimensional stability of the filter material cannot be guaranteed, as the material's return to its original shape cannot be completely prevented. Sealing the filter medium against a housing wall is only possible with considerable effort, so conventional filter elements of this design often exhibit leakage between the housing and the filter medium.Furthermore, the choice of filter medium in this manufacturing method is additionally limited by the material's suitability for bonding with the supporting layer, e.g., its weldability. This often prevents the use of filter materials with better filtration properties due to their insufficient bonding suitability to the supporting layer.

[0005] From DE 10 2017 008 421 A1, a brake dust particle filter for a disc brake assembly with a brake disc and a brake caliper is known. At least one tongue is arranged or formed in the interior of the brake dust particle filter housing, with at least a section of this tongue projecting radially inwards. The tongue forms a support for a filter medium of the brake dust particle filter. Furthermore, the filter medium covers the surface of the tongue at least partially, and in particular completely. The housing has the shape of an annular segment. It can be used, at least partially, to accommodate the brake disc within the housing interior. A first housing side wall, a second housing side wall, and a housing circumferential wall each form parts of the housing. The housing side walls are axially spaced apart from one another. The housing circumferential wall is arranged radially outside in the circumferential direction of the housing.The housing perimeter wall is located or formed between the first housing side wall and the second housing side wall. The brake dust particle filter is designed to capture particles generated during braking.

[0006] From US patent 2004 / 0035096A1, an air filter is known, consisting of an elastomeric flange section and a filter section mounted therein. The flange section has opposing ends and sides that form a central opening, as well as projecting parts that are integrally formed with the flange section and extend from it. The projecting parts have opposing, inwardly facing surfaces. The filter section has filter ends and sides, the filter sides being attached to the opposing surfaces by an insert-molding process or by bonding the filter sides to the respective surfaces.

[0007] From DE 10 2019 105 862 A1, a brake dust particle filter for a disc brake assembly with a brake disc and a brake caliper is known. At least one tongue is arranged or formed in the interior of the brake dust particle filter housing, with at least a section of this tongue projecting radially inwards. The tongue is formed by a filter medium of the brake dust particle filter. The housing has the shape of an annular segment. It can be used, at least partially, to accommodate the brake disc within the housing interior. A first housing side wall, a second housing side wall, and a housing circumferential wall each form parts of the housing. The housing side walls are axially spaced apart from one another. The housing circumferential wall is arranged radially outside the housing in the circumferential direction. The housing circumferential wall is arranged or formed between the first housing side wall and the second housing side wall.The brake dust particle filter is designed to capture particles generated during braking. Furthermore, a disc brake arrangement is disclosed.

[0008] It is an object of the invention to provide a filter element that keeps flow resistance low and is nevertheless cost-effective to manufacture. It is a further object of the invention to provide a filter cartridge with such a filter element, a brake dust particle filter with such a filter element, as well as a method and a tool for manufacturing such a filter element. Disclosure of the invention

[0009] This problem is solved by a filter element having the features specified in claim 1, a filter cartridge according to claim 11, a brake dust particle filter according to claim 16, a method according to claim 18, and a tool according to claim 21. Preferred embodiments are specified in the dependent claims and the description.

[0010] According to the invention, the filter element comprises a high-temperature filter medium. The high-temperature filter medium has at least one heat-resistant filter layer. The high-temperature filter medium is preferably designed for use at ambient temperatures of the filter element exceeding 300°C. This enables its use on components that heat up significantly, such as disc brakes.

[0011] Preferably, the high-temperature filter medium is multi-layered. This allows the high-temperature filter medium to be adapted particularly flexibly with regard to its filter properties.

[0012] Furthermore, the filter element has at least one mounting section formed on the high-temperature filter medium and at least one filtration section formed on the high-temperature filter medium. In other words, the mounting section and the filtration section are formed on the same high-temperature filter medium or are a single unit.

[0013] The filtration section is permeable to air and designed to separate solids, especially brake dust particles, from a flowing fluid, particularly the air flowing around the brake disc.

[0014] According to the invention, the mounting section has a flange area that is designed to connect the filter element to a housing component of the brake dust particle filter and / or a filter cartridge. This enables the filter element to be directly attached to a filter cartridge and / or a brake dust particle filter.

[0015] The mounting section, or flange area, is designed as a mechanically compacted section of the high-temperature filter medium. In other words, the high-temperature filter medium is partially deformed or compressed and has at least two different final thicknesses. Specifically, the mounting section, or flange area, has a different final thickness than the filtration section. This increases the bond strength of the filter element in the mounting section, or flange area. In particular, the mounting section thus exhibits a higher bond strength than the filtration section of the high-temperature filter medium.

[0016] The mounting section, or flange area, surrounds the at least one filtration section in a frame-like fashion. In other words, the mounting section or flange area completely surrounds the filtration section. This means that the mounting section or flange area has no gaps that could promote leakage when the filter element is installed. A leakage flow is defined as a fluid flow that can pass through the filter element outside of the filtration section and / or flow between the filter element and the mounting structure, such as the brake dust particle filter or filter cartridge.

[0017] In a further embodiment, the circumferential flange area can be provided with a stiffening element extending at least partially around its circumference. In some embodiments, the stiffening element can fully follow the contour of the flange area. In other embodiments, several stiffening elements can be arranged distributed around the circumference of the flange area. It can also be provided that the at least one stiffening element is located on only one side of the flange area. In other embodiments, the at least one stiffening element can be located on two opposite sides of the flange area. The at least one stiffening element can be connected to the flange area by force-fit and / or form-fit connection techniques, for example, by welding, brazing, flanging, riveting, or crimping. In some embodiments, the at least one stiffening element can be a sheet metal strip.In some versions, the stiffening element, which is designed as a sheet metal strip, can wrap around an outer edge of the flange area in a U-shape, further increasing the stiffening effect.

[0018] The use of at least one stiffening element in the flange area is advantageous because it relieves the high-temperature filter medium of forces that arise when the filter element is mounted in a housing. This is particularly advantageous, but not limited to, when the filter element is clamped to a housing.

[0019] The filter element preferably has at least one support layer. Particularly preferably, the at least one support layer is located on the side of the filter element facing away from the brake disc (i.e., on the downstream side) when the filter element is mounted on a brake disc. This protects the heat-resistant filter layer from external influences, such as accidental damage from unintentional contact with people and / or objects.

[0020] In a preferred embodiment of the filter element, the high-temperature filter medium has at least two, and preferably several, support layers. The heat-resistant filter layer is preferably arranged between two support layers. The support layer(s) protect the heat-resistant filter layer during operation from harmful influences such as sparks, stone impacts, and / or impermissible mechanical stresses from air currents, which could damage the sensitive heat-resistant filter layer. Furthermore, the support layer(s) can also protect the heat-resistant filter layer from accidental damage caused by unauthorized contact with persons and / or objects, for example, during maintenance or repairs.

[0021] In this case, the support layers are plastically deformable and exhibit only minimal, preferably no, elastic recovery. This allows the high-temperature filter medium to be deformed, for example, to form a particularly precise bulge and / or indentation, whereby the heat-resistant filter layer is subsequently held in its deformed shape by the two support layers. Springback of the filter element, especially the high-temperature filter medium, is thus prevented.

[0022] Preferably, the fastening section forms the flange area by connecting the at least two support layers. Furthermore, in this case, the filter layer of the high-temperature filter medium is enclosed by the support layers. In other words, after being connected, the support layers form an enclosed volume that is filled by the filter layer. This facilitates the selection of materials for manufacturing the filter layer of the high-temperature filter medium, since the high-temperature filter medium, or the filter layer, can be indirectly fastened by fastening the support layers. The filter layer is thus independent of the choice of fastening method.In principle, however, it can be said that the inventive construction of the high-temperature filter medium with support layers that laminate the heat-resistant filter layer on both sides facilitates a connection of the high-temperature filter medium and, in particular, makes welding possible even for heat-resistant filter layers that are themselves electrically non-conductive, e.g., also for glass fiber-based heat-resistant filter layers.

[0023] In a further preferred embodiment of the filter element, the flange area has at most an insignificant, and in particular no, indentation or protrusion compared to the filtration section. In other words, the flange area is preferably flat. This allows the filter element to be attached to the brake dust particle filter and / or the filter cartridge particularly quickly and easily.

[0024] Alternatively or additionally, the mounting section can have a lower air permeability than the filtration section, or in particular, no air permeability at all. In other words, the mounting section can be airtight. The air permeability of the high-temperature filter medium in the filtration section can be between 200 and 4000 l / m according to DIN EN ISO 9237. 2 / s, preferably between 1500 - 3000 l / m 2 / s. In other words, the preferably airtight mounting section preferably surrounds an air-permeable inner area of ​​the high-temperature filter medium, or completely encloses the air-permeable filtration section of the high-temperature filter medium. This allows the airflow through the filter element to be reliably guided through the filtration section, thus preventing leakage.

[0025] The filter element can have multiple filtration sections. The mounting sections, which preferably completely enclose the filtration sections, can in this case be continuous. A mounting section can be configured to partially enclose another filtration section. In other words, a mounting section can adjoin multiple filtration sections.

[0026] In a particularly multi-layered configuration, the high-temperature filter medium has four or more layers. Preferably, the first and last layers are support layers, and the remaining layers are filter layers. Furthermore, and preferably, the filter layers have a decreasing diameter of the separable solids, especially brake dust particles, from the air in the direction of flow through the high-temperature filter medium. This allows the solids holding capacity or dust holding capacity of the high-temperature filter medium to be utilized particularly effectively. Furthermore, the separation efficiency of the high-temperature filter medium can be improved.

[0027] In a particular embodiment of the filter element, at least one, and preferably each, filter layer is designed as a medium for depth filtration. This effectively prevents the formation of a so-called filter cake. Furthermore, the at least one filter layer preferably comprises or consists of metal fibers, particularly stainless steel fibers, glass fibers, mineral fibers, especially with basalt or alkaline earth silicate, and / or comprises a nonwoven material, particularly a glass fiber nonwoven.

[0028] In a particular embodiment, the fibers of the filter layer have a fiber diameter between 2 µm and 40 µm. This allows for a constant separation efficiency of the high-temperature filter medium. When using multiple filter layers, the fiber diameter can be reduced in the direction of flow. The size of the solids or particles that can be separated by the high-temperature filter medium decreases with decreasing fiber diameter. Preferably, a filter layer arranged upstream in the direction of flow, or a filter layer on the upstream side, has a fiber diameter between 12 µm and 40 µm. More preferably, a filter layer arranged downstream in the direction of flow, or a filter layer on the downstream side, has a fiber diameter between 2 µm and 8 µm.

[0029] The fiber diameter distribution is preferably uniform across the filter layer. This ensures a consistent separation efficiency across the entire filter element.

[0030] The at least one heat-resistant filter layer, preferably the entire high-temperature filter medium, can be impregnated, particularly with a water-repellent finish. This can improve the oxidation resistance and / or the water separation efficiency of the filter element, as well as increase the adsorption capacity of the high-temperature filter medium.

[0031] Preferably, at least one, and in particular each, support layer is designed as a perforated sheet, slotted screen, expanded metal mesh, or wire mesh, and / or one, and in particular each, support layer consists of a metal or a metal alloy, especially steel, preferably stainless steel. Preferably, the support layers have a large openness ratio, or a large ratio between the area through which flow passes and the area that is not open to flow. This reduces the flow resistance caused by the support layers and increases the area through which flow passes through the heat-resistant filter layer.

[0032] Preferably, the support layers are made of a heat-resistant material and designed for continuous use at temperatures above 300°C. Furthermore, the support layers preferably consist of a high-strength material. This allows the impervious surface area of ​​the support layers to be reduced while maintaining the same strength.

[0033] Preferably, the support layers have a mesh size of 0.02 to 2.2 millimeters, particularly preferably 0.45 to 1.4 millimeters. This is particularly advantageous with regard to the flow permeability of the support layers.

[0034] Preferably, at least one, and in particular each, support layer has a web width of 0.03 to 0.35 millimeters, and in particular of 0.1 to 0.25 millimeters. This is particularly advantageous with regard to the formability and dimensional stability of the support layers.

[0035] In a preferred embodiment, at least one, and in particular each, support layer has a layer thickness of at most 0.7 millimeters, in particular of at most 0.3 millimeters, and most preferably of at most 0.1 millimeters.

[0036] A further preferred design is one in which at least one, in particular each, support layer has a bending stiffness between 1.5 and 20 newton millimeters, in particular between 2 and 6 newton millimeters.

[0037] The filtration section has at least one bulge and / or indentation, preferably at least one fold, to increase the surface area. Surface area increase refers to a flat initial state of the filter layer without a bulge or indentation. In other words, in an initial state, the projected area of ​​the filtration section is equal to the effective filter area of ​​the filtration section in the projection direction. The projection direction is preferably an axial direction and / or a main flow direction of the filter element. A bulge or indentation, on the other hand, increases the effective filter area of ​​the filtration section while keeping the projected area constant. This reduces the flow resistance of the filter element, which has a positive effect on the dynamic pressure caused by the filter element and the amount of air that can be filtered per unit of time.

[0038] In a preferred embodiment of the filter element, the mounting flange is formed by positive locking and / or material locking, in particular by interlocking and / or wedging, of the support layers. This allows the mounting section to be formed particularly simply, quickly, and with exceptional durability.

[0039] In a further preferred embodiment of the filter element, the at least one bulge and / or the at least one indentation projects unidirectionally beyond the flange area. Unidirectional projection means that the at least one bulge and / or the at least one indentation extends beyond the flange area on one side. Preferably, the at least one bulge and / or the at least one indentation projects beyond the flange area in the axial direction of the filter element. The axial direction is preferably the main flow direction through the filter element. More preferably, when the filter element is mounted on a brake disc, the at least one bulge and / or the at least one indentation projects beyond the mounting flange in the direction of the brake disc. This allows for effective use of the available installation space and reduces flow resistance on the upstream side of the filter element.In other versions, at least one protrusion can extend beyond the flange area in a direction pointing away from the brake disc when the disc is in a state arranged on a brake disc.

[0040] A main flow direction is a theoretical global flow direction through the filter element. The main flow direction preferably results from the sum of the local flow directions through the high-temperature filter medium. For example, the main flow direction of a flat filter element without a bulge or indentation can be oriented perpendicular to the filter element.

[0041] A preferred embodiment features at least one filtration section of the filter element having a plurality of protrusions and / or indentations, particularly multiple folds arranged adjacent to, preferably parallel or aligned with, the filtration section. In the case of protrusions, this allows for a particularly large surface area increase with the smallest possible protrusion or fold height. Similarly, in the case of indentations, the particularly large surface area increase is achieved with the smallest possible indentation or fold depth. In both cases, the available installation space can be used particularly effectively.

[0042] Particularly preferably, several, and especially all, bulges or indentations, particularly folds, have the same bulge height or indentation depth, bulge width or indentation width, and / or bulge length or indentation length. The bulge height or indentation depth refers to a bulge extent or indentation extent in or against the main flow direction of the filtration section. The bulge width or indentation width and the bulge length or indentation length are bulge extents or indentation extents in the area of ​​the filtration section projected in the main flow direction. In other words, the bulge height or indentation depth can be determined perpendicular to the bulge width or indentation width and the bulge length or indentation length. A high degree of uniformity of the bulges or indentations is desirable.Indentations facilitate quick and easy manufacturing of the filter element.

[0043] In a preferred embodiment of the filter element, the fastening section is formed by mechanical compaction, in particular by pressing, of the support layers. Mechanical compaction represents a particularly fast, cost-effective and reliable method for forming the fastening section.

[0044] A further preferred embodiment of the filter element is one in which the flange area is predominantly formed in a plane orthogonal to the main flow direction of the filtration section or predominantly curved around an axis of curvature orthogonal to the main flow direction of the filtration section. In other words, the filter element can be bent in the plane projected in the main flow direction or around an axis of curvature parallel to this plane. This is particularly advantageous for enabling the filter element to be configured as an axial filter element and / or as a radial filter element.

[0045] The axial filter element is a filter element designed for arrangement in the axial direction of a disc brake or brake disc. The axial filter element is essentially flat and shaped like a circular segment. In other words, the axial filter element is modeled after the axial contour of the brake disc.

[0046] The radial filter element is a filter element designed for arrangement in a radial direction along the disc brake or brake disc. The radial filter element is essentially curved in space and rectangular in shape. In other words, the radial filter element is modeled after the radial circumference of the brake disc.

[0047] In a preferred embodiment of the filter element, at least a portion of the flange area is inclined from the plane orthogonal to the main flow direction in the direction of the main flow of the filtration section. In other words, a portion of the flange area or the mounting section is angled relative to the surface projected in the direction of the main flow of the filtration section. Preferably, the entire flange area is inclined from the orthogonal plane in the direction of the main flow. Particularly preferably, the at least one portion, and especially the entire flange area, is parallel to the main flow direction. Preferably, the mounting section or the flange area runs parallel to the main flow direction of the filtration section.This allows the filter element to be arranged or attached to a cartridge body or a brake dust particle filter with particular flexibility.

[0048] The problem is further solved according to the invention by a filter cartridge for a brake dust particle filter comprising the filter element and a cartridge body. Preferably, the filter element is permanently attached to the cartridge body by means of the fastening section.

[0049] The cartridge body is designed to at least partially accommodate a brake disc. The cartridge body can be designed to grip the brake disc on two or three sides. In other words, the cartridge body can have an L-shape, a C-shape, or a U-shape in a cross-section that grips the brake disc. This allows the cartridge body to reduce the flow around the filter element.

[0050] The cartridge body has at least one filter element recess. This recess is designed to accommodate the filter element. Preferably, the recess has a surrounding rim that is designed to secure, and in particular fasten, the filter element. This simplifies the arrangement and fastening of the filter element to the filter cartridge.

[0051] In combination with a previously described flange area—which has at least one section inclined from the plane orthogonal to the main flow direction in the direction of the main flow of the filtration section—the filter element can be attached to an adjacent side surface of the cartridge body or the brake dust particle filter. In this embodiment, the filtration section of the filter element can overlap the filter element recess of the cartridge body, so that an effective flow cross-section, which is crucial for throttling the airflow to be filtered, does not coincide with a flow cross-section of the filter element recess. In this case, the effective flow cross-section can be located upstream or downstream of the filter element recess of the cartridge body in the main flow direction of the filter element.The flow cross-section provided by the filter element recess is therefore not further restricted by the effective flow cross-section of the filter element itself. This allows the flow resistance through the filter element to be reduced, or a higher volume of air to be filtered per unit of time.

[0052] Preferably, the cartridge body has two or more filter element recesses. This allows for the particularly easy arrangement of additional filter elements on the filter cartridge.

[0053] The cartridge body is preferably made of a thermally resistant material, particularly metal. However, it can also be made of a plastic, especially a thermoplastic, which offers advantages for injection molding. A plastic cartridge body can certainly be used in specific cases, depending on the expected thermal stress in the brake environment. In the case of a plastic cartridge body, the filter element is preferably connected to the cartridge body by welding the mounting section of the filter element to a rim surrounding the filter element recess in the cartridge body. Ultrasonic welding is particularly suitable as a welding method, since it is both reliable and can be implemented with short cycle times.

[0054] The cartridge body is preferably formed in one piece. More preferably, the cartridge body is manufactured from a single blank, particularly by sheet metal forming. This enables the particularly fast and cost-effective production of the cartridge body without the need for tooling.

[0055] The mounting section of the filter element is attached to the cartridge body, preferably at an edge of one of the filter element recesses, in an airtight manner. This effectively prevents leakage flow from the filter element via the mounting section or between the mounting section and the cartridge body.

[0056] The filtration section of the filter element closes or covers the filter element recess. Preferably, the filtration section completely closes or covers the filter element recess. In other words, the filtration section has at least the same area as the filter element recess. This allows the available filter element recess to be used effectively with regard to minimum flow resistance.

[0057] In a preferred embodiment of the filter cartridge, the cartridge body forms a circular annular segment in a plane parallel to the brake disc to be received. This allows the filter cartridge to be arranged on the disc brake in a particularly space-saving manner.

[0058] A preferred embodiment of the filter cartridge is one in which the filter element is positively attached to the cartridge body, particularly by crimping, and / or by welding. The exemplary fastening methods described above are advantageous with regard to a particularly high degree of process automation.

[0059] A particularly preferred embodiment of the filter cartridge is one in which the filter cartridge has at least two filter elements, and these at least two filter elements are attached to the cartridge body, preferably facing different sides of the brake disc. In other words, the filter elements are preferably formed on different side surfaces of the cartridge body. This allows the filtering of air flowing from the brake disc and contaminated with brake dust in multiple directions. Furthermore, the flow resistance of the entire filter cartridge and / or the brake dust particle filter is improved.

[0060] A preferred embodiment of the filter cartridge provides that the at least two filter elements are arranged opposite each other and / or at right angles to each other on the cartridge body. In other words, in this embodiment, the filter elements are arranged axially opposite each other on the brake disc. This allows for a particularly large filtration area.

[0061] The problem is also solved by a brake dust particle filter for a means of transport having a brake disc, in particular for a wheel-driven vehicle, especially preferably for a motor vehicle, with a filter housing and the filter element.

[0062] The filter element is preferably designed to filter brake dust from the air flowing around the brake disc and is arranged in the immediate vicinity of the brake disc.

[0063] The filter housing is designed to cover the filter element. This effectively prevents unwanted contact between objects and / or people and the interior of the brake dust particle filter. Furthermore, the brake dust particle filter is effectively protected from contaminants and / or liquids, especially splashing water.

[0064] The filter element can be located directly on the brake dust particle filter. This eliminates the need for additional components, which can have a positive impact on production costs.

[0065] In a preferred embodiment, the brake dust particle filter comprises a filter cartridge, wherein the filter element is integrated into the filter cartridge. In other words, the filter element is arranged directly on the filter cartridge. The filter cartridge can be detachably or replaceably attached to the brake dust particle filter. This reduces maintenance and repair costs, as only a portion of the brake dust particle filter needs to be replaced once the filter element is saturated.

[0066] The task is also solved by a method for manufacturing the filter element from a filter preform with the following process steps: a) Prefabrication of the filter form, in particular designed as a high-temperature filter medium, by forming bulges and / or indentations, in particular by introducing folds by pleating, in a single-layer arrangement, in particular with at least one filter layer and at least two support layers; b) Fixing the filter form; c) partial mechanical compaction, in particular compression, of the filter form to form the mounting section which surrounds the filtration section in a frame-like manner.

[0067] The filter element is preferably designed as a formed high-temperature filter medium. More preferably, the high-temperature filter medium is a multi-layered filter medium with at least one bulge and / or indentation to increase the surface area. The formed high-temperature filter medium preferably comprises a single-layer composite with at least one filter layer and at least two support layers. In the case of a high-temperature filter medium with at least two support layers, the filter layer is particularly preferably arranged between the support layers.

[0068] A preferred further development of the method provides that the mechanical compaction is carried out by pressing the filter form, wherein the pressing is carried out in particular with a pressing force between 300 kilonewtons and 1000 kilonewtons, preferably between 600 kilonewtons and 800 kilonewtons.

[0069] In a preferred embodiment of the method, the filter element is trimmed along an outer edge of the mechanically compacted, in particular pressed, fastening section, especially during process step c) or immediately following process step c). This allows the filter element to be trimmed using the same lifting device as for the mechanical compaction. This enables the filter element to be manufactured efficiently in a single lifting motion.

[0070] Furthermore, the problem is solved by a tool for producing the filter element from the filter blank. The tool can be part of a production line, particularly an automated one. Preferably, the tool is designed for immediate downstream use with a forming device for creating at least one bulge and / or at least one indentation, e.g., a pleating unit.

[0071] The tool has two jaws that are movable relative to each other and are designed for mechanically compacting, in particular pressing, the filter element and for forming the mounting section. For this purpose, the tool jaws can have at least one press block and / or at least one press ram, which are preferably movable in the direction of the main flow through the filtration section. The press block and / or the press ram further preferably have a pressing surface that corresponds to the surface area of ​​the complete mounting section of the finished filter element. This allows the mounting section to be formed efficiently in a single pressing operation.

[0072] The tool jaws feature a filter medium fixation for positioning and holding the filter forming within the tool.

[0073] The filter medium fixation is designed to be at least partially complementary to the at least one bulge and / or the at least one indentation of the filter element. In other words, the filter medium fixation can have recesses and / or projections, particularly ridges in the case of folds, that are complementary to the at least one bulge and / or the at least one indentation and engage in the bulge and / or indentation during the mechanical compaction, especially the pressing, of the fixing section. This allows the filter form to be positioned and fixed before and during the mechanical compaction, especially the pressing, so that more precise mechanical compaction, especially pressing, of the fixing section can take place.Furthermore, the filter medium fixation serves to ensure dimensionally accurate production of the filter element, as this allows the intended deformation to be limited to the fastening section and essentially prevents deformation in the area of ​​bulges or indentations.

[0074] The filter medium fixation can have a gap, particularly in the direction of the bulge height or indentation depth, between the filter medium fixation of one tool jaw and the filter medium fixation of the other tool jaw, which is not completely filled by the filter blank. In other words, the filter blank is loosely arranged within the filter medium fixation. The gap can be adapted to different dimensions of the filter blank. This prevents deformation of the bulges and / or indentations of the filter blank during mechanical compaction, especially pressing, by the tool jaws.

[0075] In a preferred embodiment, the gap dimension can be reduced to a smaller dimension than the filter blank in certain areas. In other words, the filter blank is clamped by the filter medium fixation in certain areas. For example, a projection of the filter medium fixation on one tool jaw can engage in the bulge and / or indentation, particularly a comb in the base of a fold, and press it against the filter medium fixation of the other tool jaw. In this case, the filter blank is clamped within the filter medium fixation. This allows the filter blank to be fixed particularly securely.

[0076] Preferably, the gap dimension can be configured to form the bulge height or indentation depth, bulge width or indentation width, and / or bulge length or indentation length of the at least one bulge and / or indentation. In this case, the filter medium fixation is designed as a press mold for the filtration section of the filter element. The at least one bulge and / or the at least one indentation of the filter blank can thus be adjusted in a particularly simple manner, and inaccuracies in the forming process for creating the at least one bulge and / or the at least one indentation can be compensated for.

[0077] The filter medium fixation preferably has a fixing surface with recesses and / or projections that correspond to the area of ​​the filtration section projected in the main flow direction. This allows the entire filtration section to be fixed by means of the filter medium fixation and protected from deformation.

[0078] A preferred embodiment of the tool provides that the press block and / or the press ram of at least one tool jaw is movable along the stroke axis of the tool relative to the filter medium fixation of the same tool jaw, in particular in a way that extends and / or shortens the stroke. This allows mechanical compaction, in particular pressing, or fixing to be carried out upstream and / or downstream of the manufacturing process, depending on the manufacturing requirements.

[0079] Preferably, at least one, and in particular each, tool jaw has a cutting die and / or a cutting punch designed to cut through the filter element. The at least one cutting die and / or the at least one cutting punch is preferably designed along the stroke axis of the tool relative to the press punch and / or the filter medium fixation. This allows the filter element to be cut immediately after the mechanical compaction, in particular pressing, of the mounting section.

[0080] The at least one cutting die and / or the at least one cutting punch are specifically designed to cut the filter element along an outer edge of the mounting section. This allows, by means of a stroke movement, the fixing and retention of the at least one protrusion and / or the at least one indentation, mechanical compaction, in particular compression, of the mounting section, and trimming of the filter element. Brief description of the drawings

[0081] Further features and advantages of the invention will become apparent from the following detailed description of exemplary embodiments of the invention, from the claims, and from the figures in the drawing, which illustrate details of the invention. The aforementioned and further described features can be implemented individually or in any suitable combination in variants of the invention. The features shown in the drawing are presented in such a way as to clearly demonstrate the special features of the invention.

[0082] The drawing shows: Fig. 1 a brake dust particle filter according to the invention comprising a filter cartridge and two filter elements in a state arranged on a disc brake; Fig. 2. the brake dust particle filter Fig. 1 in a sectioned view along the section edge BB in Fig. 1; Fig. 3. Remove the brake dust particle filter cartridge from the Fig. 1 and Fig. 2 in a state detached from the disc brake; Fig. 4 a perspective view of the filter element from Fig. 3; Fig. 5 a perspective view of another embodiment of a filter cartridge, comprising a filter element with an angled mounting section; Fig. 6. Remove the filter cartridge. Fig. 5 in a sectional view; Fig. 7 the filter element from the Fig. 5 and Fig. 6 in a perspective view detached from the filter cartridge; Fig. 8 another embodiment of a filter cartridge with a filter element having a recess; Fig. 9 the filter element having the recess made of Fig. 8 in a top view; Fig. 10 the filter element having the recess from the Fig. 8 and Fig. 9 in a perspective view; Fig. 11 a schematic arrangement of a single-layer arrangement for the production of a filter form designed as a high-temperature filter medium, comprising a heat-resistant filter layer arranged between two support layers; Fig. 12 a schematic representation of an exemplary forming process of the single-layer arrangement Fig. 11 to a filter form designed as a high-temperature filter medium; Fig. 13 a schematic representation of a filter form designed as a high-temperature filter medium; Fig. 14 a schematic representation of a filter element with a formed fastening section; Fig. 15 a cutaway view of an embodiment of a tool according to the invention for producing a filter element from a filter blank with two tool jaws and a filter element fixation in an open state; Fig. 16 the tool from Fig. 15 in a closed state. Embodiments of the invention

[0083] Fig. Figure 1 shows a disc brake 10 with a brake disc 12, a brake caliper 14, and a brake dust particle filter 16. According to the illustrated embodiment, the brake dust particle filter 16 is positioned downstream of the brake caliper 14 in a direction of rotation 18 of the brake disc 12. Such an arrangement is particularly effective if the direction of rotation 18 of the disc brake 10 is a primary direction of rotation or a predominantly used direction of rotation. For example, the direction of rotation 18 of a wheel of a motor vehicle mounted on the brake disc 12 in forward motion. Brake dust generated during the braking process (not shown) is carried along mainly in the direction of rotation 18 over a certain angular range and subsequently separated. In a disc brake 10 that does not have a primary direction of rotation, it can be provided that a brake dust particle filter 16 is positioned upstream of the brake caliper 14 (not shown) and a further brake dust particle filter 16 is positioned downstream.

[0084] The brake dust particle filter 16 extends in the direction of rotation 18 over an angular range of 100° ± 45°, in particular ± 30°, preferably ± 15°. This allows for effective separation of brake dust via the brake dust particle filter 16 while simultaneously ensuring good air cooling of the brake disc 12. In other embodiments, the angular extension can also be greater and, for example, range between 150° and 280°.

[0085] The brake dust particle filter 16 surrounds the brake disc 12 at its radially outer edge. This prevents a large proportion of brake dust-laden air from flowing unfiltered around the brake dust particle filter 16 (see also Fig. 2).

[0086] Fig. 2 shows the disc brake 10 out Fig. 1 in a view of the cutting edge BB from Fig. 1. The brake dust particle filter 16 comprises a filter holder 20, a filter housing 22, and a filter cartridge 24. The filter cartridge 24 comprises a cartridge body 26 and two filter elements 28.

[0087] The cartridge body 26 has a substantially L-shaped cross-section and is designed for arrangement on, or attachment to, the filter holder 20. Preferably, the cartridge body 26 is welded, glued, and / or screwed to the filter holder 20. In other words, the cartridge body 26, together with the filter holder 20, forms a U-shaped or C-shaped cross-section, respectively.

[0088] Alternatively or additionally, the cartridge body 26 can be designed to have a substantially U-shaped or C-shaped cross-section. This allows filter elements 28 to be arranged on all sides of the cartridge body 26 facing the brake disc 12.

[0089] The filter holder 20 serves to mount the brake dust particle filter 16 on the disc brake 10. Preferably, the brake dust particle filter 16 is detachably mounted on the disc brake 10 for better maintenance and repair.

[0090] In this embodiment, a filter element 28 is designed as a radial filter element 30. The radial filter element 30 is arranged radially to the brake disc 12, directly adjacent to the filter cartridge 24, or indirectly adjacent to the brake dust particle filter 16. The radial filter element 30 has a main flow direction 32 that is radial with respect to the brake disc 12.

[0091] The other filter element 28 is designed as an axial filter element 34 according to the illustrated embodiment. The axial filter element 34 is arranged in the axial direction of the brake disc 12 directly adjacent to the filter cartridge 24, or indirectly adjacent to the brake dust particle filter 16. The axial filter element 34 has a main flow direction 36 that is axial with respect to the brake disc 12.

[0092] A main flow direction 32, 36 is understood to be a global flow direction related to the filter element 28, whereby each filter element 28 can have several local, different flow directions.

[0093] The filter elements 28 are arranged in an L-shape according to the illustrated embodiment. The filter elements 28 are fluid-tightly attached to the cartridge body 26, for example by welding, gluing, clamping and / or soldering. This prevents fluid from flowing around the filter elements 28 and improves the separation efficiency of the brake dust particle filter 16.

[0094] In the event of a braking process, or the active braking of the brake disc 12 by the brake caliper 14 (see Fig. 1) Brake dust (not shown) is generated by friction between the brake caliper 14 and the brake disc 12 in the mounted brake pads. This dust is carried along in an airflow (not shown) forced by the rotation of the brake disc 12. The airflow is guided by the rotation of the brake disc 12 along an exemplary flow path 38 through the filter element 28 – here the axial filter element 34 – where the brake dust is separated. The cleaned airflow is then directed into the environment through the filter housing 22 of the brake dust particle filter 16.

[0095] Fig. Figure 3 shows the filter cartridge 24 in one of the brake dust particle filters 16 (see Fig. 1 and Fig. 2) detached rear view of the axial filter element 34.

[0096] The cartridge body 26 is essentially designed in the form of a circular segment. At one end, the cartridge body 26 can have a brake caliper end section 40 adapted to the brake caliper 14. This allows the filter cartridge 24, or the brake dust particle filter 16 (see Fig. 1 and Fig. 2) are arranged on the brake caliper 14 with as few gaps as possible, thereby reducing leakage flows between the brake caliper 14 and the brake dust particle filter 16. At the other end, the cartridge body 26 can have a brake disc end section 42. The brake disc end section 42 preferably points axially towards the brake disc 12 (see Fig. 1 and Fig. 2) Protruding end sections (not visible) that extend as close as possible to the brake disc 12 without contacting it. This allows for the lowest possible leakage flow through the brake disc end section 42, resulting in a higher proportion of airflow passing through the filter elements 28.

[0097] The cartridge body 26 has a filter element recess 44 for arranging the filter element 28 – here the axial filter element 34. In other words, the filter element 28 covers the filter element recess 44 of the cartridge body 26. According to the embodiment, the filter element 28 has a filtration section 46 that substantially, and in particular completely, covers the filter element recess 44 of the cartridge body 26. The filtration section 46 is, according to Fig. 3 is indicated by a dashed line. Filtration section 46 is permeable to air, but is designed to separate solids, or brake dust particles, from the air.

[0098] According to the embodiment shown, the filtration section 46 is formed orthogonally to the main flow direction 36 of the filter element 28. The main flow direction 36 is directed out of the plane of the image in the figure.

[0099] The filter element 28 is fluid-tightly attached to the cartridge body 26. According to the embodiment, the filter element 28 has a fastening section 48 for this purpose, which is attached to an edge 50 of the filter element recess 44.

[0100] The mounting section 48 and the filtration section 46 are preferably formed on the filter element 28. In other words, the filtration section 46 and the mounting section 48 have the same materials or the same material composite.

[0101] Fig. Figure 4 shows the filter element 28 designed as an axial filter element 34. Fig. 3 in a single representation. The filter element 28 has a circular segment in its basic form (see also Fig. 3) According to the illustrated embodiment of the filter element 28, the mounting section 48 encloses the filtration section 46. The mounting section is preferably designed with reduced air permeability or even airtightness by thermal, mechanical, and / or chemical treatment. Particularly preferably, the mounting section is made airtight by mechanical compaction. In other words, air cannot enter the filter element 28 – in a manner attached to the cartridge body 26 (see Figure 1). Fig. 3) arranged state of the filter element 28 - pass only through the filtration section 46.

[0102] The fastening section 48 forms a plane according to the design. This allows for a particularly simple and at the same time reliably fluid-tight arrangement on the cartridge body 26.

[0103] The filtration section 46 has several – here exactly 25 – bulges 52 – here in the form of folds 54 (for clarity, only three bulges 52 or folds 54 are labelled). The bulges 52 have a bulge height 56 ​​in the main flow direction 36, a bulge length 58, and a bulge width 60. The bulge length 58 and the bulge width 60, as designed, span a plane orthogonal to the main flow direction 36.

[0104] The protrusions 52 are arranged adjacent to each other along the filter element 28, which extends as a circular segment. The protrusions 42 can align at a common fold center (not shown). The protrusions 52 can be arranged fanned out in the direction of the protrusion lengths 58. Accordingly, in the illustrated embodiment, the protrusion width 60 can increase with increasing radial distance from the fold center. Preferably, in a state of the filter element 28 arranged on a disc brake 10, the fold center lies at a center of rotation (not shown) of the brake disc 12 (see Fig. 1 and Fig. 2) In an embodiment not shown, the protrusions 42 can also run parallel to each other in the form of filter folds.

[0105] According to the illustrated embodiment, the protrusions 52 are unidirectional with respect to the mounting section 48. In other words, the protrusions 52 project beyond the mounting section 48 in only one direction with a protrusion height 56. In this embodiment, the protrusions 52 project beyond the mounting section 48 opposite to the main axial flow direction 36. Therefore, when the filter element 28 is mounted on a disc brake 10, the protrusions 52 project towards the brake disc 12. This allows the maximum flowable cross-section in the filtration section 46 to be increased on the upstream side of the filter element 28, thus improving flow efficiency.

[0106] The previously described formation of the bulges 52 can be applied analogously to the radial filter element 30 (see Fig. 2) be transferred.

[0107] Fig. Figure 5 shows another embodiment of a filter cartridge 24 in a perspective view. The filter cartridge 24 has exactly one filter element 28, which is designed as an axial filter element 34.

[0108] The filter element 28 is in a disc brake 10 (see Fig. 1 and Fig. 2) arranged state of the filter element 28 on a side facing the brake disc 12, or on an inside of the filter cartridge 24.

[0109] The filter element 28 has several protrusions 52 which are fanned out on the filter element 28 (for clarity, only three protrusions 52 are provided with a reference numeral).

[0110] Fig. Figure 6 shows a cutaway view of filter cartridge 24. Fig. 5. The filter element 28, designed as an axial filter element 34, has a main flow direction 36, which originates from an interior 62 of the cartridge body 26, or of the brake dust particle filter 16 (see Fig. 1 and Fig. 2) is directed towards the surroundings 64. The filtration section 46 has a plane 66 orthogonal to the main flow direction 36. The mounting section 48, as shown, has a flange area 68 that is inclined – here essentially perpendicular to the orthogonal plane 66. In other words, the mounting section 48, according to the embodiment shown, is essentially parallel to the main flow direction 36. This allows the axial filter element 34 – as shown – to be attached to a side surface of the cartridge body 26 adjacent to the side surface forming the filter element recess 44 by means of the flange area 68. This allows the filtration section 46 to significantly overlap the filter element recess 44 in the orthogonal plane 66, thereby increasing the effective flow cross-section through the filter element 28.The strength of the cartridge body 26 is not affected by this, provided the dimensions of the filter element recess 44 remain constant. In other words, the effective flow cross-section of the filtration section 46 of the filter element 28 is shifted in front of the filter recess 44 in the main flow direction 36, resulting in lower flow resistance.

[0111] Furthermore, a further development may provide for a larger dimension of the filter element recess 44 of the cartridge body 26 while keeping the dimensions of the cartridge body 26 constant. This is advantageous in cases where only a small bulge height 56 ​​is possible, but a reduction in flow resistance is still desired.

[0112] According to the embodiment shown, the filtration section 46 completely covers the filter element recess 44 of the filter element 28.

[0113] Fig. Figure 7 shows filter element 28 from the Fig. 5 and Fig. 6 in one of the filter cartridge 24 (see Fig. 5 and Fig. 6) detached representation. The flange area 68 of the fastening section 48, which is angled according to the design, is formed around the perimeter and parallel to the main flow direction 36.

[0114] Fig. Figure 8 shows another embodiment of a filter cartridge 24 with two filter elements 28. One of the filter elements 28 is designed as an axial filter element 34 and the other filter element 28 as a radial filter element 30.

[0115] Both the axial filter element 34 and the radial filter element 30 are designed - in one on the disc brake 10 (see Fig. 1 and Fig. 2) arranged state of the filter cartridge 24 - on one of the brake discs 12 (see Fig. 1) attached to the side of the cartridge body 26 facing the cartridge.

[0116] The mounting sections 48 (here concealed by the cartridge body 26) of the filter elements 28 can be arranged in an overlapping manner. In other words, the flange area 68 (here concealed by the cartridge body 26) can be arranged in layers and attached together to the cartridge body 26, e.g. by soldering, welding and / or gluing.

[0117] The cartridge body 26 and the radial filter element 30 have a recess 70. In other words, the radial filter element 30 is designed to fit the cartridge body 26. This allows the cartridge body 26 to be adapted to the prevailing installation conditions on a disc brake 10 in a particularly space-saving manner. For the sake of completeness, it should be noted that the cartridge body 26 and the radial filter element 30 can also have a bulge. The described recess 70 and / or bulge can, of course, also be formed in an axial filter element 34.

[0118] Fig. Figure 9 shows the radial filter element 30 in a top view and Fig. Figure 10 shows the radial filter element 30 in a perspective view. The radial filter element 30 forms several – here exactly 25 – bulges 52 – here folds 54. The main flow direction 32 of the radial filter element 30 is opposite to the direction of formation of the folds 54 from one of the disc brakes 10 (see Fig. 1 and Fig. 2) in the arranged state of the filter element 28, the side facing the disc brake 10 is directed towards the side of the filter element 28 facing away from the disc brake 10. In other words, the main flow direction 32 is directed from a brake disc 12 (see Fig. 1 and Fig. 2) directed radially outwards. This allows the flow cross-section, which is throttled by the filter element 28, to be increased.

[0119] The radial filter element 30 has an axis of curvature 72. According to the illustrated embodiment, the axis of curvature 72 runs parallel to the direction of extension of the folds 54, which has a bulge length 58. The axis of curvature 72 is orthogonal to the main flow direction 32. In the illustrated embodiment, the filter element 28 is curved about the axis of curvature 72. The filter element 28 can have a constant curvature, or the mounting section 48 can have a constant distance from the axis of curvature 72 at every point. In other words, the filter element 28 can be circularly curved. Alternatively, the filter element 28 can be non-uniformly curved, or the mounting section 48 can have varying distances from the axis of curvature 72. In this case, the filter element 28 can, for example, be elliptically curved.

[0120] The curved mounting section 48 forms a curved flange area 68. This allows the filter element 28 to be attached to the mounting cartridge 24 particularly easily and fluid-tight (see Fig. 8) be attached.

[0121] The bulge height 56 ​​of the bulges 52 is, according to the embodiment, constant both within a bulge 52 and across all bulges 52. The bulge width 60 is, according to the illustrated embodiment, constant both within a bulge 52 and across all bulges 52. The bulge length 58 varies according to the illustrated embodiment as a sequence of the recess 70 of the filter element 28. The bulges 52, or the folds 54 of the radial filter element 32, are formed parallel to each other on the filter element 28.

[0122] The features described herein by way of example for a radial filter element 32 with regard to a curvature of the filter element and bulges of variable length are expressly transferable to other filter elements according to the invention, independent of further features.

[0123] The fastening section 48 has a constant width and follows the outer contour of the filter element 28. The filter element 28 is designed as consisting of a single layer arrangement 74 (see Fig. 11) manufactured. In other words, the fastening section 48 and the filtration section 46 are formed on the same single-layer assembly 74. The filtration section 46 and the fastening section 48 are thus formed in one piece.

[0124] Fig. Figure 11 shows a schematic representation of a single-layer arrangement 74 for a high-temperature filter medium 76 to be manufactured (see Fig. 13) The single-layer arrangement 74 comprises, as a design, a heat-resistant filter layer 78 and two support layers 80. The heat-resistant filter layer 78 is arranged between the support layers 80. In other words, the support layers 80 are arranged on both sides of the heat-resistant filter layer 78.

[0125] The heat-resistant filter layer 78 is designed for depth filtration. Here, separated particles are stored in the filter layer 78, effectively preventing the formation of a so-called filter cake.

[0126] The heat-resistant filter layer 78 can, for example, contain or consist of metal fibers, in particular stainless steel fibers, glass fibers, mineral fibers, in particular with a basalt or alkaline earth silicate, and / or be constructed as a nonwoven fabric, in particular as a glass fiber nonwoven and / or as a metal fiber nonwoven.

[0127] The support layers 80 are designed in a grid-like structure. This minimizes the flow resistance of the support layers 80. Preferably, the support layers 80 are made of metal. Metal exhibits particularly high strength and can be used at high temperatures. This ensures dimensional stability in all application areas of the high-temperature filter medium 76.

[0128] The heat-resistant filter layer 78 and / or the support layers 80 can, for example, be unrolled from one and / or more layer carriers (not shown), e.g., rollers. The heat-resistant filter layer 78 and / or the support layers 80 are preferably guided by means of one or more guides, in particular roller guides.

[0129] In the schematic representation, the heat-resistant filter layer 78 and the two support layers 80 are loosely arranged next to each other, or loosely layered on top of each other.

[0130] Fig. Figure 12 shows the single-layer arrangement 74 from Fig. 11 during an exemplary forming process for the production of the high-temperature filter medium 76 (see Fig. 13) The single-layer assembly 74 is guided by a folding device 82 according to the illustrated embodiment. By means of two folding knives 84 movable transversely to the filter layer 78 and the support layers 80, bulges 52 – or in this case folds 54 – are formed on the single-layer assembly 74. Indentations (not shown) can be formed in the single-layer assembly in an analogous manner.

[0131] The forming process causes the filter layer 78 – here – to be deformed together with the two support layers 80. While the solitary filter layer 78 would largely return to its original shape after deformation without additional fastening, the filter layer 78 remains in its deformed state when positioned between the support layers 80. This enables the dimensionally stable formation of the bulges 52 and the folds 54, respectively, and simultaneously provides a dimensionally stable high-temperature filter medium 76.

[0132] Fig. Figure 13 shows a schematic representation of the high-temperature filter medium 76 after completion of the forming process. The filter layer 78 and the two support layers 80 are arranged in a pleated or folded configuration. Preferably, the degree of the bulges 52, or in this case the shape of the folds 54, is selected such that the support layers 80 are permanently attached to the filter layer 78 by wedging the individual layers together during the forming process.

[0133] Fig. Figure 14 shows in a schematic representation the filter element 28 after completion of the mechanical compaction, for example the mechanical compression, in particular the pressing, to form the fastening section 48 on the filter element 28.

[0134] During mechanical compaction, preferably two press jaws (not shown) are arranged on both sides of the filter element 28 and moved towards each other in a pressing motion. This mechanically compacts the bulges 52 – here the folds 54 – in certain areas, in particular, compressing them mechanically. Specifically, the support layers 80 can be interlocked by mechanical pressing, resulting in a particularly durable connection. The filter layer 78 arranged between the support layers 80 is also compacted, in particular, compressed, during the pressing process. This leads to a higher density of the fastening section 48.

[0135] As in Fig. As shown in Figure 14, the fastening section 48 encloses the filtration section 46. This preferably completely prevents the escape of a cross-flow within the filter element 28 via the fastening section 48.

[0136] As a result of mechanical compaction, in particular mechanical compression, especially pressing, the fastening section 48 forms flange surfaces on both sides of the flange area 68 for arranging the filter element 28 on the filter cartridge body 26. This makes the filter element 28 particularly flexible for arrangement on the filter cartridge 24.

[0137] Alternatively, it can be provided that a flat flange area 68 is produced by a further downstream manufacturing step.

[0138] As designed, the protrusions 52 project bidirectionally beyond the mounting section 48. By appropriately positioning the press jaws in relation to the filter medium 76 to be deformed (see Fig. 13) In addition, a unidirectional formation of the bulges 52 can be achieved.

[0139] The Fig. 15 and Fig. Figure 16 shows an embodiment of a tool 86 for mechanically compacting - here for pressing - a, in particular as a high-temperature filter medium 76 (see Fig. 13) trained, filter forming.

[0140] The tool 86 has two tool jaws 90a, 90b that are movable relative to each other along a stroke axis 88. The tool jaws 90a, 90b are for pressing the filter form and for forming the fastening section 48 (see e.g. Fig. 14) trained.

[0141] For this purpose, the tool jaws 90a, 90b feature a filter medium fixation 92 – here in the form of two interlocking combs 94a, 94b – for positioning and holding the filter form within the tool 86. The filter medium fixation 92 has complementary projections 52 (see, for example, Figure 1). Fig. 4) the protrusions and / or recesses formed in the filter element 28. During the pressing process, the filter medium fixation 92 engages in the protrusions 52 of the filter element 28 and thereby fixes the filter element 28 within the tool 86. The filter form is not squeezed or compressed by the filter element fixation 92 according to the design.

[0142] According to the embodiment shown, the filter medium fixation 92 is circular (directed in the plane of the drawing) and thus serves to fix a ring-shaped filter element 28 - in particular an axial filter element 34 (see e.g. Fig. 3 and Fig. 4) trained.

[0143] The tool 86, or tool jaw 90a, has a press stock 96, and the tool jaw 90b has a press ram 98. The press stock 96 and the press ram 98 can be movable along the stroke axis 88 of the tool 86 relative to the filter medium fixation 92 of the respective tool jaw 90a, 90b. In other words, the press stock 96 and the press ram 98 can be configured to extend and / or shorten the stroke. According to the embodiment shown, the press ram 98 is movable, and the press stock 96 is fixed relative to the respective filter element fixation 92. By positioning the press stock 96 and the press ram 98 relative to the filter element fixation 92, the position of the fastening section 48 relative to the protrusions 52 can be determined.

[0144] According to the illustrated embodiment, the tool 86, or rather the tool jaw 90a, has a cutting die 100 and the tool jaw 90b a cutting punch 102. The cutting die 100 and the cutting punch 102 can serve to trim the filter element 28 after the formation of the mounting section 48. Preferably, the filter element 28 is trimmed directly at the outer end of the mounting section 48 by the cutting die 100 and the cutting punch 102. For this purpose, the cutting die 100 and the cutting punch 102 can be designed to extend or shorten the stroke with respect to the filter element fixation 92 and / or the press punches 96a, 96b.

[0145] Fig. Figure 15 shows the tool 86 in an open state. The tool 86 is designed to receive a filter preform, in particular a high-temperature filter medium 76 (see Figure 15). Fig. 13) prepared. After inserting the filter form, the following steps can then be carried out according to... Fig.16. The tool 86 transitions into a closed state of the tool jaws 90a, 90b. Preferably, the filter medium fixation 92 is first moved along the stroke axis 88 to fix the filter blank. Subsequently, the press ram 98 is moved along the stroke axis 88 to the press block 96 to form the fastening section 48 by selectively mechanically compacting the filter blank. Subsequently and / or simultaneously, the cutting ram 102 can be moved along the stroke axis 88 to the cutting die 100 to trim the filter blank at the outer edge of the mechanically compacted area.

[0146] The tool 86 can then be opened by moving the tool jaws 90a, 90b along the stroke axis 88 and the finished filter element 28 can be removed. Reference symbol list 10 disc brakes; 12 brake disc; 14 brake calipers; 16 brake dust particle filters; 18 Main direction of rotation; 20 filter holders; 22 filter housings; 24 filter cartridges; 26 cartridge bodies; 28 filter elements; 30 radial filter elements; 32 radial main flow direction of the radial filter element 30; 34 Axial filter element; 36 axial main flow direction of the axial filter element 34; 38 Flow path; 40 Brake caliper end section; 42 Brake disc end section; 44 Filter element recess of the cartridge body 26; 46 Filtration section of filter element 28; 48 Mounting section of the filter element 28; 50 Edge of the filter element recess 44; 52 bulges; 54 folds; 56 bulge height; 58 bulge length; 60 bulge width; 62 Interior of the cartridge body 26; 64 surroundings; 66 orthogonal plane; 68 Flange area of ​​the fastening section 48; 70 recess; 72 Axis of curvature; 74 Single layer arrangement; 76 High-temperature filter medium; 78 heat-resistant filter layers; 80 Support position; 82 Folding device; 84 folding knives; 86 tools; 88 Stroke axis of the tool 86; 90a, 90b Tool jaws; 92 Filter medium fixation; 94a, 94b Comb; 96 Pressstock; 98 press dies; 100 cutting dies; 102 cutting stamps.

Claims

[1] Filter element (28) for a brake dust particle filter (16) comprising a high-temperature filter medium (76) forming at least one filtration section (46) and at least one mounting section (48), wherein the high-temperature filter medium (76) comprises at least one heat-resistant filter layer (78); wherein the fastening section (68) surrounds at least one filtration section (46) in a frame-like manner; and wherein the filtration section (46) has at least one bulge (52) and / or one indentation, preferably at least one fold (54), to increase the surface area; characterized by , that the fastening section (48) forms a flange area (68) which is designed to connect the filter element (28) to a housing component of a brake dust particle filter (16) and is designed as a mechanically compacted section of the high temperature filter medium (76). [2] Filter element (28) according to claim 1, wherein the high temperature filter medium (76) has at least two support layers (80), and wherein the at least one heat-resistant filter layer (78) is arranged between the support layers (80). [3] Filter element (28) according to claim 2, wherein the fastening section (48) forms the flange area (68) by connecting the at least two support layers (80). [4] Filter element (28) according to claim 2 or 3, wherein the flange area (68) is formed by positive locking and / or material locking connection of the support layers (80). [5] Filter element (28) according to claim 2 or 3, wherein the fastening section (48) is formed by mechanically compacting the support layers (80). [6] Filter element (28) according to one of claims 1 to 5, wherein the flange area (68) has an insignificant indentation and / or protrusion (52) compared to the filtration section (46) and / or has a lower air permeability compared to the filtration section (46). [7] Filter element (28) according to one of the preceding claims, wherein the at least one protrusion (52) and / or the at least one indentation projects unidirectionally over the flange area (68). [8] Filter element (28) according to one of the preceding claims, wherein the at least one filtration section (46) has a plurality of protrusions (52) and / or indentations. [9] Filter element (28) according to one of the preceding claims, wherein at least the flange area (68) is formed predominantly in a plane (66) orthogonal to the main flow direction (32, 36) of the filtration section (46) or predominantly curved to an axis of curvature (72) orthogonal to the main flow direction (32, 36) of the filtration section (46). [10] Filter element (28) according to claim 9, wherein at least a partial section of the flange area (68) is inclined from the orthogonal plane (66) in the direction of the main flow direction (32, 36) of the filtration section (46). [11] Filter cartridge (24) for a brake dust particle filter (16), comprising the filter element (28) according to one of claims 1 to 10, and a cartridge body (26), wherein the cartridge body (26) is designed to at least partially accommodate a brake disc (12); and wherein the cartridge body (26) has at least one filter element recess (44) and the fastening section (48) of the filter element (28) is airtightly attached to an edge (50) of the filter element recess (44); and wherein the filtration section (46) of the filter element (28) closes the filter element recess (44) in an air-permeable manner. [12] Filter cartridge (24) according to claim 11, wherein the cartridge body (26) forms an annular segment in a plane parallel to the brake disc (12) to be received and / or wherein the cartridge body (26) is L-shaped or U-shaped in a cross-section encompassing the brake disc (12) received at a radially outer edge. [13] Filter cartridge (24) according to one of claims 11 or 12, wherein the filter element (28) is attached to the cartridge body (26) in a form-fitting and / or material-fitting manner. [14] Filter cartridge (24) according to one of claims 11 to 13, wherein the filter cartridge (24) has at least two filter elements (28). [15] Filter cartridge (24) according to claim 14, wherein the at least two filter elements (28) are arranged opposite each other and / or at an angle to each other on the cartridge body (26). [16] Brake dust particle filter (16) for a transport means having a brake disc (12), comprising a filter housing (22) and a filter element (28) according to one of claims 1 to 10, wherein the filter element (28) is arranged for filtering brake dust in the vicinity of the brake disc (12); and wherein the filter housing (22) is designed to receive the filter element (28). [17] Brake dust particle filter (16) according to claim 16, comprising a filter cartridge (24) according to any one of claims 11 to 15, which contains the filter element (28). [18] Method for manufacturing the filter element (28) according to any one of claims 1 to 10, comprising the method steps: a. Prefabrication of a filter form designed as a high-temperature filter medium (76) by forming bulges (52) and / or indentations into a single-layer arrangement (74); b. Fixing the filter form; c. Selective mechanical compaction of the filter form to form the mounting section (48) which surrounds the filtration section (46) in a frame-like manner. [19] Method according to claim 18, wherein the mechanical compaction is carried out by pressing the filter preform. [20] Method according to claim 18 or 19, wherein the filter forming is trimmed along an outer edge of the compacted attachment section (48). [21] Tool (86) for producing the filter element (28) according to one of claims 1 to 10 from a filter preform, wherein the filter preform is designed as a formed high-temperature filter medium (76); comprising two tool jaws (90a, 90b) movable relative to each other, which are designed for mechanically compacting the filter preform and for forming the fastening section (48); wherein the tool jaws (90a, 90b) have a filter medium fixation (92) for positioning and holding the filter preform within the tool (86); wherein the filter medium fixation (92) is designed at least partially complementary to the at least one protrusion (52) and / or the at least one indentation of the filter element (28). [22] Tool (86) according to claim 21, wherein at least one tool jaw (90a, 90b) is designed for mechanically compacting the filter forming and has a press stock (96) and / or a press plunger (98) which are designed to be movable along a stroke axis (88) of the tool (86) relative to the filter medium fixation (92) of the same tool jaw (90a, 90b).

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