FILTER STAGE

Description

AREA OF INVENTION

[0001] The present invention relates to a filter stage for use in a filter module. Furthermore, the invention relates to a method for transporting several filter stages. TECHNICAL BACKGROUND

[0002] Filter modules are used for various applications. For example, they can be used in spray booths to capture paint mist. The filter modules serve to clean the air exhausted from the spray booth. Paint particles that do not adhere to the object being sprayed can be separated by the filter modules. Such filter modules can therefore also be referred to as separators or separator modules.

[0003] Filter modules typically have an inlet side designed to allow the airflow to enter and be cleaned. An outlet side, preferably located on the opposite side, serves to release the cleaned airflow.

[0004] For example, several identical filter modules can be arranged side by side or on top of each other to create a continuous surface that can be positioned, for instance, below or to the side of the object to be sprayed. All inlet sides are located on one side of this continuous surface. Preferably, a negative pressure is created behind the filter modules, generating an airflow through them from the inlet side towards the outlet side. This airflow draws the air to be cleaned through the filter modules, where the particles adhere to or are deposited within the filter modules.

[0005] The publication EP 1 492 609 B1 describes a filter module in the form of a hollow body made of paper. Within the filter module, at least two walls are arranged transversely to the direction of the incoming airflow. Each wall has openings, with the openings decreasing in size from the inlet side towards the outlet side and / or being offset from one another. The walls create chambers within the base body. The airflow to be cleaned is guided in a meandering pattern through the differently arranged openings in the walls, which are positioned one behind the other. At least one chamber can be opened by means of a handle, allowing a filling material or a further filter stage to be inserted into the chamber.

[0006] Furthermore, a filter module is known from EP 3 167 948 A1, which also consists of a hollow body in which different cleaning structures can be inserted. The cleaning structures arranged one behind the other can be removed individually, so that cleaning structures with varying levels of soiling can be replaced at different intervals. Likewise, other cleaning structures, in particular as second filter stages, can be used to achieve fine final filtration.

[0007] A disadvantage of such filter modules is that, due to the redirection of the airflow in different directions, particle adhesion within the module varies considerably, meaning it is very unevenly distributed. This results from the meandering airflow path, which, upon entering the module, redirects the airflow by approximately 90° in every possible direction. This abrupt redirection of the airflow, for example, to the left, right, up, or down within the filter module, causes a sudden and significant deceleration. Consequently, the first chamber, located between the first and second walls, which the airflow to be cleaned first reaches, captures the majority of the particles. Chambers located further back are only reached by a few particles.This reduces the efficiency and lifespan of each filter module, as they need to be replaced even when areas further back within the filter module only show very low particle accumulation.

[0008] In EP 3 167 948 A1, this is solved by allowing individual cleaning structures, arranged one behind the other within the base body, to be removed individually. This allows the cleaning structure closest to the inlet side to be replaced.

[0009] Reference can also be made to US 2003 / 159415 A1, which shows a zigzag-shaped filter element for an air conditioner or a heating appliance. The filter element is held in a receiving element, the receiving element having a sawtooth-shaped strip designed for the placement of the zigzag-shaped filter element.

[0010] Another filter is shown in EP 2 532 409 A1, which is designed as a paper mesh filter. Several zigzag-shaped layers are arranged on top of each other.

[0011] EP 3 354 353 A1 shows a zigzag-shaped filter element consisting of individual sections that are not connected to each other. To ensure stability in the filter element, the individual sections are connected to each other via conically shaped filling elements.

[0012] During operation in a jump simulator, where several identical filter modules are typically arranged side-by-side or stacked to form a continuous surface, replacing individual cleaning elements from each module is extremely time-consuming. Specifically, replacing a cleaning element from each module requires opening each individual hollow section. This is impossible with modules arranged side-by-side or stacked on top of each other. Therefore, the entire continuous surface of filter modules would first have to be disassembled to access each individual module. This results in an enormous amount of time. In practice, replacing individual cleaning elements is thus virtually impossible.Consequently, experience shows that the entire filter module is replaced when only the first cleaning element is so dirty that the airflow can no longer pass through it.

[0013] A further disadvantage is the cumbersome transport of unassembled filter modules or cleaning structures, as the folded structure means that an unassembled filter module, which is essentially a two-dimensional element, takes up a lot of space and is unwieldy. Components that are folded inwards during assembly protrude at the edges and can also be damaged. SUMMARY OF THE INVENTION

[0014] Against this background, the present invention aims to provide an improved filter stage.

[0015] According to the invention, this problem is solved by a filter stage with the features of claim 1 and by a method for transporting several filter stages with the features of claim 17.

[0016] Accordingly, the following is planned: A filter stage for use in a filter module designed for separating paint particles from an airflow, comprising a receiving element having an inlet side for the inlet of an airflow to be cleaned and an outlet side for the outlet of the cleaned airflow, wherein the inlet side and the outlet side are arranged opposite each other on the receiving element, a filter insert which is received in the receiving element, wherein the receiving element is made of cardboard, wherein the filter insert has at least two subsections, each designed as a flat surface and extending from the inlet side to the outlet side, wherein at least two subsections are arranged inclined to each other such that they contact and are connected to each other at a side section which is arranged between an upper edge and a lower edge of the subsections.wherein the filter insert is a single piece and the side section is formed as a fold, creating a zigzag structure, wherein the inlet side and the outlet side have at least one rib extending transversely to the orientation of the sub-elements, wherein at least one tab is arranged on the rib which engages between two sub-sections and positions them, wherein the at least one tab of the rib on the inlet side is offset with respect to a length of the rib from the at least one tab of the rib on the outlet side. A method for transporting multiple filter stages, wherein the receiving element has identical dimensions in two spatial directions in an unfolded three-dimensional state and in an unfolded two-dimensional state, such that assembled and unassembled filter stages can be transported in a receiving element of a filter module.

[0017] The underlying insight of the present invention is that a durable and effective filter module can be formed by a uniform distribution of the particles between the inlet side and the outlet side.

[0018] The idea underlying the present invention is not to slow down or redirect the airflow, but instead to allow a uniform flow through the filter stage from the inlet side to the outlet side in order to enable a balanced adhesion of the particles to the filter insert within the receiving element.

[0019] Advantageously, the filter element does not need to be replaced over the entire lifespan of the filter stage, and all elements of the filter stage can be used until they become unusable, i.e., until they are clogged by separated particles.

[0020] Preferably, the filter stage can be integrated as a separate filter stage into known filter modules, as described in the prior art. This allows for coordinated filtration within the filter module, thereby optimizing the separation results.

[0021] The geometry of the filter stage can be adapted and integrated into other filter modules using a modular system. This results in a more efficient overall separation performance of the filter module.

[0022] Furthermore, with the proposed filter stage, the filter insert does not need to be glued or clamped to the receiving element, as it is held in place by the shape of the receiving element.

[0023] A filter stage is an element that possesses specific filtering properties. The filter stage can form a complete filter module or be a sub-element, i.e., a purification stage within a filter module. In this case, the filter stage can be used as a kind of post-purification stage and inserted into known filter modules as a quasi "final" purification stage.

[0024] A filter element is defined as an element to which particles are separated or adhere. The filter element is preferably designed as a flat surface without significant cutouts or holes, so that the airflow can be guided along the flat surface and is not deflected by it. Furthermore, the filter element is preferably at least partially made of an air-permeable material, so that the airflow can at least partially pass through the material of the filter element.

[0025] Preferably, each subsection is vertically oriented within the receiving element. In particular, each subsection extends over the entire height of the receiving element, forming separate vertical chambers bounded by the subsections and running from the inlet side to the outlet side.

[0026] The inlet side and the outlet side each have at least one opening, allowing the airflow to pass through the filter stage.

[0027] The filter element is made of cardboard. Advantageously, the entire filter element is made of cardboard. Such a filter module can be easily disposed of, especially by incineration, even with adhering particles. Furthermore, the manufacturing costs are minimal.

[0028] According to the invention, at least two sections are arranged at an inclination towards each other such that they contact and / or are connected to each other at a side section located between the upper and lower edges. This allows for a higher degree of purification, for example in the sense of fine or final cleaning, since the airflow must pass through the filter element when flowing from the inlet side to the outlet side. In such an embodiment, the filter element is therefore made of an air-permeable material, for example, a polyester material.

[0029] According to the invention, the filter insert is a single piece and the side section is formed as a fold, resulting in a zigzag structure. Advantageously, this method allows for the creation of a filter insert with a stable three-dimensional structure.

[0030] According to the invention, the filter element is designed as a one-piece zigzag structure and is vertically oriented within the receiving element, creating individual pockets that are oriented perpendicular to the airflow within the receiving element. These pockets are formed by sub-elements of the filter element that are arranged at an angle to one another. This allows for particularly effective fine filtration with the filter stage.

[0031] According to the invention, the inlet side and / or the outlet side have at least one web extending transversely to the orientation of the component elements. The web preferably extends transversely through the opening on the inlet side and / or the outlet side. In particular, the web is horizontal, so that the component elements can be stabilized by the web. The web preferably has a small width, so that the airflow is hardly affected by the web. Advantageously, the opening on the inlet side is hardly reduced in size by the web. Advantageously, the web is formed integrally with the receiving element.

[0032] According to the invention, at least one tab is arranged on the web, which engages between two sub-sections and positions them. The tab is preferably designed as a type of flap oriented in the direction of the airflow. This ensures that the airflow is not affected by the tab. The tab can be designed as a planar element that contacts at least one sub-section, in particular two sub-sections, and thus holds or positions them in their orientation. The tab can also serve to direct the airflow, as it can create a separation of the airflow below and above the web. In particular, the tab can also serve to separate particles from the airflow.

[0033] According to the invention, at least one tab of the web on the entry side is offset with respect to a length of the web relative to at least one tab of the web on the exit side. This allows partial elements from the entry side to the exit side to be held and positioned within the receiving element, inclined to a connecting plane between the entry side and the exit side.

[0034] Advantageous designs and further developments result from the further sub-claims as well as from the description with reference to the figures in the drawing.

[0035] According to an advantageous embodiment, the filter element can have at least three, and in particular three to fourteen, sections. Advantageously, the sections are arranged parallel to each other and oriented parallel to the incoming airflow. The sections are preferably not in direct contact and form a kind of shear surface over which the airflow passes. This prevents an abrupt deceleration of the flow velocity.

[0036] According to a further development, at least two, and in particular all, subsections can be aligned parallel to a connecting plane between the inlet and outlet sides. The connecting plane is understood to be a plane extending from the inlet to the outlet. Preferably, the connecting plane is arranged perpendicular to both the inlet and outlet sides. Consequently, the subsections are preferably aligned perpendicular to both the inlet and outlet sides. The subsections are preferably not in direct contact, allowing the airflow between each pair of subsections to pass through, in particular, unimpeded. In this way, both similar and separate airflows can be formed within the filter stage.

[0037] According to one embodiment, at least two, and in particular all, subsections can be inclined, especially at an angle between 5 and 50°, and aligned with a connecting plane between the inlet side and the outlet side. This allows for a higher degree of cleaning, for example in the sense of fine cleaning or final cleaning, since the subsections are inclined relative to the direction of airflow.

[0038] According to one embodiment, each bridge can have at least two tabs that are offset along the length of the bridge on the inlet and outlet sides such that recesses are formed along the bridges in which the sections are held. A filter insert can be positioned within the receiving element particularly advantageously without an adhesive bond. Advantageously, such an embodiment is designed for a filter insert that has a zigzag structure. In other words, the filter insert is designed as a type of pleat. If the filter insert has a zigzag structure, the tabs preferably engage in the pockets to hold the filter insert securely and stably, especially if it is made of a polyester fleece. The filter stage can therefore be assembled particularly easily by inserting the filter insert into the receiving element from above.The receiving element can then be closed with a snap closure, similar to a cardboard box.

[0039] In an advantageous embodiment, the tabs can be integrally connected to the bridge and arranged to tilt relative to the bridge by means of a hinge. The hinge can be formed, in particular, by perforation or embossing. This allows the receiving element to be easily folded from a substantially two-dimensional element into a three-dimensional filter stage during assembly, without requiring specialized knowledge.

[0040] The tabs can be formed from the existing waste material, which would be cut out for the openings on the entry side and / or exit side, in particular by punching using a punching geometry.

[0041] In an advantageous embodiment, the tabs can have conical side edges, so that the filter element sections are held at an angle between the inlet and outlet sides. This embodiment is particularly suitable for a filter element with a zigzag structure.

[0042] According to an advantageous embodiment, the receiving element can have a fold on at least two side walls arranged between the inlet side and the outlet side, so that the receiving element can be folded into a substantially two-dimensional element. The fold is preferably arranged centrally in the respective side wall, so that the side walls can be folded in on themselves.

[0043] According to a further development, the filter element can contain a recyclable material and / or polyester material. The filter element can be made of a paper mat, a polyester nonwoven, a nonwoven fabric, a polyester, in particular with a density of 250 g / m² to 300 g / m², preferably 290 g / m², and / or a 3D filament. This allows the filter element to have a comparatively small cross-section compared to the remaining spaces between the individual components, resulting in improved filter properties. Preferably, the filter element is made of a foldable or formable polyester material with a zigzag structure. Such a filter module can be easily disposed of, in particular by incineration, even with adhering particles. Furthermore, the manufacturing costs are minimal.

[0044] According to an advantageous embodiment, the receiving element can have a square or rectangular base shape at the inlet and outlet sides, wherein the distance between the inlet and outlet sides is less than a side edge of the base shape, in particular, the distance is at most half the length of a side edge. This distance describes the depth of the filter stage. This depth can be, in particular, 80 to 500 mm, preferably 150 to 300 mm. The base can be rectangular or square, with a side length of 400 to 600 mm, in particular 500 mm. mm.

[0045] Preferably, the filter stage is designed as a type of cardboard. This allows for the creation of a three-dimensional structure that can be assembled quickly and easily. Gluing, clamping, or block gluing of the individual components is unnecessary, greatly simplifying the manufacturing process. Furthermore, space-saving storage before assembly is ensured.

[0046] The above embodiments and further developments can be combined with one another as appropriate. Further possible embodiments, further developments, and implementations of the invention also include combinations of features of the invention described previously or subsequently with regard to the exemplary embodiments, even if not explicitly mentioned. In particular, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention. CONTENT OF THE DRAWING

[0047] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawing. These figures show: Fig. 1 shows an embodiment of a filter module; Fig. 2 shows a top view of Fig. 1 Fig. 3 shows an embodiment of a filter stage; Fig. 4 shows another embodiment of a filter stage; Fig. 5 shows a front view of the embodiment according to Fig. 4 Fig. 6 shows another front view of the embodiment according to Fig. 4 with filter element inserted; Fig. 7 a sectional view from Fig. 6 ; Fig. 8 a sectional view from Fig. 6 without filter insert; Fig. 9 another embodiment of a filter stage; Fig. 10 a sectional view from Fig. 9 .

[0048] The accompanying figures are intended to provide a further understanding of the embodiments of the invention. They illustrate embodiments and, in conjunction with the description, serve to explain the principles and concepts of the invention. Other embodiments and many of the advantages mentioned will become apparent with reference to the drawings. The elements of the drawings are not necessarily shown to scale.

[0049] In the figures of the drawing, identical, functionally equivalent and similarly acting elements, features and components - unless otherwise stated - are each provided with the same reference symbols. DESCRIPTION OF EXAMPLES OF EXECUTION

[0050] Fig. 1 Figure 1 shows an embodiment of a filter module 1 designed for separating paint particles from an airflow. The filter module 1 has a receiving element 2 which is equipped internally with three cavities 11. The foremost cavity 11 is connected to the opening 13 on the inlet side 9. Different filter stages, in the form of, for example, different cleaning structures, can be inserted into each of the cavities 11. For example, a filter stage 10 can be inserted into one of the cavities 11 from above.

[0051] Fig. 2 shows a top view of Fig. 1 In this illustration, the filter stage 10 is visible, which in this embodiment has four subsections 15. The subsections 15 run parallel to a connecting plane, which is oriented from the inlet side 9 to the outlet side 8.

[0052] Fig. 3 Figure 1 shows an embodiment of a filter stage 10. Only the receiving element 2 is depicted in this illustration. This element has two openings 13 on both the inlet and outlet sides, each separated by a web 3. The web 3 is formed integrally with the receiving element 2.

[0053] Fig. 4 Figure 1 shows another embodiment of a filter stage 10. In this embodiment, several tabs 6 are arranged on the web 3. The tabs 6 can be tilted relative to the web 3 in the direction of the arrow shown via a hinge 12, so that they are aligned in a position that is essentially perpendicular to the web 3. This is, for example, Fig. 7 The tabs 6 can be formed from the material that would have been removed as residual material during manufacturing in the area of ​​the openings 13.

[0054] The receiving element 2 has a rectangular or square shape, with the distance between the inlet side 9 and the outlet side 8 being smaller than a side edge of the basic shape. This allows the filter stage 10 to be particularly advantageously retrofitted as a second filter stage in an existing filter module 1.

[0055] Fig. 5 a front view of the embodiment according to Fig. 4 In this illustration, the tabs 6 are shown before they are angled along the joints 12. The tabs 6 have conical side edges so that inclined sections between the entry side and the exit side can be held in the receiving element 2.

[0056] Fig. 6 shows another front view of the embodiment according Fig. 4 with filter insert 4 in place. In the upper opening on the entry side, the tabs 6, which engage between the filter insert 4 and position it, are shown with a dashed line.

[0057] Fig. 7 shows a cross-sectional view from Fig. 6 The tabs 6 on the inlet side are offset from the tabs 6 on the outlet side with respect to the length of the web 3. This creates similarly offset recesses 7 in which the sections 15 are held. The filter element 4 has a zigzag structure. In an embodiment not shown, the tabs 6 with their conical side edges can be adapted to the inclination of the zigzag structure.

[0058] Fig. 8 shows a cross-sectional view from Fig. 6 Without filter insert 4. Here, the recesses 7 are visible, with the recesses 7 on the inlet side being offset from the recesses 7 on the outlet side. The two side walls, which are arranged between the inlet side 9 and the outlet side 8, each have a fold 14, so that the receiving element 2 can be folded into a substantially two-dimensional element. The folding direction is shown by the arrows. In an unassembled state, the tabs 6 are preferably arranged parallel to the webs 3, so that a substantially two-dimensional element is formed.

[0059] Fig. 9 Figure 1 shows a further embodiment of a filter stage 10. In this embodiment, the filter insert 4 has a plurality of mutually inclined sub-sections 15. The upper edge 16 and the lower edge 17 of each sub-section 15 extend from an upper edge to a lower edge of the receiving element 2, and therefore over the entire height of the receiving element 2.

[0060] Fig. 10 shows a cross-sectional view from Fig. 9 To achieve the zigzag structure, the individual sub-elements 15 contact each other. A continuous filter insert 4 is therefore formed by sub-elements 15 which are connected to each other in one piece by a fold 5.

[0061] Although the present invention has been fully described above with reference to preferred embodiments, it is not limited thereto, but can be modified in a variety of ways. For example, the webs 3 and the tabs 6 can have a geometry that differs from the embodiment shown. For example, the tabs 6 can be semicircular, rectangular, or square. Reference symbol list

[0062] 1 Filter module 2 Mounting element 3 Bridge 4 Filter insert 5 Rebate of the filter element 6 Tab 7 Recess 8 Outlet side 9 Inlet side 10 Filter stage 11 Cavity 12 Joint 13 Opening of the inlet side 14 Rebate 15 Section 16 Top edge 17 Bottom edge

Claims

1. Filter stage (10), for use in a filter module (1) configured for separating paint particles from an airflow, comprising a receiving element (2) which has an inlet side (9) for admitting an airflow to be cleaned and an outlet side (8) for discharging the cleaned airflow, the inlet side (9) and the outlet side (8) being arranged opposite one another on the receiving element (2), a filter insert (4) which is received in the receiving element (2), the receiving element (2) being made of cardboard, wherein the filter insert (4) has at least two sub-portions (15) which are each formed as a planar face and extend from the inlet side (9) to the outlet side (8), at least two sub-portions (15) being arranged at an inclination to one another in such a way that they contact at a side portion, arranged between an upper edge (16) and a lower edge (17) of the sub-portions (15), and are interconnected, the filter insert (4) being formed in a single piece and the side portion being formed as a fold (5) so as to result in a zigzag structure, wherein the inlet side (9) and the outlet side (8) have at least one web (3) which extends transverse to the orientation of the sub-elements (15), at least one tab (6) being arranged on the web (3) and engaging between two sub-portions (15) and positioning them, the at least one tab (6) of the web (3) of the inlet face (9) being arranged offset from the at least one tab (6) of the web (3) of the outlet face (8) in terms of a length of the web (3).

2. Filter stage (10) according to claim 1, characterised in that the filter inset (4) has at least three, in particular three to fourteen, sub-portions (15).

3. Filter stage (10) according to any of the preceding claims, characterised in that at least two, in particular all, sub-portions (15) are orientated parallel to a connecting plane between the inlet side (9) and the outlet side (8).

4. Filter stage (10) according to either claim 1 or claim 2, characterised in that at least two, in particular all, sub-portions (15) are at an inclination, in particular at an angle of between 5 and 50°, to a connecting plane between the inlet side (9) and the outlet side (8).

5. Filter stage (10) according to claim 1, characterised in that each web (3) has at least two tabs (6), which are arranged offset, in terms of a length of the web (3) of the inlet side (9) and outlet side (9), so as to result in clearances (7), in which the sub-portions (15) are held, along the webs (3).

6. Filter stage (10) according to any of claims 1 to 5, characterised in that the tabs (6) are integrally connected to the web (3) and arranged tiltable, by way of a hinge (12), with respect to the web (3).

7. Filter stage (10) according to any of claims 1 to 6, characterised in that the tabs (6) have conical side edges, in such a way that the sub-portions (15) of the filter insert (4) are held at an inclination between the inlet side (9) and the outlet side (8).

8. Filter stage (10) according to any of the preceding claims, characterised in that the receiving element (2) has a fold (14) on each of at least two side walls which are arranged between the inlet side (9) and the outlet side (8), in such a way that the receiving element (2) can be folded to form a substantially two-dimensional element.

9. Filter stage (10) according to any of the preceding claims, characterised in that the filter insert (4) contains a recyclable material and / or polyester material.

10. Filter stage (10) according to any of the preceding claims, characterised in that the receiving element (2) has a square or rectangular base shape on the inlet side (9) and on the outlet side (8), a distance between the inlet side (9) and the outlet side (8) being less than a side edge of the base shape, in particular the distance being at most half the length of a side edge.

11. Method for transporting a plurality of filter stages (10) according to any of claims 8 to 10, wherein the receiving element (2) has an identical size in two spatial directions in an unfolded, three-dimensional state and in a nonunfolded, two-dimensional state, in such a way that assembled and unassembled filter stages (10) can be transported in a receiving element (2') of a filter module (1).