Equipment and methods for manufacturing filter panels

Abstract

A method and associated installation for the manufacture of a filter panel (8) made of a filter fabric (5) fixed and tensioned inside a frame (7) consisting of two interconnected half-frames (7a, 7b), in which the shaping of the frame (7) of said panel (8), the unwinding of said fabric (5) from a feed roller (4) and the tensioning of the same fabric (5) on said frame (7) are carried out, the latter being carried out automatically during said shaping process. Compared to the solutions used in the prior art, the installation and method of the present invention offer the advantage of automating all the operations for assembling the filter panel, fixing the fabric in a central position on the as-manufactured frame, tensioning the fabric and cutting off the fabric around the frame already shaped on the panel.

Description

Background Art

[0001] The present invention relates to equipment and related methods for manufacturing filter panels.

[0002] The field of the present invention is the field of manufacturing filter panels that stretch the fabric of the filter material and fix it inside the frame for shaping. This type of panel is used for filtering municipal and industrial wastewater, separating flour, screen printing, and the like.

[0003] The method currently used to manufacture the above-mentioned filter panel is to place the filter fabric that has already been cut according to the measurements of the frame that supports the filter fabric, and then fix it onto the frame by a manual centering operation between these parts. The prior operation of cutting the fabric requires, in particular, the execution of perforations necessary to achieve the reference points required to manually center the fabric with respect to the frame before the frame is shaped.

[0004] However, the above operations not only lengthen the manufacturing time of the filter panel, but also increase the possibility of errors in the manual assembly of the fabric onto the frame, resulting in a significant number of defective products and consequently a high manufacturing cost for the overall product.

Summary of the Invention

[0005] The main object of the present invention is a novel method and related equipment for shaping filter panels of the above-mentioned type, which, compared to the prior art, enables the acceleration of panel manufacturing in a completely automatic manner, without errors, and significantly reduces defective products of the filter fabric used.

[0006] This object and other objects are achieved by the claims 1 described setting equipment. Some preferred embodiments of the present invention result from the remaining claims.

[0007] Compared to solutions used in the prior art, the equipment and method of the present invention have the advantage of automating all operations for assembling the filter panel, fixing the centered fabric in place on the frame being formed, stretching the fabric, and then cutting the fabric from the fabric feed roller itself.

[0008] These purposes, advantages, and features, as well as other purposes, advantages, and features, are derived from the following description of the equipment and methods of the present invention shown in the accompanying drawings, in a non-limiting manner. [Brief explanation of the drawing]

[0009] [Figure 1] This shows a schematic overall diagram of the equipment of the present invention. [Figure 2] This shows a fixed mold half and a movable mold half attached to the equipment of the present invention. [Figure 3] The preceding figure shows a movable mold half of the equipment, which is provided with a sliding mold insert having a matrix for forming the first half frame of the filter panel. [Figure 3a] The preceding figure shows a movable mold half of the equipment, which is provided with a sliding mold insert having a matrix for forming the first half frame of the filter panel. [Figure 4] This shows a fixed mold half of the equipment of the present invention, which is provided with a mold insert for forming a first half frame and a mold insert for forming a second half frame of the filter panel on the first half frame. [Figure 5] Figure 3 shows details of the sliding mold insert of the movable mold half. [Figure 6] Figure 3 shows details of the seat for the sliding mold insert in Figure 5 within the movable mold half. [Figure 7] Figure 3 shows details of the system for securing, tensioning, and cutting the filter fabric on a sliding mold insert. [Figure 8] Figure 4 shows details of the upper mold insert of the fixed mold half, which supports the matrix for molding the second half frame of the filter panel. [Figure 9] Figure 4 shows details of the lower mold insert of the fixed mold half that supports the punch for forming the first half frame of the filter panel. [Figure 10] This shows a brief overview of the positions of the fixed and movable mold halves during the initial molding process of the filter panel. [Figure 11a] This shows the process of forming the first half-frame of the filter panel. [Figure 11b] This shows the process of forming the first half-frame of the filter panel. [Figure 12] This shows the position of the sliding mold insert of the moving mold half during the second half-frame forming process, which involves stretching and cutting the filter fabric. [Figure 13] Figure 2 shows a half-mold, where the filter fabric fixing, tensioning, and cutting systems can be seen. [Figure 14] A filter panel manufactured using the equipment and method shown in the previous figure is shown in a plan view. [Figure 15] A side view shows a filter panel manufactured using the equipment and method described in the previous figure. [Modes for carrying out the invention]

[0010] The apparatus of the present invention, referenced collectively by reference numeral 1 in Figure 1, comprises a frame in which a movable mold half 2 and a fixed mold half 3 are mounted. Further present are feed rollers 4 for the filter fabric 5 of panel 8, as shown in Figures 14 and 15. The apparatus of the present invention further includes a press 6 for injection molding the frame 7 of panel 8.

[0011] Figures 2 and 3 show a mold half 2 that is movable in the direction of arrow F1 with respect to the fixed mold half 3, and it is possible to see a mold insert 9 that is attached so as to slide in the direction of arrow F2 inside a mold insert holder seat or a guide 10 within the same mold half 2.

[0012] In particular, as shown better in Figure 13, the mold insert 9 is slid in the direction of arrow F2 inside the mold insert holder seat 10 of the movable mold half 2 by the associated carriage 20. In the first step of forming the half-frame 7a of the panel 8, the mold insert 9 is arranged at the lower position 2a of the mold half 2 of the equipment 1. In the next step of forming the half-frame 7b, on the half-frame 7a that has already been formed in the previous step, the mold insert 9 moves from the lower position 2a where the half-frame 7a was formed towards the upper position 2b where the half-frame 7b of the filter panel 8 is formed.

[0013] According to the present invention, the mold insert 9 is further movably attached inside the seat 21 within the carriage 20 in the direction of arrow F3 in Figures 3a and 13, in contrast to the action of the spring 18.

[0014] As shown better in Figure 4, the lower part 3a of the fixed mold half 3 of the equipment 1 of the present invention includes a lower mold insert 22 that cooperates with the matrix 19 of the mold insert 9 at the position 2a of the mold half 2 to support a punch 23 for forming the first half-frame 7a of the panel 8 in Figure 15.

[0015] The fixed mold half 3 includes, at its upper part 3b, an upper mold insert 24 that supports a matrix 25 for forming the second half-frame 7b on the half-frame 7a formed at the respective lower parts 2a and 3a of the mold halves 2 and 3.

[0016] As shown in FIGS. 5, 7, and 13, the sliding mold insert 9 of the moving mold half 2 preferably has inserts 11a, 11b, 11c, 11d made of an elastomeric material, and the inserts 11a, 11b, 11c, 11d are suitable for fixing the filter fabric 5 by cooperation with corresponding inserts 12a, 12b, 12c, 12d provided on the mold insert 24 of the upper part 3b of the fixed mold half 3.

[0017] The displacement of the mold insert 9 inward toward the seat 21 supported in the carriage 20, in contrast to the action of the spring 18 that provides the biasing force for the upper mold insert 24 of the half-frame 3, also contributes to the fixing of the fabric '5' described above (arrow F3 in FIGS. 3a and 13).

[0018] Furthermore, corresponding punches 13a, 13b, 13c, and 13d are further provided on the same mold insert 9, further inward with respect to the aforementioned inserts 11 and close to the matrix 19 for forming the half-frame 7a. The punches 13a, 13b, 13c, and 13d perform the pulling or traction of the fabric 5 inside the frame of the panel when the fabric 5 is fixed to the upper part 3b of the mold half 3 between the insert 12 of the mold insert 24 and the insert 11 of the mold insert 9.

[0019] The punches 13 of the mold insert 9 are intended to discharge these punches 13 into the mold insert 24 of the upper part 3b of the mold half 3 and cooperate with corresponding slots or grooves 14a, 14b, 14c, 14d arranged close to the matrix 25 for forming the half-frame 7b.

[0020] As better shown in FIGS. 3a, 7, and 13, on the upper part of the sliding mold insert 9, a blade 15 is further provided, which is accommodated in a corresponding seat 16 arranged above the insert 11a, is suitable for cutting the fabric 5 supplied by the roller 4, and cooperates with a corresponding hollow part 17 provided on the mold insert 24 of the upper part 3b of the fixed mold half 3 in FIG. 8.

[0021] The steps of the present invention are clearly illustrated in Figures 10 to 12.

[0022] In the first step of this method, the mold insert 9 of the movable mold half 2 is positioned at position 2a in the lower part 3a of the fixed mold half 3 (Figure 10). At this position, the movable mold half 2 closes in the direction of arrow F4 in Figure 11a with respect to the mold insert 22 provided in part 3a of the fixed mold half 3, and as a result, the mold insert 9 is returned to the inside of the seat 21 in the carriage 20, in contrast to the action of the spring 18 (arrow F5 in Figure 11a).

[0023] In this closed mold, the injection of the half-frame 7a inside the matrix 19 of the mold insert 9 (Figure 15) is performed in cooperation with the punch 23 provided in the aforementioned mold insert 22 (Figures 3, 11a, and 11b).

[0024] In the next step, the movable mold half 2 separates from the fixed mold half 3, leaving the half frame 7a, which has been molded as described above, on the matrix 19 of the mold insert 9.

[0025] From this position, the mold insert 9 is slid by the carriage 20 toward the upper position 2b of the mold half 2 in the direction of arrow F6 in Figure 11b until it reaches the height of part 3b of the mold half 3 (Figures 11b and 12). At this position, the fabric 5 is fed out from the roller 4 and positioned between the opposing mold insert 9 and the upper mold insert 24.

[0026] At this point, the movable mold half 2 closes towards the fixed mold half 3 in the direction of arrow F7 in Figure 12, and the mold insert 9 returns to the interior of the seat 21 of the carriage 20 of the movable mold half 2 (arrow F8).

[0027] During this process, the following actions are performed automatically. The filter fabric 5 is fixed in a predetermined position on the previously formed half-frame 7a by interference between the insert 11 of the mold insert 9 of the mold half 2 and the insert 12 of the upper mold insert 24 of the mold half 3; As the punch 13 of the mold insert 9 is inserted into the groove 14 of the mold insert 24, the corresponding portion of the fabric 5 is pulled into these grooves, and as a result the fabric itself is stretched, the fabric 5 is pulled to a central position relative to the half frame 7a housed in this moving mold insert 9; A half-frame 7b is formed on a half-frame 7a to form the frame 7 of the filter panel 8.

[0028] Next, the fabric 5 is cut at the top by the blade 15 and thus released from the feed roller 4.

[0029] Next, by opening the mold, the filter fabric 5, which is stretched and fixed in a perfectly centered manner on the frame 7, is left behind, and the excess fabric portion that protrudes outside the frame can be easily removed to give the panel 9 the structure shown in Figure 14.

[0030] The method for forming the panel of the present invention is preferably carried out at a temperature of 200 to 300°C, a holding pressure of 25 to 50 bar of press in the forming process of two half-frames, and a conditioning temperature of 20 to 60°C for the same mold.

[0031] As described above and illustrated, several modifications can be made to the present invention to realize several variations that still fall within the technical scope of the following claims. For example, the material for manufacturing the frame 7 of panel 8 may be reinforced or unreinforced, suitable for injection molding, and preferably suitable for use in medical and food applications, any thermoplastic polymer. On the other hand, the material for manufacturing the fabric 5 may consist of polyamide, polyether, and the like.

Claims

1. Equipment for manufacturing a filter panel (8) made of a filter fabric (5) fixed and stretched inside a frame (7) consisting of two mutually connected half-frames (7a, 7b), The aforementioned equipment comprises a press (6) and a movable die half (2) relative to a fixed die half (3), The apparatus is characterized in that the movable mold half (2) includes a mold insert (9) that slides between a first position for forming the half frame (7a) of the panel (8) and a second position for forming a second half frame (7b) of the same panel (8) on the half frame (7a).

2. The apparatus according to claim 1, characterized in that the moving mold half (2) is provided with a guide (10) for the sliding of the mold insert (9).

3. The apparatus according to claim 2, wherein the fixed mold half (3) comprises a mold insert (22) that supports a punch (23) for forming the half frame (7a) in cooperation with the matrix (19) of the moving mold insert (9).

4. The apparatus according to claim 3, wherein the fixed mold half (3) further comprises a mold insert (24) having a matrix (25) for molding the half frame (7b).

5. The apparatus according to claim 1, characterized in that the sliding mold insert (9) has inserts (11a, 11b, 11c, 11d) for fixing the filter fabric (5) in cooperation with corresponding inserts (12a, 12b, 12c, 12d) provided on the mold insert (24) of the fixed mold half (3).

6. The apparatus according to claim 1, wherein the sliding mold insert (9) comprises punches (13a, 13b, 13c, 13d) positioned in close proximity to the matrix (19), the punches (13a, 13b, 13c, 13d) cooperate with corresponding grooves (14a, 14b, 14c, 14d) positioned around the matrix (25) for forming the half-frame (7b) or in close proximity to the matrix (25) for forming the half-frame (7b) in order to pull the filter fabric (5).

7. The apparatus according to claim 2, further comprising a carriage (20) for the slide of the mold insert (9) in the guide (10).

8. The apparatus according to claim 7, characterized in that the mold insert (9) is further movable inside the seat (21) in the carriage (20) in contrast to the action of the spring (18).

9. The apparatus according to one or more of claims 1 to 8, further comprising a blade (15) housed in a corresponding seat (16) of the sliding mold insert (9), wherein a corresponding cavity (17) is provided within the mold insert (24) for performing cutting of the fabric (5) supplied by each roller (4).

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