Respirator filter element for increasing effective filtration area

Abstract

Disclosed in the present invention is a respirator filter element for increasing an effective filtration area. The respirator filter element comprises two or more filter layers, one or more separators, and a connector, wherein two adjacent filter layers are separated by means of one separator to form an air flow cavity, and the separator is connected to the filter layers on two sides in a covered and sealed manner; and the two adjacent filter layers and the separator therebetween enclose the air flow cavity, a through hole is provided on the outer side of the outermost filter layer, and the connector, which connects to a respirator, is mounted at the through hole. Compared with existing filter elements, the filter element of the present invention has a larger effective filtration area, a simpler structure, and better air permeability and comfort.

Description

A respirator filter element with increased effective filter area TECHNICAL FIELD

[0001] The present application belongs to the technical field of respirators, in particular to a respirator filter element with increased effective filter area. BACKGROUND

[0002] Respirators, as a kind of professional personal protective equipment, play a crucial role in modern life and work. It is mainly used to block dust, smoke, fog and other particulate pollutants in the air, preventing these harmful substances from entering the respiratory organs of the human body, thereby protecting the life safety of individuals. These particulate pollutants may come from multiple fields, including but not limited to industrial production, construction, agricultural activities, and medical environments, etc.

[0003] The protective effect of respirators mainly depends on the built-in filter elements. These filter elements are usually made of melt-blown cloth material with electrostatic adsorption characteristics, which can effectively capture and fix tiny particulate pollutants. However, over time, the accumulation of particles on the filter element will reduce its filtering effect. Therefore, it needs to be replaced regularly to maintain its good protective performance.

[0004] The applicant has previously applied for a replaceable filter element of a respirator (patent application number 2024206870040). The inner cavity of the filter element has two layers of filter layers next to each other, and the folded wave-like structure formed by multiple bends can effectively block particulate pollutants in the air, providing good filtering effect. Under normal circumstances, the filter layer itself has a relatively thick thickness, but the outer circle of the two filter layers will cause the outer circle to collapse and be squashed together after forming a pressed edge by heat melting, as shown in Figure 1 at A, which makes the folded wave-like structure of the outer circle obstructed by gas flow, forming a "ineffective filter area" without gas flow, as shown in Figure 2 at B, and only the inner circle is left to form an "effective filter area", as shown in Figure 2 at C, which greatly reduces the actual filtering effect. On the one hand, on the other hand, the two filter layers are offset at an angle from each other originally to enable smooth air flow, but due to the collapse and squashing of the outer circles of the two filter layers, the air flow between the two outer circles collides and generates "turbulence", causing the gas flow to be turbulent, thereby forming internal resistance, making the wearer feel poor air permeability.

[0005] In summary, the previous filter element has the problems of large air resistance, poor air permeability, and reduced "effective filter area", and the applicant proposes a new technology for this. TECHNICAL PROBLEM

[0006] The purpose of the present application is to provide a respirator filter element with large effective filter area, simple structure, and comfortable air permeability. TECHNICAL SOLUTION

[0007] To achieve the above object, the present application provides a respirator filter element with increased effective filter area, comprising two or more filter layers, one or more separators and a connector, two adjacent filter layers are separated by a separator to form an air flow channel, and the separator and the filter layers on both sides are connected together by a cover seal, the two adjacent filter layers and the separator therebetween form an air flow channel, wherein a through hole is provided on the outer side of the outermost filter layer, and a connector connected to the respirator is installed at the through hole.

[0008] Preferably, the edges of the separator form a complete closed contour.

[0009] Preferably, the edges of the separator are the same size as the edges of the two adjacent filter layers and are fixed by a cover seal.

[0010] Preferably, the outer contour of the separator is a circular ring, a square, a triangle, a trapezoid or a special shape.

[0011] Preferably, the separator is made of plastic.

[0012] Preferably, each filter layer is a folded wave structure formed by multiple bending.

[0013] Preferably, each filter layer is made of melt-blown cloth.

[0014] Preferably, the adjacent filter layers and filter layers are staggered at an angle.

[0015] Preferably, the angle between the adjacent filter layers and filter layers is 1° to 90°.

[0016] Preferably, the connector is coaxially arranged with the filter layer. Advantages

[0017] After adopting the above scheme, the gain effect of the present application is that:

[0018] The innovation of the present application lies in the introduction of the partition design, which ingeniously separates the two layers of filter layers and ensures that the two layers of filter layers can be spread out, thereby effectively avoiding the area loss of the filter layers due to lodging and mutual extrusion. This design maximizes the "effective filtering area" and greatly improves the filtering efficiency. In contrast, when the traditional filter element has 10% of the "ineffective filtering area" in each of the two layers of filter layers, the overall effective filtering area can only reach 80%. However, by introducing the partition, the present application almost achieves 100% of the "effective filtering area", which is 20% higher than the traditional design, and the filtering effect is significantly improved. At the same time, the partition not only optimizes the layout of the filter layers, but also ensures that the folded wave structure can fully play its advantages, making the filtering effect more outstanding. In addition, due to the design of the partition, "turbulent flow" is not easy to occur during the filtering process, the internal resistance is significantly reduced, and the air permeability is optimized, thereby improving the comfort of the wearer. It is worth mentioning that the partition also provides certain rigid support for the entire filter element, enhancing its durability and reducing the risk of damage. In summary, the overall structure of the present application is more lightweight and simple, reducing production costs and making the present application more cost-effective. BRIEF DESCRIPTION OF DRAWINGS

[0019] Fig. 1 is a sectional view of a prior art filter element;

[0020] Fig. 2 is a schematic view of the overall structure of the prior art filter element;

[0021] Fig. 3 is an exploded view of the present application with one partition and two layers of filter layers;

[0022] Fig. 4 is a schematic view of the overall structure of the present application with one partition and two layers of filter layers (front view);

[0023] Fig. 5 is a schematic view of the overall structure of the present application with one partition and two layers of filter layers (back view);

[0024] Fig. 6 is a sectional view of the present application with one partition and two layers of filter layers;

[0025] Fig. 7 is an exploded view of the present application with two partitions and three layers of filter layers;

[0026] Fig. 8 is a schematic view of the overall structure of the present application with two partitions and three layers of filter layers.

[0027] Label explanation:

[0028] 1, filter layer; 11, through hole; 2, partition; 21, air flow cavity; 3, joint. Best mode of the present application

[0029] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are the preferred embodiments of the present application, and should not be regarded as exclusive to other embodiments. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort belong to the scope of protection of the present application.

[0030] The present application provides a respirator filter element with increased effective filter area, as shown in FIGS. 3-5, comprising two or more filter layers 1, one or more separators 2, and a connector 3, two adjacent filter layers 1 are separated by a separator 2, and the separator 2 and the filter layers 1 on both sides are connected together by sealing, two adjacent filter layers 1 and the separator 2 therebetween form an airflow passage 21, and a through hole 11 is provided on the outer side of the outermost filter layer 1 for connecting with the respirator.

[0031] The number of filter layers 1 can be two, three, etc., and two filter layers 1 correspond to one separator 2, and three filter layers 1 correspond to two separators 2, as shown in FIGS. 7 and 8, and so on. Therefore, the number of separators 2 can be one, two, etc., according to the number of filter layers 1. The benefits of such a multi-layer stack include, but are not limited to, using the least amount of material to improve the filtering effect of the filter element.

[0032] As shown in FIG. 3, the edges of the separator 2 form a complete closed contour, which can be a circular ring, a square, a triangle, a trapezoid, or a special shape, thereby corresponding to the overall shape of the filter element. The preferred embodiment is a circular ring, as shown in FIGS. 3-8. The separator 2 also serves as a support between adjacent filter layers 1 and is the source of rigidity of the entire filter element. Each filter layer 1 is a folded wave structure formed by multiple bending. The airflow passage 21 formed in the middle of the separator 2 not only allows smooth airflow between each folded wave structure, but also provides enough space for the airflow to be buffered for a distance before being inhaled or exhaled, reducing resistance and increasing overall air permeability. The edges of the separator 2 and the edges of the adjacent filter layers 1 can be the same size, including but not limited to being fixed by heat sealing, and can also be fixed by glue.

[0033] The folded wave structure of the filter layer 1 can increase the filtering area of the airflow passage 21, according to the pressure P = pressure F / area S, when F is constant, increasing S can reduce the value of P, when the penetration resistance F is constant, the folded part can be controlled by the number of folds and the height of the folds to increase the filtering area S of the air passing by several times, which can reduce the value of the pressure P, that is, reduce the breathing resistance, and make the air permeability of the respirator increase several times.

[0034] As shown in FIGS. 3 and 4, the adjacent filter layer 1 and the filter layer 1 can be staggered at an angle, the angle is 1° to 90°, preferably 90°, which can make the gas flow more fully and improve the filtering effect.

[0035] The position of the joint 3 on the filter layer 1 is not limited, which can be eccentric or coaxial with the filter layer 1.

[0036] The filter element of the present application is made of light weight material, and has simple and neat structure, so that the filter element of the present application is light when worn with the respirator, and is convenient to carry.

[0037] The present application also provides a method for manufacturing a respirator filter element with increased effective filtering area, comprising the following steps:

[0038] S1: making a filter layer 2, modifying the melt-blown cloth by controlling the temperature to obtain a soft filter layer 2, and preparing a continuous roll of first filter layer 21 material roll and second filter layer 22 material roll; after the outline of the shell 1 and the predetermined fold height and fold number are determined, the continuous roll of first filter layer 21 material roll and second filter layer 22 material roll is transported to the folding mechanism, and the folding is performed according to the predetermined fold height to form a folded wave shape;

[0039] S2: making a front shell 13 fixed with a joint 3 and a first filter layer 21, determining the outer contour shape of the filter element and making a roll cutter with the same outer contour shape, preparing a continuous roll of front shell 13 material roll and first filter layer 21 material roll, first transporting the front shell 13 material roll and the first filter layer 21 material roll to the punching mechanism, stacking the first filter layer 21 material roll on the front shell 13, then the punching mechanism punches holes in the front shell 13 and the filter layer 2 together to form through holes 12, then the edges of the joint 3 and the through holes 12 are welded with the first filter layer 2 and the front shell 13, and finally the roll cutter is cut to obtain the front shell 13 fixed with the joint 3 and the first filter layer 2;

[0040] S3 back shell 14 edge sealing: prepare continuous roll of back shell 14 roll and second filter layer 22 roll, first cover the second filter layer 22 roll transmission and at an angle offset to the first filter layer 21, then the back shell 14 roll transmission cover to the second filter layer 22, finally, the knife roll cutting and welding edge, so that the front shell 13, the first filter layer 21, the second filter layer 22 and the back shell 14 edge sealing fixed together, complete the filter element.

[0041] In the claims, the specification, and the drawings of the present application, terms such as "including" and "having," and variations thereof, mean "including but not limited to."

[0042] In the claims, the specification, and the drawings of the present application, unless otherwise expressly specified, the orientation words such as "front", "back", "inner", "outer", "upper", "lower", "first", "second", etc. indicate the orientation or positional relationship based on the orientation and position relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation or be constructed and operated in a particular orientation, so it cannot be understood as limiting the specific protection scope of the present application.

[0043] The above is only the preferred embodiment of the present application, not the limitation of the design, any equivalent changes made according to the key design of the present application, falls within the protection scope of the present application.

Claims

1. A respirator filter element with increased effective filter area, characterized in that: it comprises two or more filter layers (1), one or more separators (2) and a connector (3), two adjacent filter layers (1) are separated by a separator (2) to form an airflow channel (21), and the separator (2) and the filter layers (1) on both sides are connected together by a cover seal, two adjacent filter layers (1) and the separator (2) between them form an airflow channel (21), and the outermost filter layer (1) is provided with a through hole (11) on the outside, and a connector (3) connected to the respirator is installed at the through hole (11).

2. A respirator filter element for increasing effective filter area as defined in claim 1, wherein: The edges of the separator (2) form a complete closed contour.

3. A respiratory device filter element for increasing the effective filter area as claimed in claim 2, wherein: The edges of the separator (2) are the same size as the edges of the adjacent filter layers (1) and are fixed by a cover seal.

4. A respiratory device filter element for increasing the effective filter area as claimed in claim 2, wherein: The outer contour of the separator (2) is circular, square, triangular, trapezoidal or irregular.

5. A respirator filter element for increasing effective filter area as defined in claim 1, wherein: The separator (2) is made of plastic.

6. A respirator filter element for increasing effective filter area as defined in claim 1, wherein: Each filter layer (1) is a folded wave structure formed by multiple bending.

7. A respiratory device filter element for increasing the effective filter area as claimed in claim 1, characterized in that: Each filter layer (1) is made of melt-blown cloth.

8. A respiratory device filter element for increasing effective filter area as defined in claim 1, wherein: Adjacent filter layers (1) and filter layers (1) are staggered at an angle.

9. A respiratory device filter element for increasing the effective filter area as claimed in claim 8, characterised in that: The angle between adjacent filter layers (1) and filter layers (1) is 1° to 90°.

10. A respiratory device filter element for increasing effective filter area as defined in claim 1, wherein: The connector (3) is coaxially arranged with the filter layer (1).

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