FILTER ELEMENT FOR A FILTER UNIT

Abstract

A filter element for a filter unit for filtering a fluid may include a filter element body. The filter element body may include at least one structural body and a support body. The structural body may have a filter structure which is permeable for the fluid. The filter structure may have a plurality of meshes/pores. The filter structure may be structured as a three-dimensionally interlinked lattice structure having a repeating regularity. The plurality of meshes/pores may be formed as a plurality of clear spaces by a plurality of lattice rods that are securely connected to one another. The support body may include a support structure that is permeable for the fluid. The structural body and the support body may each be produced via a 3D printing method. The structural body and the support body may be 3D printed from at least one of various materials and material compositions.

Claims

1. A filter element for a filter unit for filtering a fluid, comprising: a filter element body through which the fluid is flowable, the filter element body including at least one structural body and a support body; the the at least one structural body having a filter structure which is permeable for the fluid, the filter structure having a plurality of meshes/pores; the filter structure structured as a three-dimensionally interlinked lattice structure, the three-dimensionally interlinked lattice structure having a repeating regularity; the plurality of meshes/pores formed as a plurality of clear spaces by a plurality of lattice rods that are securely connected to one another; wherein the support body includes a support structure that is permeable for the fluid; wherein the at least one structural body and the support body are each produced via a 3D printing method; and wherein the at least one structural body and the support body are 3D printed from at least one of various materials and material compositions.

2. (canceled)

3. The filter element according to claim 1, wherein the at least one structural body and the support body are each 3D printed from at least one of a plastic and a plastic material.

4. The filter element according to claim 1, wherein: the support structure of the support body has a cell structure, which has a plurality of passages formed by a plurality of cells; and the plurality of meshes/pores of the at least one structural body are smaller than at least one of the plurality of cells and the plurality of passages of the support body.

5. The filter element according to claim 1, wherein: the support structure of the support body has a cell structure, which has a plurality of passages formed by a plurality of cells; and the plurality of lattice rods of the lattice structure of the at least one structural body have a smaller cross section than a plurality of cell rods of the cell structure of the support body.

6. The filter element according to claim 4, wherein at least one of the plurality of cells and the plurality of passages of the support body are at least one of at least two-times, five-times and ten-times larger than the plurality of meshes/pores of the at least one structural body.

7. The filter element according to claim 5, wherein the cross section of the plurality of cell rods of the cell structure of the support body are at least one of at least two-times, five-times and ten-times larger than the cross section of the plurality of lattice rods of the lattice structure of the at least one structural body.

8. The filter element according to claim 1, wherein: the support structure of the support body has a cell structure, which has a plurality of passages formed by a plurality of cells; and a portion of the plurality of lattice rods of the lattice structure penetrate at least one of (i) into the plurality of passages of the cell structure and (ii) through the plurality of passages of the cell structure.

9. The filter element according to claim 8, wherein the portion of the plurality of lattice rods of the lattice structure penetrate at least one of (i) into the plurality of passages of the cell structure and (ii) through the plurality of passages of the cell structure such that the lattice structure is positively fastened on the cell structure.

10. The filter element according to claim 4, wherein: the at least one structural body includes a single structural body; the cell structure of the structural body is arranged in an interior of the lattice structure of the structural body; and at least a few of the plurality of lattice rods penetrate the plurality of cells.

11. The filter element according to claim 4, wherein: the at least one structural body includes two structural bodies arranged coaxially inside one another; the support body is arranged between the two structural bodies; and at least a few of the plurality of lattice rods penetrate the plurality of cells of the cell structure of the support body and connect the two structural bodies to one another.

12. The filter element according to claim 1, wherein: the at least one structural body and the support body are of hollow cylindrical configuration and arranged coaxially inside one another; and the at least one structural body and the support body are arranged approximately parallel to one another.

13. The filter element according to claim 1, wherein: the at least one structural body is securely connected to the support body; and the secure connection between the at least one structural body and the support body is formed via a materially-bonded connection.

14. The filter element according to claim 1, wherein: the at least one structural body includes two structural bodies, the two structural bodies including a first structural body and a second structural body; a plurality of further structural bodies are arranged on the two structural bodies, which are arranged coaxially inside one another; an inner region of a first further structural body of the plurality of further structural bodies is in direct contact with an outer region of the first structural body and is securely connected thereto; and an outer region of a second further structural body of the plurality of further structural bodies is in direct contact with an inner region of the second structural body and is securely connected thereto.

15. The filter element according to claim 14, wherein the two structural bodies penetrate one another in an overlapping manner over a plurality of outer regions and a plurality of inner regions thereof at least in certain regions.

16.-17. (canceled)

18. The filter element according to claim 1, wherein: a plurality of materials/substances that are reactive or act catalytically on the fluid are embedded inside the plurality of meshes/pores formed by the plurality of interlinked and securely connected lattice rods; and the fluid to be filtered has a coalescent effect to form particles that are precipitable.

19. The filter element according to claim 1, wherein the plurality of meshes/pores of the support body formed by the plurality of connected lattice rods each have an edge length that is at least one of: 0.05 mm to 15 mm for the filtration of liquid fluids; and 0.1 mm to 40 mm for the filtration of gaseous fluids.

20. The filter element according to claim 1, wherein: the at least one structural body includes a plurality of structural bodies; a plurality of adjacent structural bodies of the plurality of structural bodies have different interlinked lattice structures from one another; the plurality of adjacent structural bodies have different material properties of the interlinked lattice structures from one another; and the interlinked lattice structures that are different from one another and the material properties of the interlinked lattice structures that are different from one another change at least one of abruptly and continuously.

21. The filter element according to claim 1, wherein the at least one structural body and the support body are each structured from one piece.

22. The filter element according to claim 1, wherein: a plurality of flow guidance elements/guide bodies are arranged at least one of on and inside the at least one structural body and the support body; the plurality of flow guidance elements/guide bodies are arranged in an overlapping manner on at least one of a plurality of further structural bodies and the support body; the plurality of flow guidance elements/guide bodies have at least one of a planar shape, a curved shape, and a wound shape; and the plurality of flow guidance elements/guide bodies change at least one of abruptly and continuously in terms of shaping.

23. The filter element according to claim 1, wherein: the filter element is configured as a ring filter element, in which the at least one structural body and the support body form at least one of an annular ring filter body and at least one annular part of the ring filter body; and the filter element further comprises two end plates respectively arranged at an axial end of the ring filter body.

24. A ring filter element for a filter unit for filtering a fluid, comprising: an annular ring filter body including a filter element; two end plates respectively arranged at an axial end of the ring filter body; the filter element including: a filter element body through which the fluid is flowable, the filter element body including at least one structural body and a support body; the at least one structural body having a filter structure which is permeable for the fluid, the filter structure having a plurality of meshes/pores; the filter structure structured as a three-dimensionally interlinked lattice structure, the three-dimensionally interlinked lattice structure having a repeating regularity; the plurality of meshes/pores formed as a plurality of clear spaces by a plurality of lattice rods that are securely connected to one another; the support body including a support structure that is permeable for the fluid; wherein the at least one structural body and the support body are each produced via a 3D printing method; and wherein the at least one structural body and the support body are 3D printed from at least one of various materials and material compositions.

25. A filter unit comprising a housing and a filter element inserted into the housing, wherein: the filter element includes: a filter element body through which the fluid is flowable, the filter element body including at least one structural body and a support body; the at least one structural body having a filter structure which is permeable for the fluid, the filter structure having a plurality of meshes/pores; the filter structure structured as a three-dimensionally interlinked lattice structure, the three-dimensionally interlinked lattice structure having a repeating regularity; the plurality of meshes/pores formed as a plurality of clear spaces by a plurality of lattice rods that are securely connected to one another; the support body including a support structure that is permeable for the fluid; the at least one structural body and the support body are each produced via a 3D printing method; and the at least one structural body and the support body are 3D printed from at least one of various materials and material compositions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In the figures, in each case schematically

[0040] FIG. 1 shows a hollow cylindrical filter element constructed from support body and structural bodies,

[0041] FIG. 2 shows a hollow cylindrical support body with cell structure,

[0042] FIG. 3 shows a hollow cylindrical structural body with a three-dimensionally interlinked lattice structure made from rod elements,

[0043] FIG. 4 shows a hollow cylindrical filter element constructed from support body and structural bodies with a plurality of sections of different lattice structures,

[0044] FIG. 5 shows a hollow cylindrical filter element constructed from support body and structural bodies having flow guidance elements/guide bodies arranged inside and outside the lattice structure,

[0045] FIG. 6 shows a 3D printed filter unit consisting of housing, flanges and filter element.

DETAILED DESCRIPTION

[0046] FIG. 1 shows a cylindrical filter element 1, the filter element body 3 of which is constructed from a support body 5 and from structural bodies 6, 7. In the case of the filter element 1, a corresponding coaxially and concentrically positioned hollow cylindrical structural body 6, 7 is arranged both on the inner region 14 and on the outer region 13 of the support body 5. A throughflow 8 of the fluid through the filter element 1 takes place here for example from the outside of the hollow cylindrical filter element 1 into the inner region of the hollow cylindrical filter element 1, whereupon the fluid is then guided further substantially parallel to the central axis 2. Of course, it is possible that instead of the hollow cylindrical filter element 1, filter elements 1 with structural bodies 6 and support bodies 5 in any desired geometric configuration may be used. Here, flat and/or cubic filter elements 1 are preferably used.

[0047] The outer structural body 6 is constructed as a three-dimensionally interlinked lattice structure 15 and is produced by means of a 3D printing method and is aligned orientated substantially parallel to the support body 5. The inner region 19 of the outer structural body 6 is in direct contact in certain regions with the outer region 13 of the support body 5 and is securely connected to the support body 5 in this contact region. This connection can take place by means of adhesive bonding of the contact region or by a materially-connected method of the contact regions. A further connection possibility of both bodies 5, 6—not illustrated in the figures—consists in the three-dimensionally interlinked lattice structure 15, which consists of rod elements 16, engaging using the rod elements 16 through the structure of the support body 5 and in this manner producing the connection of both bodies 5, 6.

[0048] As the inner region 19 of the outer structural body 6 is in contact with the outer region 13 of the support body 5, the analogous consideration applies to the outer region 18 of the lattice structure 15 of the inner structural body 7 and the inner region 14 of the support body 5, which is contacted at least in certain regions. Likewise, the three-dimensional interlinking of the rod elements 16 through the cell structure 10 of the support body 5 to connect both bodies 5, 7 is possible, wherein the cell structure 10 has a three-dimensional honeycomb structure 11, but may also have other shapes of any type.

[0049] In FIG. 2, the interlinking and the mutual dimensionally stable connection of both bodies 6, 7 takes place by the engagement of the rod elements 16 of the lattice structure 15 through cells of the cell structure 10 of the support body 5, wherein the engagement at the support body 5 takes place through the clear space of the cell structure 10 or through the walls of the cell structure 10. As the support body 5 must hold and support a plurality of lattice structures 15 as support body for example and additionally must also absorb the forces arising due to the flowing fluid, the support body 5 is realized in a very stable shape. In the example shown, the support body 5 has a honeycombed structure, namely the cell structure 10, which has a larger material strength and wall strength 11 of the honeycomb structure 10 for the purpose of supporting forces. This means that rod-shaped cell rods of the cell structure 10 have a larger cross section than the lattice rods 16 of the lattice structure 15. It is also possible that when printing the support body 5, a filament material with higher strength is used and/or during the 3D printing process of the cell structure 10, particular strength-increasing material constituents are introduced into the melt of the filament. The choice of a possible cell structure 10, here a hexagonal honeycomb structure 10, particularly beneficially supports the forces and at the same time creates passages 12 which are sufficiently large and regular for the through-flowing fluid and the rod elements 16 running through these passages 12, which are used as connections between the support body 5 and the outer structural body 6, or as a connection of an inner structural body 7 to the outer structural body 6 through the support body 5. The rod elements 16 protruding through the passage openings 12 of the support body 5 may run directly through the passage opening 12 and/or penetrate regions of the honeycomb structure 10 and are thus securely connected to the same. This penetration of the rod elements 16 and the cell structure 10 additionally reinforce the connection.

[0050] A hollow cylindrical structural body 6, 7 with a lattice structure 15 that is constructed in a three-dimensionally interlinked manner from rod elements or lattice rods 16 is depicted in FIG. 3. The rod elements 16 are here arranged combined and interlinked stellately and radially in a multiplicity of arrangements that repeat in such a manner. The hollow cylinder depicted here shows this interlinked structure in terms of its longitudinal extent 21 and in terms of its width 20, so that a three-dimensionally interlinked, hollow cylindrical structural body 6, 7 is created.

[0051] Due to the three-dimensionally interlinked lattice structure 15, the stellately arranged rod elements 16 create clear spaces, which are arranged and orientated in such a manner as meshes 17 or pores 17 that the fluid to be filtered can flow through the structural bodies 6, 7 optimally. Contaminants are left behind in the meshes/pores 17 or at the rod elements 16 in this case, wherein the structural bodies 6, 7 filling with contaminants ensure a satisfactory throughflow 8 of the structural body 6, 7 for a long time due to the large number of meshes/pores 17, without the increasing dynamic pressure when flowing through 8 the structural body 6, 7 reaching critical values. On the inner 14 or outer region 13 of the structural body 6, 7, the lattice structure 15 is provided with an adhesive for connection to further structural bodies 6, 7 that are arranged coaxially inside one another, preferably concentrically. This adhesive may for example have been positioned in these regions as filler material with the filament during the printing process, wherein a subsequent adhesive coating of this inner 14 and outer region 13 is also possible. Likewise, it is possible that substances are introduced into the lattice structure 15 during the 3D printing method with the filaments or as additionally supplied material, which substances collect in a concentrated manner in the meshes/pores 17 in order to create specific reactions and/or catalytic effects of the fluid to be filtered there. These may inter alia be suitable for permanently adhering certain contaminants to the rod elements 16 and/or joining/linking substances present in the fluid to one another and these can therefore be filtered out as contaminant by the lattice structure 15.

[0052] A hollow cylindrical filter element 1 is illustrated in FIG. 4, which is constructed from support body 5 and structural bodies 6, 7 with a plurality of sections 22, 23, 24 of different lattice structures 15 of the structural body 6, 7. The structural bodies 6, 7 are here arranged coaxially, particularly concentrically inside one another, wherein the support body 5 is positioned between the two structural bodies 6, 7.

[0053] The structural bodies 6, 7 may for example be divided in terms of their longitudinal extent 21 into a plurality of sections, here into three sections 22, 23, 24. In these divisions, the sections 22, 23, 24 for example consist of different materials and/or the lattice structure 15 differs in terms of its number of rod elements 16 realized or the number of meshes/pores 17. Thus, it is possible that in a first section 22, a coarse-meshed lattice structure 15, which consists of few rod elements 16, is depicted and the section 23 adjoining this section 22 has a finer lattice structure 15, with a plurality of shorter rod elements 16 than are present in section 22.

[0054] Analogously, the subsequent section 24 may have a further, clearly differing lattice structure 15.

[0055] The transitions between the individual sections 22, 23, 24 and the different lattice structures 15 may here take place abruptly or continuously smoothly. This division into sections of a structural body 6, 7 can, as previously mentioned, be divided into further concentrically arranged structural bodies 6, 7 and/or also into radial sections that are not depicted here. Here also, coarse to less coarse lattice structures 15 may follow and these may of course also have abrupt and/or continuously smooth transitions. In this case, it is not important whether the structural bodies 6, 7 exist as individual lattice structures 15 or consist of lattice structures 15 that are connected together and thus of a plurality of structural elements 6, 7 that are connected.

[0056] The division into different sections 22, 23, 24, wherein the sections 22, 23, 24 can be independent of one another and differently dimensioned is important for optimum filtering of the fluid. Thus, for example, fluid can flow optimally through regions of the structural body 6, 7, through which fluid flows less intensively, due to a change of the dynamic pressure by means of coarser or smaller meshes/pores 17 and less or more rod elements 16, and as a result the regions filter the fluid efficiently.

[0057] FIG. 5 shows a hollow cylindrical filter element 1 constructed from support body 5 and structural bodies 6, 7, in which the structural bodies 6, 7 are arranged coaxially, preferably concentrically with respect to one another. In the region of the support bodies 5, flow guidance elements 28, what are known as guide bodies/flaps 28, are integrated into the lattice structures 15 of the structural bodies 6, 7. These guide bodies 28 are printed inside or outside the lattice structures 15 of the structural bodies 6, 7 during the 3D printing process.

[0058] Such a guide body 28 positioned on the edge region of the lattice body 15 can guide the fluid to be filtered in a targeted manner due to its geometric shaping and positioning or to certain regions of the lattice body 15, so that the previously described optimum throughflow 8 and filtering effect of the filter element 1 is achieved. A circular swirling of the fluid in the form or manner of a cyclone may constitute one possible effect here, for example. During the throughflow 8 of the structural bodies 6, 7, the targeted steering of the fluid may also be achieved by means of guide bodies 28 that are arranged inside the lattice body 15 and shaped correspondingly. Also, these inner guide bodies 28 are also introduced or printed into the same directly during the 3D printing of the lattice body 15.

[0059] Furthermore, the guide bodies 28 can also be arranged both inside the lattice body 15 and between two or more lattice bodies 15. Thus, the fluid flowing in in a lattice body 15 can very effectively and quickly be guided into further lattice bodies 15 or distributed into the same by the overlapping arranged guide bodies 28. Also, the fluid can be steered in alternating directions and thus into different filter regions by a plurality of guide bodies 28 that are assigned to one another. To this end, the guide bodies 28 are designed as curved-surface, wound surfaces of increasing or decreasing size, wherein additional protruding or recessed mouldings may be present on the guide bodies 28 to support the guiding function of the fluid.

[0060] Instead of the flat guiding bodies 28, geometric solid bodies, for example in a cubic shape, may be introduced into the lattice bodies 15 and the fluid may flow around them as flow resistance. Here, swirling is created, which in turn influences the flow behaviour of the fluid in such a manner that the same is as a result steered in a targeted manner into certain regions of the filter element 1 and into the lattice bodies 15.

[0061] A 3D printed filter unit 30 with housing 31, flanges 33 and a filter element 1 is illustrated in FIG. 6. Here, during the 3D printing process, for example, the outermost structural body 6 is not printed as a lattice body 15 but rather as a solid body in the form of a housing wall 31. The housing 31 depicted in FIG. 6 substantially corresponds to the geometric shaping of the filter element 1 and is as such constructed solidly. Also, the housing 31 can be printed at the same time with the filter element 1 and as a one-piece component. Fastening flanges 33 are moulded at the ends of the housing 31, which are used for example for mounting the filter unit 30 on a machine. The flanges 33 are to this end realized with fastening holes 35 for mounting by means of suitable fastening means and have corresponding inlet and outlet openings 34 for the supply or drainage of the fluid. Both the fastening holes 35 and the inlet and outlet openings 34 are correspondingly moulded during the 3D printing method. In this manner, a complete filter unit 30 with filter element 1, housing 31 and fastening flanges 33 can be used and replaced as a completely printed design. Here, the housing 31 advantageously consists of a material with greater strength, which is created during the printing process by means of correspondingly suitable filaments. Furthermore, it is conceivable that corresponding filler materials are supplied to the filament used here to increase the strength.

[0062] One possible further embodiment consists in producing the housing 31 as a separate component without a filter element 1 by means of a 3D printing method. In this case, the filter element 1 is introduced and positioned in the housing 31 at a later time.

[0063] For positioning, a limit stop 32 or an insertion boundary 32 can be moulded in or on the housing 31 during the 3D printing process. The filter element 1 that is pushed in can be fixed in the housing 31, wherein the flange 33 can here also be used as a fixing from the insertion side. The fastening flanges 33 are also here attached to the housing 31 again, wherein a flange for mounting the filter element 1 is designed to be detachable. Instead of the printed housing 31, the previously produced filter element 1 can of course be pushed into a customary housing 31 that is present, wherein instead of the housing 31, a suitable position in a pipeline can also be used. Thus, it is for example possible to be able to use such filter elements 1 at virtually any desired position in a pipe system of a machine/motor.

[0064] This detachable flange 33 is subsequently connected to the housing 31 by means of a suitable connection such that it can be detached again or fixedly. The particular advantage for such a 3D printed housing 31 of a filter unit 30 consists in it being possible for the housing 31 to deviate in terms of its shape and dimensions from symmetrical shapes, and complex housings 31 with frequently changing shape progressions can be realized. The filter elements 1 to be used here correspondingly correspond to this housing shape. Specifically in the case of these filter elements 1 with shapes that change multiple times, the guide bodies 28 described in FIG. 5 are of particular interest, so that all important regions of the filter element 1 can be flown through effectively.

[0065] In principle, the respective structural body 6, 7 and the support body 5 can be 3D printed from various materials and/or material compositions. In this case, the respective structural body 6, 7 and the support body 5 can in each case be 3D printed from plastic and/or plastic material.

[0066] Preferred is an embodiment, in which the structure of the support body 5 has a cell structure 10, which has passages 12 formed by cells. In this case, the cells are formed using bar-shaped cell rods of the cell structure 10. Preferably, the meshes/pores 17 of the respective structural body 6, 7 are smaller than the cells or the passages 12 of the support body 5. For example, the cells or the passages 12 of the support body 5 can be at least twice or five-times or ten-times larger than the meshes/pores 17 of the respective structural body 6, 7.

[0067] Furthermore, it may be provided that the lattice rods 16 of the lattice structure 15 of the respective structural body 6, 7 have a smaller cross section than cell rods of the cell structure 10 of the support body 5. For example, the cross section of the cell rods of the cell structure 10 of the support body 5 may be at least twice or five-times or ten-times larger than the cross section of the lattice rods 16 of the lattice structure 15 of the respective structural body 6, 7.

[0068] As explained above, a portion of the lattice rods 16 of the lattice structure 15 penetrate into the passages 12 of the cell structure 10 or through the same. Preferably, a portion of the lattice rods 16 of the lattice structure 15 penetrate in such a manner into the passages 12 of the cell structure 10 or in such a manner through the same, that the lattice structure 15 is positively fastened on the cell structure 10. A further additional fixing by fusion connections can then be dispensed with.

[0069] According to FIG. 7, the filter element 1 can be configured as a ring filter element 40, in which the respective structural body 6, 7 and the support body 5 form an annular ring filter body 41. In other words, in this case, the filter element body 3 is configured annularly and forms the said ring filter body 41. The filter element 1 or the ring filter element 40 additionally has two end plates 42, 43, which are respectively arranged at an axial end of the ring filter body 41. The upper end plate 42 in FIG. 7 is configured as an open end plate and accordingly has a central passage opening 44, which is open towards an interior 45 surrounded by the ring filter body 41. The lower end plate 43 in FIG. 7 may likewise be configured as an open end plate. Alternatively, the lower end plate 43 may also be configured as a closed end plate which axially closes the interior 45. At least one of the end plates 42, 43 can be printed onto the ring filter body 41 by means of 3D printing.

[0070] FIG. 7 accordingly shows a ring filter element 40, particularly for a filter unit 30 for filtering a fluid, wherein the ring filter element 40 is equipped with an annular ring filter body 41, which is formed by a filter element 1 of the previously described type, and with two end plates 42, 43, which are respectively arranged at an axial end of the ring filter body 41. The ring filter body 41 is flowed through radially during the operation of the ring filter element 40. Cleaned fluid can be drained or uncleaned fluid can be supplied through the throughflow opening 44—depending on the direction of throughflow. The axial direction of the ring filter element 40 is defined by the central longitudinal axis 46 thereof.