Method and Device for Manufacturing Filter Elements and Filter Element

Abstract

A filter medium is embossed to form embossments and the filter medium is then cut at least in some sections by a cutting device such as a water jet, a laser beam, an ultrasonic cutting device, or a cutter, by moving a point of impact of the cutting device relative to the filter medium to produce a cutting line. After cutting, the filter medium is folded. Alternatively, the filter medium is folded to folds and then at least some of the folds are pulled apart at least partially. In a region of the folds which have been pulled apart, the filter medium is cut at least in some sections thereof by the cutting device by moving a point of impact of the cutting device relative to the filter medium to produce a cutting line. After cutting, the folds are reset.

Claims

1. A method for cutting a filter medium, comprising the steps of: providing a filter medium sheet of filter medium; conveying the flat filter medium sheet in a conveying direction of movement while practicing the method; embossing the flat filter medium sheet to form embossments; after embossing, cutting the filter medium sheet at least in some sections thereof by a laser beam cutting device by moving a point of impact of a laser beam on the filter medium sheet relative to the filter medium sheet to produce a circumferentially closed cutting line forming a circumferentially closed cutout through the filter medium sheet, by moving the point of impact of the laser beam at least at times simultaneously with a conveying movement of the filter medium sheet in the conveying direction, wherein a relative movement of the point of impact relative to the filter medium sheet is at least intermittently comprised of the conveying movement of the filter medium sheet and an additional movement, the additional movement comprising at least intermittently a movement component parallel to the conveying direction; a movement component perpendicular to the conveying direction; or a movement parallel and perpendicular to the conveying direction to form the circumferentially closed cutout completely surrounded by filter medium sheet; after cutting, applying a trace of sealant to the filter medium sheet at least in some sections of the filter medium sheet adjacent to the circumferentially closed cutout; after applying the trace of sealant, folding the filter medium sheet to form a plurality of parallel folds, each fold extending across the filter medium sheet in a direction traverse to the conveying direction.

2. The method according to claim 1, wherein the sealant is a hot-melt adhesive.

3. The method according to claim 1, wherein the filter medium is selected from the group consisting of paper, cellulose-based filter media, nonwovens, plastics-based filter media, woven fabric, cellulose mixed fiber media, meltblown media, spunbond media, and combinations thereof.

4. The method according to claim 3, wherein the filter medium is comprised of polyester, polyethylene, polyamide or polystyrene.

5. The method according to claim 1, further comprising conveying the filter medium in at least one conveying direction and moving the point of impact of the cutting device relative to the filter medium along a path that extends at least in some sections obliquely to the conveying direction.

6. The method according to claim 1, further comprising conveying the filter medium in at least one conveying direction and moving the point of impact of the cutting device relative to the filter medium along a path that is curved at least in some sections.

7. The method according to claim 1, wherein the method further comprises: injection molding an additional seal onto the filter medium at an edge of the circumferentially closed cutout, wherein the addition seal comprises a PUR foam.

8. The method according to claim 1, wherein the step of cutting the filter medium sheet further comprises: cutting the filter medium sheet at least in some sections thereof by the laser beam cutting device by moving a point of impact of the laser beam on the filter medium relative to the filter medium sheet to produce an open cutting line extending in a direction parallel or oblique to the conveying direction and dividing the filter medium in the conveying direction into at least two portions.

9. The method according to claim 8, wherein the step of applying a trace sealant is practiced by: applying the trace of sealant to the filter medium sheet at least in some sections of the filter medium sheet adjacent to the circumferentially closed cutout and adjacent to the open cutting line.

10. A method for cutting a filter medium, comprising: folding a filter medium to form folds; after folding, pulling apart at least some of the folds at least partially; in a region of the folds which have been pulled apart at least partially, cutting the filter medium at least in some sections thereof by a cutting device, selected from the group consisting of a water jet, a laser beam, an ultrasonic cutting device, and a cutter, by moving a point of impact of the cutting device on the filter medium relative to the filter medium to produce a cutting line; after cutting, resetting the folds.

11. The method according to claim 10, further comprising, before resetting of the folds, applying a trace of sealant to the filter medium at least in some sections of the filter medium adjacent to the cutting line.

12. The method according to claim 11, wherein the sealant is a hot-melt adhesive.

13. The method according to claim 10, wherein the cutting line is a continuous cutting line.

14. The method according to claim 10, wherein the filter medium is selected from the group consisting of paper, cellulose-based filter media, nonwovens, plastics-based filter media, woven fabric, cellulose mixed fiber media, meltblown media, spunbond media, and combinations thereof.

15. The method according to claim 14, wherein the filter medium is comprised of polyester, polyethylene, polyamide or polystyrene.

16. The method according to claim 10, further comprising: conveying the filter medium in a conveying direction and moving the point of impact of the cutting device at least at times simultaneously with a conveying movement of the filter medium in the conveying direction, wherein a relative movement of the point of impact relative to the filter medium is at least intermittently comprised of the conveying movement of the filter medium and an additional movement, the additional movement comprising at least intermittently a movement component parallel to the conveying direction; a movement component perpendicular to the conveying direction; or a movement parallel and perpendicular to the conveying direction.

17. The method according to claim 10, further comprising: conveying the filter medium in at least one conveying direction and moving the point of impact of the cutting device relative to the filter medium along a path that extends at least in some sections obliquely to the conveying direction.

18. The method according to claim 10, further comprising: conveying the filter medium in at least one conveying direction and moving the point of impact of the cutting device relative to the filter medium along a path that is curved at least in some sections.

19. The method according to claim 10, wherein in the step of cutting a cutout, the cutout is a circumferentially closed cutout completely surrounded by the filter medium.

20. A method for producing a filter element, comprising the steps of: providing a filter medium sheet of filter medium; conveying the flat filter medium sheet in a conveying direction of movement while practicing the method; embossing the flat filter medium sheet to form embossments; after embossing, cutting the filter medium sheet at least in some sections thereof by a laser beam cutting device by moving a point of impact of a laser beam on the filter medium sheet relative to the filter medium sheet to produce a circumferentially closed cutting line forming a circumferentially closed cutout through the filter medium sheet, by moving the point of impact of the laser beam at least at times simultaneously with a conveying movement of the filter medium in the conveying direction, wherein a relative movement of the point of impact relative to the filter medium sheet is at least intermittently comprised of the conveying movement of the filter medium sheet and an additional movement, the additional movement comprising at least intermittently a movement component parallel to the conveying direction; a movement component perpendicular to the conveying direction; or a movement parallel and perpendicular to the conveying direction to form the circumferentially closed cutout completely surrounded by filter medium sheet; after cutting, applying a trace of sealant to the filter medium sheet at least in some sections of the filter medium sheet adjacent to the circumferentially closed cutout; after applying the trace of sealant, folding the filter medium sheet to form a plurality of parallel folds, each fold extending across the filter medium sheet in a direction traverse to the conveying direction.

21. The method according to claim 20, further comprising, after folding the filter medium sheet, applying a seal onto lateral edges of the folded filter medium, the seal adapted to seal relative to a filter housing.

22. The method according to claim 21, further comprising forming the seal peripherally around the filter element.

23. The method according to claim 22, wherein the seal is comprised of polyurethane foam.

24. The method for producing a filter element according to claim 20, wherein the step of cutting the filter medium sheet further comprises: cutting the filter medium sheet at least in some sections thereof by the laser beam cutting device by moving a point of impact of the laser beam on the filter medium relative to the filter medium sheet to produce an open cutting line extending in a direction parallel or oblique to the conveying direction and dividing the filter medium in the conveying direction into at least two portions.

25. The method for producing a filter element according to claim 24, wherein the step of applying a trace sealant is practiced by: applying the trace of sealant to the filter medium sheet at least in some sections of the filter medium sheet adjacent to the circumferentially closed cutout and adjacent to the open cutting line.

26. A method for producing a filter element, comprising: folding a filter medium to form folds; after folding, pulling apart at least some of the folds at least partially; in a region of the folds which have been pulled apart at least partially, cutting the filter medium at least in some sections thereof by a cutting device, selected from the group consisting of a water jet, a laser beam, an ultrasonic cutting device, and a cutter, by moving a point of impact of the cutting device on the filter medium relative to the filter medium to produce a cutting line; after cutting, resetting the folds; applying a seal on the folded filter medium, the seal adapted to seal relative to a filter housing.

27. The method according to claim 26, further comprising forming the seal peripherally around the filter element.

28. The method according to claim 27, wherein the seal is comprised of polyurethane foam.

29. The method according to claim 26, further comprising: forming a filter bellows by cutting external end edges by a laser beam.

30. A device for cutting a filter medium, the device comprising: a conveying device adapted to convey a filter medium in a conveying direction; an embossing device adapted to introduce embossments into the filter medium; a cutting device selected from the group consisting of a water jet cutting device, a laser beam cutting device, an ultrasonic cutting device, and a cutter; a fold setting device disposed in the conveying direction of the filter medium after the cutting device.

31. A device for cutting a filter medium, the device comprising: a conveying device adapted to convey a filter medium in a conveying direction; a folding device adapted to fold the filter medium to folds; a device adapted to pull apart the folds; a cutting device selected from the group consisting of a water jet cutting device, a laser beam cutting device, an ultrasonic cutting device, and a cutter, the cutting device mounted in the conveying direction after the device adapted to pull apart the folds; a fold setting device mounted in the conveying direction after the cutting device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIGS. 1a and 1b show a filter element with a cutout.

[0028] FIG. 2 shows a device for producing a filter element in which the folded bellows is cut.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0029] FIGS. 1a and 1b show as details a filter element 112, a so-called filter insert, in cross-section, in one case along fold edges 128 of the filter paper or filter medium 129 (FIG. 1b) and in the other case transversely with respect thereto (FIG. 1a). In both cases, the cut extends centrally through the cutout 124, wherein it is clear that the cutout has a rectangular cross-section in the drawing plane. The cutout 124 has a circular cross-section perpendicular to the drawing plane. Along the fold edges 128, the cutout 124 has a transverse edge 130 and, at right angles thereto, it has an end edge 131. The additional seal 125 is injection molded on the upper edge forming the unfiltered media side of the filter element 112 and consists of PUR foam. It has the same profile as the edge seal 117 which is affixed on end edges 132 and lateral edges 133 and is likewise made of PUR foam.

[0030] For sealing of the end edges 131, the additional seal 125 can be extended down to the lower edge forming the clean side of the filter element 112. However, this is not illustrated in FIGS. 1a and 1b. The sealing of the respective adjacent filter folds or the lateral sealing of the fold pockets takes place here through a trace of sealant consisting of hot-melt adhesive, a so-called glue bead 134, applied on one side, as can be seen in FIG. 1a in the plan view of the end edge 131.

[0031] According to FIG. 1a, the glue bead 134 is located only in the region of the cutout 124. However, it is equally possible to lengthen this bead as far as the end edges 132 of the filter element 112 so that a stabilizing effect takes place in the transverse direction of the folds. The position of the glue beads 134 can also be seen from FIG. 1b, where they are illustrated by broken lines. The lateral edges 133 of the filter element are likewise closed by glue beads 134a.

[0032] The cutout 124 has been introduced, wherein the filter medium 129 has first of all been provided with embossments. After embossing, the filter medium 129 was cut with the aid of a cutting device such as a water jet, laser beam, ultrasonic cutting device or a cutter at least in some sections, i.e. either completely cut through or perforated. The point of impact of the water jet, laser beam, the ultrasonic cutting device or the cutter on the filter medium is moved relative to the filter medium 129. After cutting, the filter medium 129 was folded. The glue bead 134 was applied before this folding operation. The folded filter medium 129 is optionally conveyed through a curing oven. The cutout was then pressed out of the completed folded bellows and then the seals 117 and 125 were applied.

[0033] Alternatively, the cutout 124 was introduced, the filter medium 129 having first been folded. After folding, at least some of the folds are pulled apart again at least partially. In the region of the folds which have been at least partially pulled apart again, the filter medium 129 was cut with the aid of a cutting device such as a water jet, laser beam, ultrasonic cutting device or a cutter at least in some sections. The point of impact of the water jet, laser beam, the ultrasonic cutting device or the cutter on the filter medium 129 moved relative to the filter medium 129. After cutting, the folds were reset, wherein the glue beads 134 were applied before this second folding operation. The folded filter medium 129 is optionally conveyed through a curing oven. The cutout was optionally pressed out of the completed folded bellows and then the seals 117 and 125 were applied.

[0034] A device 200 for carrying out a method for producing a filter element 112 is illustrated in the schematic FIG. 2. First of all, the filter medium 129, for example the filter paper, is removed in the form of a filter medium sheet from a drum 217 and is conveyed through the device 200 along a conveying direction 201 which extends in particular perpendicular to the subsequently produced fold edges 128.

[0035] In a first processing step, the filter medium 129 is guided between a lower and an upper embossing roller 218. The lower embossing roller is not visible in the drawing. It is located immediately below the embossing roller 218. Folding edges 219 are embossed into the filter medium 129 by means of these embossing rollers. In addition bumps, reinforcing beads or spacers can also be embossed. Alternatively or additionally, the filter medium 129 can also be folded and stretched again in a pre-folding station 202.

[0036] The embossed or stretched filter medium 129 is delivered to a cutting device 203. The cutting device 203 comprises a laser cutting unit. The laser cutting unit comprises at least one deflecting device for the laser cutting beam, by means of which the point of impact of the laser beam on the filter medium 129 can be moved both parallel to the conveying direction 201 of the filter medium 129 (in FIG. 2 from top to bottom and vice versa) and also perpendicular to the conveying direction 201 of the filter medium 129 (in FIG. 2 from left to right and vice versa). The working range in which the laser cutting beam can be moved extends over the entire width of the filter medium sheet and moreover has a sufficient extent in the conveying direction 129. For example, two separate deflecting devices can be provided, by means of which in each case a laser cutting beam can be moved into a section of the working range.

[0037] The movement of the point of impact through the deflecting device can take place simultaneously with the conveying movement of the filter medium 129 so that the resulting relative movement of the point of impact relative to the filter medium 129 results from the conveying movement and the movement of the point of impact controlled by the deflecting device.

[0038] By means of the laser beam, the filter medium 129 can be cut through along a continuous cutting line. Alternatively a perforation can also be introduced and the complete cutting through action only takes place later. In the illustrated example, a closed cutting line 205 for forming the cutout 124 and a cutting line 204 extending obliquely with respect to the conveying device are introduced into the filter medium 129. In the case where the cutting line 205 is a continuous cutting line, the inner cutout can be removed downward on the laser cutting unit by means of its suction device.

[0039] The laser cutting unit is distinguished by particularly high dynamics in comparison with other cutting units with alternative cutting tools. Owing to these high dynamics, cutouts such as the illustrated cutout 124 can be introduced into the moved filter medium 129.

[0040] Two different filter elements 112 (one with and one without a cutout 124) are produced from the filter medium 129, which are disposed adjacent to each other transverse to the conveying direction 201. However, two similar filter elements 112 can also be produced adjacent to one another, for example. Depending upon the design of the filter elements 112, a reduction in waste is obtained.

[0041] Then, the filter medium 129 is provided with the necessary glue beads 134, 134a. For this purpose, first of all two glue application devices 221, 222 are provided. They each consist of a spindle 223, 224 on which support heads 225, 226 are located. Two glue application nozzles 227 are disposed on each of these support heads 225, 226. The application of the glue beads 134, 134a takes place while the filter medium 129 is being moved through below the glue application devices 221, 222 according to the arrow 201. In this case, the spindles 223, 224 are correspondingly rotated, so that the support heads 225, 226 carry out a transverse movement. The support head 226 serves for applying glue beads 134 on both sides of the cutout 124. The support head 225 serves for applying glue beads 134a along the cutting line 204. They both produce two glue beads 134, 134a in each case on the upwardly facing side of the filter medium 129 which is running through.

[0042] The support heads 225, 226 can also be moved by a belt or toothed belt. In particular when a toothed belt is used, the possibility exists of positioning the support heads with very high precision. Moreover, in the case of a belt or toothed belt drive, the adjustment speed is somewhat higher than in the case of a threaded spindle.

[0043] Of course the possibility also exists of producing filter elements 112 or carrying out the method solely with one glue application device. Depending upon the arrangement of the glue beads, however, it may however be necessary for this glue application device to be brought from the end position into the starting position at a very high speed in order to avoid gluing of a longer intermediate piece in case the glue application nozzles are not stopped. The gluing of two to three folds transversely with respect to the transport direction may in some circumstances be acceptable. If a plurality of folds are caused to be glued, this intermediate piece cannot be used, and unnecessary waste would be produced. Moreover two glue beads extending adjacent to one anotheras is required in the examplecannot be applied by means of one individual glue bead applicator, at least above a certain spacing.

[0044] Two glue application devices 232, 233 are provided in addition to the glue application devices 221, 222. These produce glue beads 134a on the two end faces. After the application of all the glue beads 134, 134a, the zigzag folding of the filter material is carried out by means of a fold setter 236.

[0045] Optionally, one or more further glue application devices (not shown) can be provided after the fold setter 236. If need be, these apply a glue bead to the folded bellows which does not serve as a seal but as a supporting glue bead. Furthermore, the device 200 optionally also has a curing oven 240 through which the folded filter medium 129 is conveyed.

[0046] Then the folded filter medium 129 is cut in particular transversely with respect to the conveying direction 201 (along the fold edges 128) at a cutting station 250. Where appropriate, perforated contours are pressed out. This can take place automatically or manually. Individual folded bellows are produced which are then provided with seals 117, 125 in a further work station 260. For example, here they are placed individually in casting shells and, for example, PUR foam is added which is to be cured.

[0047] It will be understood that in a modified construction interim storage or at least transfer to the following station can take place between individual processing steps.

[0048] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.