The present invention relates to a non-circular filter core for removing suspended particles from fluid and a rolling method thereof, especially to a filter core of a racetrack-shaped filter cartridge used for a truck.
A conventional filter cartridge comprises a filter frame and a filter core. The filter core is mounted in the filter frame, and comprises a wavy filtering sheet and a flat filtering sheet. The filtering sheets are rolled into the shape of a cylinder and are alternately stacked to form multiple axial channels, which have the same shape and size. Each of half of the channels is coated with an end-sealing adhesive layer at one axial end adjacent to an inlet of the filter core to seal said channel. Each one of the other half of the channels is coated with another end-sealing adhesive layer at the other axial end adjacent to an outlet of the filter core to seal said channel. Therefore, the fluid to be filtered enters half of the channels, flows along said half of the channels, hits the end-sealing adhesive layer adjacent to the outlet, and is forced to pass through the wavy filtering sheet and the flat filtering sheet to the other half of the channels, such that the fluid can leave the filter core. The fluid is filtered to make dusts in the fluid attached to the wavy and flat filtering sheets when the fluid is forced through the wavy and flat filtering sheets.
With reference to
With reference to
However, because the leading edge 911 of the flat filtering sheet 91 and the leading edge 923 of the wavy filtering sheet 92 are only about as thick as two paper sheets, it is difficult for a machine to coat glue 94 very accurately to adhere the leading edges 911, 923 together properly. Therefore, currently the glue 94 is coated to the leading edge 911 and the leading edge 923 manually using a glue gun to coat glue 94 along the leading edges 911, 923 to adhere the leading edges 911, 923 together and seal the gap between the leading edges 911, 923. The filtering sheets 91, 92 are rolled after the gap between the leading edges 911, 923 are sealed. However, the current operating method has the following disadvantages:
Firstly, coating the glue manually means that the filter core cannot be rolled into the cylindrical shape fully automatically. That is, before each filter core, production equipment needs to be paused to wait for manual gluing process, which means more pauses and more waiting time, which lowers a production efficiency.
Secondly, even if a worker can manually coat the glue along the thin leading edges 911, 923, it is still a challenging and time-consuming process that affects the production efficiency.
Thirdly, quality of the product can be unstable due to varying proficiencies of the workers.
Fourth, a larger amount of glue is often coated during the manual gluing process to ensure the gap is properly sealed. However, the glue keeps dripping to the ground, which pollutes the working environment and causes waste of resources. Furthermore, because the glue keeps dripping to the ground may reduce sealing efficacy, it is difficult to enhance the sealing efficacy by coating more glue.
To overcome the shortcomings, the present invention provides a non-circular filter core and a rolling method thereof to mitigate or obviate the aforementioned problems.
The main objective of the present invention is to provide a non-circular filter core and a rolling method thereof to ensure sealing efficacy of the glue and to make full automation possible.
The rolling method of a non-circular filter core has steps as follows:
(a) adhering together a wavy filtering sheet and a flat filtering sheet, wherein the flat filtering sheet used for removing suspended pollutants has a flat leading edge; the wavy filtering sheet used for removing suspended pollutants has multiple peaks, a first edge, a second edge disposed opposite to the first edge, a first surface, a second surface disposed opposite to the first surface, and a wavy leading edge; the wavy leading edge connects the first edge and the second edge; a first end-sealing adhesive layer is coated on the first surface of the wavy filtering sheet and coated along the first edge; the flat filtering sheet is adhered to the first surface of the wavy filtering sheet via the first end-sealing adhesive layer;
(b) coating an edge-sealing adhesive layer, wherein a second end-sealing adhesive layer and the edge-sealing adhesive layer are coated on the second surface of the wavy filtering sheet; the second end-sealing adhesive layer is coated along the second edge of the wavy filtering sheet; two ends of the edge-sealing adhesive layer extend toward the first edge and the second edge respectively; the edge-sealing adhesive layer is connected to the second end-sealing adhesive layer;
(c) rolling, wherein the wavy filtering sheet and the flat filtering sheet are folded in a direction in which the wavy leading edge and the flat leading edge are toward the edge-sealing adhesive layer, and the wavy leading edge and the flat leading edge are buried in the edge-sealing adhesive layer to adhere together the wavy leading edge and the flat leading edge; then the wavy filtering sheet and the flat filtering sheet are rolled such that the wavy filtering sheet and the flat filtering sheet are alternately stacked, and the second end-sealing adhesive layer keeps the wavy filtering sheet and the flat filtering sheet alternately stacked.
The non-circular filter core has a flat filtering sheet, a wavy filtering sheet, a first end-sealing adhesive layer, a second end-sealing adhesive layer, and an edge-sealing adhesive layer. The flat filtering sheet is used for removing suspended pollutants and has a leading edge. The wavy filtering sheet is used for removing suspended pollutants and has multiple peaks, a first edge, a second edge disposed opposite to the first edge, a first surface, a second surface disposed opposite to the first surface, and a wavy leading edge connecting the first edge and the second edge. The first end-sealing adhesive layer is coated on the first surface of the wavy filtering sheet and along the first edge. The second end-sealing adhesive layer is coated on the second surface of the wavy filtering sheet and along the second edge. The edge-sealing adhesive layer is coated on the second surface of the wavy filtering sheet. A first end and a second end of the edge-sealing adhesive layer extend toward the first edge and the second edge respectively. The edge-sealing adhesive layer is connected to the second end-sealing adhesive layer. The flat filtering sheet is adhered to the first surface of the wavy filtering sheet via the first end-sealing adhesive layer. The wavy filtering sheet and the flat filtering sheet are rolled such that the wavy filtering sheet and the flat filtering sheet are alternately stacked and adhered together via the second end-sealing adhesive layer. The wavy leading edge and the flat leading edge are buried in the edge-sealing adhesive layer to adhere together the wavy leading edge and the flat leading edge.
The advantage of the present invention is that the edge-sealing adhesive layer with sufficient volume and width is coated on a site where the two filtering sheets are folded for a first time before the two filtering sheets are folded. As a result, after the two filtering sheets are folded for the first time, the two leading edges of the two filtering sheets are buried in the edge-sealing adhesive layer simultaneously to effectively adhere the two leading edges together, thereby preventing bypassing.
Furthermore, unlike the conventional method, which coats glue to peripheries (leading edges) of the two filtering sheets and results in dripping of the glue, the edge-sealing adhesive layer is coated on a surface of the wavy filtering sheet. Even if a larger amount of glue is coated, the glue does not overflow from the leading edge to the ground, ensuring that the glue enhances the sealing efficacy instead of dripping to the ground, polluting the working environment, and having no effect on improving sealing as the glue in the conventional method does.
Moreover, by merely coating the edge-sealing adhesive layer on a specific location of a surface of the wavy filtering sheet, the leading edges can be automatically adhered together after folding. As a result, coating the edge-sealing adhesive layer is simple and fast, which improves efficiency and can be done by a machine instead of by human workers. Therefore, the present invention can easily be automated to reduce an amount of production equipment that needs to be paused for manual operation and to reduce the waiting time for manual operation, thereby further improving efficiency. Finally, by reducing manual operation, which is unstable due to varying proficiencies of the workers, quality of the product can be improved.
Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
With reference to
The first step (S1) is adhering together a wavy filtering sheet and a flat filtering sheet. With reference to
A first end-sealing adhesive layer 31 is coated on a first surface 24 of the wavy filtering sheet 20 and coated along the first edge 21. The flat filtering sheet 10 is adhered to the first surface 24 of the wavy filtering sheet 20 via the first end-sealing adhesive layer 31. Note that the first end-sealing adhesive layer 31 coated along the first edge 21 does not mean that the first end-sealing adhesive layer 31 is in close proximity or attached to the first edge 21. Rather, it means that a coating direction of the first end-sealing adhesive layer 31 is aligned with an extending direction of the first edge 21, but the coating direction of the first end-sealing adhesive layer 31 does not have to be exactly aligned with the extending direction of the first edge 21. In the preferred embodiment, the first end-sealing adhesive layer 31 is disposed apart from the first edge 21, and the coating direction of the first end-sealing adhesive layer 31 is parallel to the extending direction of the first edge 21.
The second step (S2) is coating the edge-sealing adhesive layer. With reference to
The two ends of the edge-sealing adhesive layer 33 extend toward the first edge 21 and the second edge 22 respectively, but this does not mean that the two ends of the edge-sealing adhesive layer 33 extend to the reach the first edge 21 and the second edge 22 respectively. Rather, it indicates a coating direction of the edge-sealing adhesive layer 33, which is preferably perpendicular to the first edge 21 and the second edge 22, but it is not limited thereto. With reference to
With reference to
With reference to
Then, the glue gun 41 is moved toward the first edge 21 while dispensing glue continuously. Then, the flat filtering sheet 10 and the wavy filtering sheet 20 are moved together a little bit toward the flat leading edge 11 and the wavy leading edge 23 before changing a moving direction of the glue gun 41 toward the second edge 22. The glue gun 41 keeps dispensing glue while being moved toward the second edge 22 to form the edge-sealing adhesive layer 33. In another preferred embodiment, the process that the flat filtering sheet 10 and the wavy filtering sheet 20 are moved together a little bit toward the flat leading edge 11 before changing the moving direction of the glue gun 41 can be omitted.
In the preferred embodiment, a width of the edge-sealing adhesive layer 33 is increased by moving the glue gun 41 back and forth. In another preferred embodiment, the width of the edge-sealing adhesive layer 33 can be increased via other ways such as increasing a glue output rate of the glue gun 41. Besides, the width of the edge-sealing adhesive layer 33 can be smaller when a position accuracy of the glue is increased. In the preferred embodiment, a width W1 of the edge-sealing adhesive layer 33 is roughly two times as long as a width of one of the peaks. The width of one peak is defined as a distance between two of the peaks that are adjacent to each other. In the preferred embodiment, the width of one peak is from 5 millimeters to 10 millimeters, and preferably 7.8 millimeters. Therefore, the width W1 of the edge-sealing adhesive layer 33 is from 10 millimeters to 20 millimeters, and preferably 15.6 millimeters, but not limited thereto.
With reference to
The third step (S3) is rolling. With reference to
With reference to
With reference to
Besides, the flat leading edge 11 and the wavy leading edge 23 do not have to be buried in the edge-sealing adhesive layer 33 completely. As mentioned above, the first end and the second end of the edge-sealing adhesive layer 33 can be disposed apart from the first edge 21 and the second edge 22 respectively such that only part of the flat leading edge 11 and the wavy leading edge 23 are buried in the edge-sealing adhesive layer 33 and adhered together. The edge-sealing adhesive layer 33 has to extend toward the second edge 22 only to the second end-sealing adhesive layer 32 because a region beyond the second end-sealing adhesive layer 32 has no effect on filtering, thereby having no problem of bypassing.
With reference to
A pressing distance D3 is defined as a distance by which the pressing region 27A extends from the first edge 21A toward the second edge 22A. An interval distance D4 is defined as a distance between the first edge 21A and the first end of the edge-sealing adhesive layer 33A; the pressing distance D3 is equal to or greater than the interval distance D4. In the preferred embodiment, the pressing distance D3 is preferably from 5 millimeters to 10 millimeters, wherein 5 millimeters and 10 millimeters are included, but not limited thereto.
In other words, the first end of the edge-sealing adhesive layer 33A is closer to the first edge 21A than a periphery of the pressing region 27A is. Because the peaks 26A in the pressing region 27A are pressed down, fluid is naturally bypassed when the fluid reaches the pressing region 27A of an axial channel, and therefore it is unnecessary to extend the edge-sealing adhesive layer 33A to the first edge 21A. The edge-sealing adhesive layer 33A only has to extend toward the first edge 21A such that the first end of the edge-sealing adhesive layer 33A is aligned with the pressing region 27A or that said first end is closer to the first edge 21A than the pressing region 27A is.
With reference to
A non-circular filter core in accordance with the present invention is identical to the aforementioned filter core of the rolling method. Structure of the filter core is already explained in the aforementioned steps of the rolling method, and thus the detailed structure of the filter core is not repeated.
By having the edge-sealing adhesive layer 33 with sufficient volume and width coated on a site where the filtering sheets are folded for a first time before the filtering sheets are folded, the flat leading edge 11 of the flat filtering sheet 10 and the wavy leading edge 23 of the wavy filtering sheet 20 are then buried in the edge-sealing adhesive layer 33. As a result, the flat leading edge 11 and the wavy leading edge 23 are adhered together effectively to avoid fluid bypassing.
Furthermore, the edge-sealing adhesive layer 33 is coated on a surface (second surface 25) of the wavy filtering sheet 20. Even if a larger amount of glue is coated, the glue does not overflow from the flat leading edge 11 and the wavy leading edge 23. Therefore, the edge-sealing adhesive layer 33 can effectively enhance the sealing efficacy and keep a working environment clean.
Moreover, by merely coating the edge-sealing adhesive layer 33 on a specific location of a surface (second surface 25) of the wavy filtering sheet 20, the leading edges can be automatically adhered together after folding. Therefore, coating the edge-sealing adhesive layer 33 is simple and fast, which improves efficiency and can be done by a machine instead of by human workers. As a result, the present invention can easily be automated to reduce an amount of production equipment that needs to be paused for manual operating and to reduce the waiting time for the manual operation, thereby further improving efficiency. Finally, by reducing manual operation, which is unstable due to varying proficiencies of the workers, quality of the product can be improved.
Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
Number | Date | Country | Kind |
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202010428646.5 | May 2020 | CN | national |