KR20160083561A - Filter assembly comprising media of gradually decreasing density and method for manufacturing thereof - Google Patents

Abstract

More particularly, the present invention relates to a filter aggregate including a dense impregnated filter medium and a method of manufacturing the filter aggregate, and more particularly, to a method of manufacturing a filter aggregate by combining a calendering process for controlling the density of a filter medium and a winding process for a filter material The present invention relates to a filter aggregate including a dense impulse filter medium capable of producing a filter aggregate having a high quality by improving productivity and preventing damage to filter media that may occur during the manufacturing process of the filter aggregate, and a method of manufacturing the filter aggregate.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a filter assembly including a dense impregnated filter medium,

More particularly, the present invention relates to a filter aggregate including a dense impregnated filter medium and a method of manufacturing the filter aggregate, and more particularly, to a method of manufacturing a filter aggregate by combining a calendering process for controlling the density of a filter medium and a winding process for a filter material The present invention relates to a filter aggregate including a dense impulse filter medium capable of producing a filter aggregate having a high quality by improving productivity and preventing damage to filter media that may occur during the manufacturing process of the filter aggregate, and a method of manufacturing the filter aggregate.

Recently, the pollution problem of air pollution such as atmospheric, water quality and soil has been greatly increased due to the rapid expansion of the industrial scale or the development of science and technology. Especially, the pollution of water quality, which directly affects human life, . As the diversification of industries has necessitated the refining of many kinds of plant water and wastewater as well as the refining of food and beverage, especially domestic drinking water, the filter technology itself, which is the core of the pollution control system, There have been various studies on the effective combination of industrial and household water treatment. Furthermore, techniques for controlling and treating the bubbles contained in the fluid have been developed, and Korean Laid-Open Patent Publication No. 2003-0067668 discloses a liquid filter machine having such a function.

Recently, as environmental pollution has worsened, various efforts have been made to obtain cleaner water. In particular, since water is less reliable, water purifiers are installed in homes and offices to provide clean water to people.

The core component of this water purifier is a filter which filters contaminants contained in the water coming into the water purifier. It uses a roll-shaped filter that is made up of cylindrical filter wraps of a plurality of filter nets inside a pipe, The performance of the filter is deteriorated and the ability to remove contaminants is lowered. Therefore, the amount of the filter needs to be changed regularly.

In order to increase the filtering effect of the pollutants, the filter for the water purifier recently uses a rolled-up filter wrapped with a membrane and a plurality of mesh net rolls to remove the contaminants from the filter performance over time The ability to use it has to be changed regularly, so the usage is gradually increasing.

Generally, a filter used in a water purifier is for removing foreign substances such as rust, dust, sand and the like contained in purified water. The filter is formed by winding a filter material around the core part, I have made wealth.

In the case of the conventional filter having such a structure, the density of the filter material wound on the core portion is different from each other to improve the filtration efficiency and the flow rate. In the case of the filter portion having the density difference as described above, In a sequential manner.

Accordingly, in order to manufacture a filter unit having a difference in density, a plurality of filter media and a plurality of filter media manufacturing apparatuses having different densities are required, and a manufacturing apparatus for sequentially winding the produced filter media sequentially is required. There is a problem that the manufacturing time and manufacturing cost are increased.

In the process of manufacturing a filter material having a specific density, the density of the filter material can be controlled through a calendering process. In order to carry out the calendering process, the first filter material, the calendering and the first winding process are sequentially performed, Since the density-regulated filter medium is manufactured through the second take-up of the density-adjusted filter medium and the second take-up process to the core portion, the filter medium is subjected to two or more winding processes and two or more winding processes It is required to repeatedly perform the repeated winding / winding process, and the filter material is damaged due to the damage of the filter material in the repeated winding / winding process.

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems, and one of the objects of the present invention is to provide a method of manufacturing a filter assembly by a calendering process for controlling density of a filter medium, The present invention provides a method of manufacturing a filter aggregate including a dense impulse filter material capable of manufacturing a filter aggregate having a high quality by preventing the damage of filter media that can occur during the manufacturing process of the filter aggregate.

A second problem to be solved by the present invention is to provide a filter assembly having excellent durability, which can have an improved filtration efficiency, obtain a high flow rate, and significantly improve a service life, and a filter unit including the same.

In order to solve the above-described first problem, the present invention provides a method of manufacturing a filter, comprising the steps of: (1) preparing a first roller on which a filter material having a filtering function is wound; (2) fixing one end of the filter material wound on the first roller to the second roller through a guide portion and a pair of density adjustment rollers; (3) setting a predetermined minimum value and a maximum value for the pair of density adjustment roller intervals, and setting the interval of the pair of density adjustment rollers to a minimum value; (4) rotating the first roller, the guide portion, the density adjusting roller, and the second roller; (5) incrementing a pair of density adjusting roller intervals from the minimum value to a maximum value to diminish the density of the filter medium passing through the density adjusting roller; And (6) winding the filter material having passed through the pair of density adjustment rollers to the second roller.

According to a preferred embodiment of the present invention, the filter material may include any one or more of fibers selected from the group consisting of polyolefin-based, polyester-based and polyamide-based fibers.

According to another preferred embodiment of the present invention, the filter material may be a nonwoven fabric.

According to another preferred embodiment of the present invention, in the step (1), the average fineness of the fibers included in the filter medium may be 0.5 to 1.5 μm and the basis weight of the filter medium may be 10 to 45 g / m ² .

According to another preferred embodiment of the present invention, in the step (3), the minimum value of the interval of the pair of density adjusting rollers may be 0.2 to 0.6 times the thickness of the filter material wound on the first roller.

According to another preferred embodiment of the present invention, in the step (5), the speed of increasing the pair of density adjusting roller intervals from the minimum value to the maximum value is 0.0015 to 0.01 mm / s, The speed of winding on the second roller may be 3 to 25 m / min.

According to still another preferred embodiment of the present invention, in the step (6), the second roller further includes a release preventing portion, and the release preventing portion is formed of a material that is wound on the second roller by applying a pressure of 0.1 to 0.4 MPa Can be prevented.

According to a second aspect of the present invention, And a filter part formed by winding a filter material having a filtering function around the outer periphery of the core part, wherein the filter material has a part where the density of the filter material decreases gradually from one end to the other end of the filter material wound on the outer circumference of the core part And a dense diminishing filter medium containing the dense diminishing filter medium.

According to a preferred embodiment of the present invention, the filter material may be a single filter material that does not include a cut portion between one end and the other end of the filter material.

According to another preferred embodiment of the present invention, the filter material is composed of a first filter material portion in which the density of the filter material gradually decreases from one end to the other end of the filter material wound on the outer circumference of the core portion, And the density of the filter medium may include the second filter medium portion having the lowest density of the first filter medium portion.

According to another preferred embodiment of the present invention, the portion where the density of the filter medium is reduced may be formed to have a thickness of 50% or more of the filter cross-sectional thickness in the direction from the inside to the outside of the filter portion adjacent to the core portion.

According to a second aspect of the present invention, there is provided a filter unit including a filter assembly according to the present invention and an outer case housing the filter assembly.

Hereinafter, terms used in the present invention will be defined.

The term " cross-sectional thickness of the filter assembly " used in the present invention means the shortest distance from the outer periphery of the core portion to the outer periphery of the filter portion, Thickness ratio.

The term " inside of the filter portion " means the portion of the filter portion adjacent to the core portion of the filter assembly, Means a portion where filtration proceeds in the direction of the outer side and the filtrate passing through the inside of the filter portion is filtered.

Since the calendering process for controlling the density of the filter media and the winding process for the filter media for collecting the filter media are performed through one process, the productivity of the filter aggregate manufacturing method of the present invention can be remarkably improved, And the damage of filter media which may occur during the winding / winding process of the filter media repeatedly during the process of manufacturing the filter filter assembly by the manufactured filter material is prevented, so that a filter assembly having excellent quality can be manufactured. Also, since the filter aggregate including the filter material manufactured through such a manufacturing method realizes a continuous density gradient in a single filter material, it is possible to obtain an improved filtration efficiency and at the same time to obtain a high flow rate, and the use period is remarkably improved, great.

FIG. 1A is a perspective view showing a filter manufactured by a filter manufacturing apparatus according to an embodiment of the present invention. FIG.
1B is a plan view of FIG. 1A.
2 is a perspective view schematically showing a filter manufacturing apparatus according to an embodiment of the present invention.
FIG. 3A is a perspective view showing a means for adjusting the speed at which the first roller shown in FIG. 2 is mounted.
Figure 3B is a cross-sectional view of the first roller of Figure 3A.
FIG. 4A is a perspective view showing the density adjusting roller shown in FIG. 2. FIG.
4B is a cross-sectional view of the density adjusting roller of FIG. 4A.
5 is an enlarged view of the second roller shown in Fig.
6 is a perspective view showing the guide unit shown in Fig.
FIG. 7 is an enlarged view of the support portion of FIG. 6; FIG.
FIG. 8 is a perspective view showing the cut portion and the third roller shown in FIG. 2. FIG.
9 is a cross-sectional view illustrating a method of manufacturing a filter by a filter manufacturing apparatus according to an embodiment of the present invention.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

As described above, the filter unit having the density difference is realized through a plurality of filter media and a plurality of filter media manufacturing apparatuses having different densities from each other, and a manufacturing apparatus for sequentially winding the manufactured filter media sequentially to the core unit is required There has been a problem that the equipment, manufacturing time, and manufacturing cost are increased. In order to manufacture a filter medium having a specific density and a filter medium having a density-adjusted filter medium prepared thereafter, it is necessary to repeat two or more winding processes and two or more winding processes for one filter material, There is a problem that the filter material is deteriorated due to damage of the filter material during the winding / winding process.

According to the present invention, there is provided a method of manufacturing a filter, comprising the steps of: (1) preparing a first roller on which a filter material having a filtering function is wound; (2) fixing one end of the filter material wound on the first roller to the second roller through a guide portion and a pair of density adjustment rollers; (3) setting a predetermined minimum value and a maximum value for the pair of density adjustment roller intervals, and setting the interval of the pair of density adjustment rollers to a minimum value; (4) rotating the first roller, the guide portion, the density adjusting roller, and the second roller; (5) incrementing a pair of density adjusting roller intervals from the minimum value to a maximum value to diminish the density of the filter medium passing through the density adjusting roller; And (6) winding the filter material having passed through the pair of density adjustment rollers on the second roller, thereby solving the above-mentioned problem by providing a method of manufacturing a filter aggregate including density dense filter media. As a result, the productivity can be improved remarkably, and the filter material can be manufactured by a separate process, and the manufactured filter material can be manufactured. It is possible to prevent the damage of the filter media which may occur during the winding / winding process of the repeated filter media during the manufacturing process of the filter assembly.

Before describing the method of manufacturing the filter aggregate according to the present invention, a manufacturing apparatus that can be used in the above-described manufacturing method will be described first.

FIG. 1A is a perspective view of a filter manufactured by a filter manufacturing apparatus according to a preferred embodiment of the present invention, FIG. 1B is a plan view of FIG. 1A, FIG. 2 is a schematic view of a filter manufacturing apparatus according to an embodiment of the present invention, FIG.

1A, the filter aggregate 10 is for removing contaminants contained in water or air. The filter medium 14 having a filtration function is attached to a core portion 12 having a plurality of holes formed therein The filter aggregate 10 can be manufactured.

Specifically, the filter assembly 10 may be cylindrical, and may include a tubular core portion 12 having a plurality of holes and a filter portion 14 wound around the outer periphery of the core portion 12.

At this time, the filter portion 14 may be formed such that the density of the filter portion 14 gradually decreases from the core portion 12 toward the outer side.

1B, the pore of the filter portion 14a adjacent to the core portion 12 is smaller than the pore size of the filter portion 14b wound in the outward direction in the core portion 12, .

That is, the density A on the inner side of the filter portion 14 adjacent to the core portion 12 can be made denser than the density B on the outer side of the filter portion 14. The manufacturing apparatus 100 for manufacturing the filter aggregate 10 as described above will now be described in detail with reference to FIGS. 2 to 8. FIG.

2 is a perspective view schematically showing a filter manufacturing apparatus according to an embodiment of the present invention.

In the following description of the filter manufacturing apparatus, the direction in which the second roller 130 of the filter manufacturing apparatus 100 is positioned is defined in front of the filter manufacturing apparatus 100, and the first roller 110 is positioned Will be described as the rear of the filter manufacturing apparatus 100. [

2, the filter manufacturing apparatus 100 includes a first roller 110 on which the filter material 1 is wound, a pair of density adjustment rollers 120 for adjusting the density of the filter material 1, And a second roller 130 on which the filter material 1 having passed through the regulating roller 120 is wound.

A guide 140 may be further provided between the first roller 110 and the density adjusting roller 120 to guide the media 1 toward the density adjusting roller 120.

The cutter 150 and the third roller 160 are provided between the second roller 130 and the density adjusting roller 120 to cut the media 1 fed through the density adjusting roller 120 have.

Here, the direction in which the filter material 1 wound on the first roller 110 moves is referred to as a front direction.

FIG. 3A is a perspective view showing a means for adjusting the speed of the first roller shown in FIG. 2, and FIG. 3B is a sectional view of the first roller of FIG.

The first roller 110 shown in FIG. 3A can be wound with a filter material 1, and at one end of the first roller 110, the rotation speed of the first roller 110 can be adjusted A speed adjusting means 112 may be provided.

3B, the speed adjusting unit 112 includes a housing 114 installed at one end of the first roller 110, a driving unit 114 installed in the housing 114 to drive rotation of the first roller 110, And a control unit 118 for controlling the driving unit 116 to adjust the rotational speed of the first roller 110.

The driving unit 116 may include a rotating shaft 116a for transmitting the power of the motor 116b and the motor 116b to the first roller 110. The rotating shaft 116a may be connected to one end of the motor 116b And can be coupled with the inside of the first roller 110 by being extended.

The controller 118 of the speed adjusting unit 112 may receive the signal from the tension adjusting sensor 146c to adjust the rotational speed of the first roller 110. [

Further, as the speed adjusting means 112, a powder brake may be used.

FIG. 4A is a perspective view showing the density adjusting roller shown in FIG. 2, and FIG. 4B is a sectional view of the density adjusting roller of FIG. 4A.

As shown in FIG. 4A, the density adjusting roller 120 is installed in a direction in which the filter material 1 is unwound, and may be installed adjacent to the second roller 130 in particular.

The density adjusting rollers 120 may be installed in pairs on the upper and lower sides of the filter media 1 and the pair of density adjusting rollers 120 may be spaced from each other such that the density of the filter media 1 Can be adjusted.

At this time, the density adjusting roller 120 may be made of a material such as silicon, steel, urethane, paper, and PTEE, and the pair of density adjusting rollers 120 may be made of the same material or different materials .

In addition, the density adjusting roller 120 may be formed of at least one flat roll or crown roll, and the interval between the pair of density adjusting rollers 120 may be adjusted by air pressure or hydraulic pressure, .

In addition, the pair of density adjusting rollers 120 may be provided with a heating roller which can be heated from 0 ° C to 100 ° C, and the filter material 1 may be pressed together with the heat of the heating roller.

Further, the interval of the pair of density adjustment rollers 120 may be set to a maximum value from a minimum value according to a filter material forming a desired filter, and may be initially set to a minimum value as shown in FIG. 4B.

5 is an enlarged view of the second roller shown in Fig.

As shown in Fig. 5, the second roller 130 is completed by the production of the filter aggregate (10 of Fig. 1), specifically, the filter material 1 pressurized by the pair of density adjustment rollers 120, Is transferred to the second roller 130 and wound on the second roller 130, so that the filter assembly (10 of FIG. 1) can be completed.

At this time, a tubular core portion (12 in FIG. 1) having a plurality of holes through which the filter material 1 is wound may be disposed on the second roller 130, and the filter material 1 Can be wound around the core portion (12 in Fig. 1) to complete the filter assembly (10 in Fig. 1).

The unwinding portion 170 may be provided under the second roller 130 to prevent unwinding of the filter material 1 wound on the second roller 130. In this case, It is possible to prevent the filter material 1 from being loosened by applying a certain pressure in the direction of the second roller 130 and fix the position of the second roller 130.

The release preventing portion 170 may be made of PTFE, silicone, urethane or the like.

FIG. 6 is a perspective view showing the guide portion shown in FIG. 2, and FIG. 7 is an enlarged view of the support portion of FIG. 6.

6, the guide 140 may be installed between the first roller 110 and the density adjusting roller 120 to guide the media 1 in the direction of the second roller 130. As shown in FIG.

Specifically, the guide portion 140 includes a conveying member 142 for moving the media 1 to the density adjusting roller 120, a pair of pushing members 144 for pressing the media 1, And a support member 146 for supporting the support member 146.

The conveying member 142 may be positioned below the filter material 1 and includes a pair of conveying rollers 142a and an endless track belt 142b provided at the outer periphery of the pair of conveying rollers 142a can do.

At this time, the conveying member 142 may be made of an antistatic material.

The pair of pushing members 144 can be placed side by side on the conveying member 142 and the pushing member 144 can be a free roll that can be freely rotated without any other driving means.

The pair of pushing members 144 may be installed so as to be movable up and down so as to adjust the gap with the conveying member 144 according to the thickness of the filter media.

The pressing member 144 may be made of PTFE, paper, rubber, urethane or the like in order to prevent electrostatic phenomenon of the filter material 1, and may preferably be made of PTFE.

The support member 146 may be positioned between the pair of pushing members 144 and may include a support roller 146a, a support plate 146b, and a tension measuring sensor 146c.

Specifically, the support roller 146a is provided between the pair of pushing members 144, and can contact the bottom surface of the filter material 1.

That is, the rotation axis of the support roller 146a may be disposed a greater distance from the rotation axis of the pressing member 144 with respect to the transfer member 142. [

Thus, the filter material 1 passes between the pressing member 144a of one of the pair of pressing members 144 and the feeding member 142, and is conveyed beyond the supporting roller 146a to the other pressing member 144b And then transferred to the density adjusting roller 120 through the member 142.

The support plate 146b may extend vertically at both ends of the support roller 146a and may be formed with a guide groove 146d through which the rotation axis of the support roller 146a intervenes.

At this time, the guide groove 146d is formed to extend in the up / down direction so that the rotation axis of the support roller 146a can be moved in a direction perpendicular to the moving direction of the filter material 1. That is, the rotation axis of the support roller 146a can be moved up / down along the guide groove 146d.

The tension measuring sensor 146c measures the tension of the support roller 146a moving along the guide groove 146d and may be installed on a support plate 146b provided at one end of both ends of the support roller 146a.

Specifically, tensile forces A and B are generated between the first roller 110 and one pressing member 144a and between the supporting roller 146a and the other pressing member 144b, B) force of the support roller 146a may be directed downward.

At this time, while the force of the supporting roller 146a is transmitted to the tension measuring sensor 146c, the tension measuring sensor 146c can measure the tension of the supporting roller 146a, To the speed regulation sensor 112 installed in the vehicle.

FIG. 8A is a perspective view showing a cut part and a third roller shown in FIG. 2, and FIG. 8B is a view showing a state in which the cut part of FIG. 8A is applied.

8A, the cutout portion 150 may be provided between the density adjusting roller 120 and the second roller 130 and may include a frame 152, guide rails 154 provided on the frame 152, And a pair of fastening members 158 that are installed before and after the frame 152. The fastening member 158 may be provided with a pair of fastening members 158,

Specifically, the blade portion 156 is always disposed at a position where the filter material 1 can be cut, and moves along the guide rail 154 to cut the filter material 1. [

The pair of fixing members 158 can be composed of the driving means 158a, the ascending and descending portion 158b and the fixing portion 158c, and the fixing portion 158c can be formed to have the same length as the left- .

As shown in FIG. 8B, when the filter material 10 of FIG. 1 is completed by winding the filter material 1 on the second roller 130, the pair of fixing members 158 of the cut- The blade unit 156 is moved along the guide rail 154 and the filter medium 1 passing through the density adjusting roller 120 can be cut.

At this time, since the blade portion 156 cuts the filter material 1 along the fixing portion 158c, the blade portion 156 can cut the filter material 1 properly without being twisted.

The pair of fixing members 158 can be lowered by the driving means 158a to fix the filter material 1. When the cutting of the filter material 1 is completed, And is moved up to its original position.

The third roller 160 is provided at a position corresponding to the cutout 150 and the filter material 1 passing through the density adjusting roller 120 is inserted into the core portion 12).

At this time, the third roller 160 can rotate at the same speed as the conveying member 142 and can be driven by a motor method.

In addition, the third roller 160 may be made of PTFE, rubber, or urethane to prevent static electricity of the filter material 1, and preferably a PTFE material may be used.

9 is a cross-sectional view illustrating a method of manufacturing a filter by a filter manufacturing apparatus according to an embodiment of the present invention.

Thus, the filter assembly 10 according to FIG. 1 through the above-described manufacturing apparatus comprises (1) preparing a first roller on which a filter material having a filtering function is wound; (2) fixing one end of the filter material wound on the first roller to the second roller through a guide portion and a pair of density adjustment rollers; (3) setting a predetermined minimum value and a maximum value for the pair of density adjustment roller intervals, and setting the interval of the pair of density adjustment rollers to a minimum value; (4) rotating the first roller, the guide portion, the density adjusting roller, and the second roller; (5) incrementing a pair of density adjusting roller intervals from the minimum value to a maximum value to diminish the density of the filter medium passing through the density adjusting roller; And (6) winding the filter material having passed through the pair of density adjustment rollers to the second roller.

First, in step (1) according to the present invention, a step of preparing a first roller wound with a filter having a filtering function is performed.

The filter medium may be a filter contained in a general filter aggregate having a filtering function, and is not particularly limited in its kind.

The filter material may include any one or more of fibers selected from the group consisting of polyolefin-based, polyester-based and polyamide-based fibers. Preferably polyolefin-based fibers which have improved chemical resistance and can be used for filtration of various kinds of fluids and have tensile strength for improving durability, and more preferably polyethylene, polypropylene and copolymerized polyethene Or a copolymerized polypropylene fiber.

In the structure of the filter material, the filter material may preferably be a fabric, and the fabric may be at least one of a fabric, a knitted fabric and a nonwoven fabric. The fabric means that the fibers included in the fabric have longitudinal and lateral directions, and the specific structure may be plain weave, twill weave, etc., and the density of warp and weft yarn is not particularly limited.

When the filter material is a nonwoven fabric, a nonwoven fabric manufactured by various methods including a meltblown method, a spun bond, thermal bonding, a spun lace, a flash spun, and a needle punching may be used as the filter material of the present invention. However, it may preferably be a nonwoven fabric produced by the meltblown method.

When the filter material is a nonwoven fabric, the nonwoven fabric used in a conventional cylindrical filter may be used without limitation. Preferably, the fibers have an average fineness of 0.5 to 1.5 μm and a basis weight of the filter material may be 10 to 45 g / m ² .

If the average fineness is less than 0.5 탆, not only large particle size particles but also small particle size particles may be collected at the outer side of the filter portion to cause initial clogging of the filter. In the case of a nonwoven fabric using three fineness fibers, have. If the average fineness exceeds 1.5 탆, the particle trapping ability at the outer side of the filter portion is lowered, and the particle load to be filtered at the inner side of the filter portion becomes large, so that the filter clogging phenomenon may occur rapidly. Can be degraded.

On the other hand, the fibers included in the filter material may include only fibers having the same fineness satisfying the fineness range, or fibers having different finenesses that satisfy the fineness range. The lengths of the fibers included in the filter material may be the same or different from each other.

The basis weight of the filter material may be 10 to 45 g / m 2, more preferably 15 to 20 g / m 2. If the basis weight is less than 10 g / m 2, the mechanical strength is weak, When the filter material is wound on the second roller 130, the filter material may be torn or short-circuited, and appearance problems such as wrinkles may occur. If the basis weight exceeds 45 g / m < 2 >, the filter aggregate produced may increase the filtration efficiency but may be undesirable for the production of a filter aggregate having desired properties such as a remarkable flow rate due to the generation of differential pressure. However, in consideration of the fineness of the nonwoven fabric used as a filter material of a conventional cylindrical filter, the basis weight of the nonwoven fabric is preferably in the range of the above-mentioned basis weight And thus the present invention is not limited to the range of the basis weight.

In addition, the thickness of the filter material is not limited when the thickness of the nonwoven fabric is usually manufactured or marketed, but preferably the thickness of the filter material is 100 to 360 mu m. However, the present invention is not limited to such a thickness range.

In the step (2) according to the present invention, the one end of the filter material 1 wound on the first roller 110 is wound around the guide rollers 110, (140), a pair of density adjustment rollers (120), and wound around the second roller (130).

At this time, a tubular core portion (12 in FIG. 1A) having a plurality of holes through which the filter material is wound is disposed in the second roller 130, so that the density- It is possible to omit the repeated winding / winding step by winding the core material on the core material with the density adjusted material continuously wound without being wound around the core part after being wound again to produce the filter assembly, It is possible to prevent the deterioration and to manufacture the filter aggregate with high quality.

The core part is a base material from which a filtered fluid is discharged. In general, the core part is not limited to a base material used for a filter for a cylindrical fluid. Preferably, the core part is made of a material selected from the group consisting of polyolefin, polyester and polyamide And may be any one or more materials selected. The length of the core portion may be 30 to 55 cm, the outer diameter may be 30 to 40 mm, and the inner diameter may be 24 to 34 mm. However, the present invention is not limited thereto and may be changed depending on the purpose of use of the filter aggregate, Can be used.

The pressing member 144 and the density adjusting roller 120 of the guide unit 140 can be moved up and down so that the pressing member 144 and the feeding member 142 are moved And the distance between the pair of density adjustment rollers 120 is maximized.

Thereafter, in step (3) according to the present invention, a predetermined minimum value and a maximum value for the interval of the pair of density adjustment rollers 120 are set, and the interval of the pair of density adjustment rollers is set to a minimum value .

The interval between the pair of density adjusting rollers is set to a minimum value because the filter material that is first wound around the core portion of the second roller 130 through the density adjusting roller forms the inner side of the filter portion of the filter aggregate, This is because the size of the pore size must be smaller than that of the filter material forming the outer side of the part. Accordingly, it is necessary to increase the interval to the maximum value in the step (5) after setting the interval of the density adjusting roller to the minimum value in the step (3), and then the filter material density may be decreased from the inner part to the outer part of the filter part. It is possible to manufacture a filter portion in which a pore diameter gradient is increased.

At this time, the minimum value and the maximum value with respect to the interval between the pair of density adjustment rollers 120 can be variously set according to the density of the filter material 1 forming the desired filter portion (14 in FIG. 1) (1) The density can be variously set according to the use of the filter aggregate (10 in Fig. 1).

According to a preferred embodiment of the present invention, the minimum value of the interval of the pair of density adjusting rollers can be 0.2 to 0.6 times the thickness of the filter material wound on the first roller, and the filter aggregate manufactured thereby can have better physical properties , The degree of physical properties may vary depending on the thickness of the filter material wound on the first roller, but if it is less than 0.2 times, the density of the filter material wound on the core portion of the filter assembly to be produced may be excessively increased, The flow rate may be secured and the filtration efficiency may be decreased, which may not be suitable for the production of filter aggregates having desired physical properties.

In step (4) according to the present invention, the first roller 110, the conveying member 142 of the guide part 140, the density adjusting roller 120, the second roller 130, and the third roller 160 may be rotated by a driving means (not shown).

At this time, the first roller 110 rotates while releasing the filter material 1 wound on the first roller 110, and the conveying member 142 adjusts the density of the filter material 1 unwound from the first roller 110 To the roller (120).

Next, in the step (5) according to the present invention, a step of increasing the density of the pair of density adjusting rollers from the minimum value to the maximum value is performed to reduce the density of the filter medium passing through the density adjusting roller.

When the density adjusting roller interval is increased, the density of the filter medium may gradually decrease as the pressure applied to the filter medium passing through the density adjusting roller relatively decreases, and when the interval of the density adjusting roller increases beyond the thickness of the filter medium The density of the filter material wound on the second roller 130 can be made equal to the density when the first roller 110 is wound.

The speed at which the interval between the pair of density adjusting rollers is increased from the minimum value to the maximum value is determined by influencing the density gradient of the filter material together with the speed at which the filter material is wound in the second roller 130 of the step (6) 6).

Next, in step (6) according to the present invention, a step of winding the filter material having passed through the pair of density adjustment rollers on the second roller is performed.

The second roller 130 is provided with a core portion through which the filtrate flows out from the filter assembly as described above, so that the calendered media having passed through the density adjusting roller is wound around the core portion, Aggregates.

At this time, the winding speed of the second roller 130 is influenced by the gap length of the density adjusting roller in the step (5) and the density gradient in the manufactured filter medium, . Preferably, in step (5), the speed of increasing the interval of the pair of density adjusting rollers from the minimum value to the maximum value is 0.0015 to 0.01 mm / s, and the speed at which the filter material is wound on the second roller in step (6) 3 to 25 m / min.

If the speed at which the filter material is wound on the second roller is less than 3 m / min and the density increasing roller interval is more than 0.01 mm / s, the volume of the filter material having a density gradient in the fabricated filter aggregate becomes It is possible to achieve remarkable reduction in the desired filtration efficiency, and the production time of the filter aggregate can be remarkably prolonged. Further, when the speed at which the filter material is wound around the second roller is more than 25 m / min and the interval increasing speed of the density adjusting roller is less than 0.0015 mm / s , The degree of increase of the density gradient is significantly lowered, so that the desired level of flow can not be obtained, and the generation of differential pressure in the filter is increased, which may cause a problem in the filter life.

In the step (6), the second roller 130 may further include a release preventing part 170, which is disposed in the direction of the second roller 130 in a direction of 0.1 to 0.4 MPa It is possible to prevent the loosening of the filter material that is wound around the second roller by applying pressure. If a pressure of less than 0.1 MPa is applied to the unfastening portion of the filter media, the pressure for fixing the filter media is insufficient, causing the filter material to be loosely wound or loosened in the course of winding on the second roller. If the unfastening portion has a pressure of 0.4 MPa It is possible to produce a filter material having a density gradient different from the density gradient of the filter material to be realized through the above-described interval increasing speed of the density adjusting roller and the winding speed of the second roller, There is a problem that the flow rate of the filter aggregate to be manufactured is significantly reduced, the initial filter clogging phenomenon may occur, and the differential pressure may be increased.

Meanwhile, the steps (4) to (6) may be performed at the same time, and the steps (4) to (6) do not mean the line after the step.

Finally, when the winding of the filter material 1 is completed so that the filter material 1 has a desired outer diameter on the core portion (12 in Fig. 1A) disposed on the second roller 130, the cut portion 150 cuts the filter material 1 1a can be completed.

Therefore, as the distance between the pair of density adjustment rollers is gradually changed within the set value range, the density of the filter material wound on the second roller can be decreased in the outward direction in which the filter material is wound in the core portion.

In addition, a pair of density adjusting rollers are provided in a single filter manufacturing apparatus so as to be able to vary the spacing of the density adjusting rollers so that the density of the filter media is continuously decreased so that a plurality of filter media and a plurality of manufacturing apparatuses Since the filter medium having the density adjusted and the density adjusted can be wound around the core part through one manufacturing device, the filter assembly can be manufactured in a one-step manner, and the manufacturing cost for manufacturing the filter can be reduced , The process time can be shortened.

As described above, the filter assembly manufactured by the manufacturing method described above has a core portion through which the filtered fluid is discharged; And a filter part formed by winding a filter material having a filtering function around the outer periphery of the core part, wherein the filter material has a part where the density of the filter material decreases gradually from one end to the other end of the filter material wound on the outer circumference of the core part .

Specifically, as shown in FIG. 1A, the filter assembly 10 includes a core portion 12 and a filter portion 14. 10 is a perspective view of a filter assembly according to an exemplary embodiment of the present invention. Referring to FIG. 10, the filter assembly 1000 includes an end cap 500, which functions to help maintain the shape of the cartridge, And the lower part. The material, thickness, and specific shape of the end cap 500 can be modified according to the purpose, and an end cap mounted on a conventional cylindrical fluid filter can be used

The description of the core portion 12 is the same as that described above and is omitted.

The filter portion 14 is formed by winding a filter material on the outer circumference of the core portion 12. The filter portion 14 is formed by winding a portion of the filter material 14 in which the density of the filter material gradually decreases from one end to the other end of the filter material wound around the outer circumference of the core portion Preferably, the filter material may include a portion where the density is decreased in a state of being a single filter material not including a portion cut between one end and the other end of the filter material.

Specifically, FIG. 11 is a cross-sectional view of a conventional filter aggregate, which is wound around the outer periphery of the first filter material 2 wound around the outer periphery of the core part 1 and the first filter material 2 2), the density difference is formed between the inner side portion and the outer side portion of the filter portion. Such a conventional filter aggregate is manufactured by sequentially winding up two filter media that are individually manufactured so as to have different densities, so that there is a problem that the manufacturing time is remarkably extended and the cost is increased as the filter media is multi-stage. Further, separately performing the winding process after manufacturing each of the media having different densities means that the winding / winding process of the manufactured filter material is repeated, and the repeated winding / winding process damages the filter material and causes deterioration of physical properties There has been a problem.

However, the filter material according to a preferred embodiment of the present invention includes the portion in one filter material in which the filter aggregate is not cut off although the filter material includes a portion where the density is reduced toward the other end from the one end of the filter material, Likewise, since the process of imparting the density gradient and the process of winding the core portion are simultaneously performed in one series of processes, the production time can be remarkably reduced, and the winding / winding process of the filter material can be minimized to prevent damage to the filter material There is an advantage to be able to do.

Meanwhile, according to a preferred embodiment of the present invention, the filter material includes a first filter material portion in which the density of the filter material decreases gradually from one end to the other end of the filter material wound on the outer circumference of the core portion, And a second filter material portion having a density of the filter material having a lowest density of the first filter material portion.

12 is a cross-sectional view of a filter medium according to a preferred embodiment of the present invention. In FIG. 12, the density of the first filter medium portion M decreases from one end to the other end of the filter medium, The density of the second filter material portion N is set to be equal to the density of the second filter material portion M at the point where the density reduction is completed in the first filter material portion M (M) density of the first filter portion (M), and the density may be the lowest density of the first filter portion (M).

Specifically, FIG. 13 is a cross-sectional view of a filter assembly according to a preferred embodiment of the present invention, wherein the filter cross-sectional thickness H means the shortest distance from the outer periphery of the core portion to the outer periphery of the filter portion. The first filter portion may have a thickness (x) of the filter cross-sectional thickness (H), and the second filter portion may be formed of the remaining thickness y. According to a preferred embodiment of the present invention, the first filter material portion M may be formed to be 50% or more of the filter cross-sectional thickness from the inside to the outside of the filter portion adjacent to the core portion, more preferably 70% , Even more preferably 85%, even more preferably 95% or more. If the thickness of the first filter portion M is less than 50% of the filter cross-sectional thickness, the filter life may be shortened due to the rapid density change of the filter material.

Meanwhile, according to another preferred embodiment of the present invention, the portion where the density is reduced in the filter medium may be formed to be 100% of the filter cross-sectional thickness from the inside to the outside of the filter portion adjacent to the core portion.

Meanwhile, the present invention provides a multistage filter-inducing filter assembly according to the present invention; And an outer case housing the filter assembly.

The filter assembly may include an inlet through which the fluid to be filtered flows into the housing where the inside is empty and an outlet through which the fluid filtered by the filter assembly is discharged and includes a mount capable of mounting the filter assembly according to the present invention And may further comprise structures typically included in a filtration device for a cylindrical fluid.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. It will be understood that various changes and modifications may be made without departing from the scope of the present invention. For example, each component specifically illustrated in the embodiments of the present invention can be modified and implemented. It is to be understood that all changes and modifications that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

The present invention will now be described more specifically with reference to the following examples, which should not be construed as limiting the scope of the present invention, but should be construed to facilitate understanding of the present invention.

≪ Example 1 >

A meltblown filter material having a thickness of 150 mu m and a basis weight of 15 g / m < 2 > including polypropylene fibers having a fineness of 1 mu m and wound on a first roller 110 of a filter assembly production apparatus shown in Fig. And passed through the adjustment roller 130 to be fixed to the second roller 130 having a core portion having an outer diameter of 38.4 mm as shown in FIG. Thereafter, the filter aggregate as shown in Table 1 below was set so that the outer diameter of the filter aggregate was 64 mm at the density increasing roller 130 spacing increasing speed of 0.0017 mm / s and the second roller 130 winding speed of 20 m / min. .

≪ Examples 2 to 4 >

A filter aggregate as shown in Table 1 below was prepared in the same manner as in Example 1 except that the density increasing roller 130 spacing increasing rate was 0.0033 mm / s and the winding speed of the second roller 130 was varied .

≪ Comparative Example 1 &

The meltblown media having a thickness of 150 mu m and a basis weight of 15 g / m < 2 > including polypropylene fibers having a fineness of 1 mu m were produced in the same manner as in Example 1, ), 80 탆 (B filter), 110 탆 (C filter) and 140 탆 (D filter), respectively. Each filter material was cut to a length of 2 to 3 m, and then the filter aggregate was wound in an outer diameter of 64 mm from the A filter material in the core part to the D filter material in the order of D filter material, thereby forming filter aggregates as shown in Table 2 below.

≪ Comparative Example 2 &

The minimum value of the interval between the density adjusting rollers 130 was set to 150 mu m and the rising pressure of the loosening preventing portion 170 (Fig. 2) was set to 0.1 MPa in the same manner as in Example 1, .

<Experimental Example>

1. Fabrication of Filtration Device for Fluid

The filter assemblies for cylindrical fluids prepared in the above Examples and Comparative Examples were cut into 1-inch lengths and mounted in a housing used for a conventional filtration apparatus for fluids, and the following physical properties were measured and shown in Tables 1 and 2.

1. Flow measurement

The flow rate was measured by cutting the wound filter into 1-inch length, attaching it to the flow rate evaluation cell, wetting it for 20 seconds at 20psi inflow pressure, adjusting the inflow pressure to 10-30 psi.

2. Measurement of particle removal ability

ISO Ultrafine dust was diluted with pure water and administered through a gear pump, and the number of particles larger than 1.0 μm before and after passing through the filter was measured.

3. Usage cycle evaluation

ISO Ultrafine dust was diluted in pure water, dosed through a gear pump, and the time at which the differential pressure reached 5 psi was measured to determine how fast the internal pore closure by particles occurred over time.

Specifically, FIG. 15 is a graph showing the density according to the outer diameters of filter assemblies of filter media included in the filter aggregates according to the examples and comparative examples of Table 1. As can be seen from FIG. 15 and Table 1,

It can be confirmed that the filter aggregate including four filter media having different densities as in Comparative Example 1 has a significantly higher filtering efficiency than Comparative Example 2 including the filter media having the same density but using a single filter medium and a density impression portion It can be seen that the flow rate, filtration efficiency and service life are both lower than in the examples.

On the other hand, in Example 4, Example 4 in which the ratio of the density decreasing portion to the thickness of the filter layer in the cross-sectional thickness was less than 50% showed significantly lower flow rate, filtration efficiency and cycle time than Examples 1 to 3.

Moreover, in Examples 1 to 3, the flow rate and filtration efficiency of Example 1 were significantly better than those of Examples 2 and 3, and the use period was remarkably increased.

Claims (13)

(1) preparing a first roller on which a filter material having a filtering function is wound;
(2) fixing one end of the filter material wound on the first roller to the second roller through a guide portion and a pair of density adjustment rollers;
(3) setting a predetermined minimum value and a maximum value for the pair of density adjustment roller intervals, and setting the interval of the pair of density adjustment rollers to a minimum value;
(4) rotating the first roller, the guide portion, the density adjusting roller, and the second roller;
(5) incrementing a pair of density adjusting roller intervals from the minimum value to a maximum value to diminish the density of the filter medium passing through the density adjusting roller; And
(6) winding the filter material having passed through the pair of density adjustment rollers to the second roller.
The method according to claim 1,
Wherein the filter medium comprises at least one fiber selected from the group consisting of a polyolefin-based, polyester-based, and polyamide-based fiber.
The method according to claim 1,
Wherein the dense impregnated filter medium is a nonwoven fabric.
The method according to claim 1,
Wherein the average fineness of fibers contained in the filter material wound on the first roller in the step (1) is 0.5 to 1.5 탆, and the basis weight of the filter material is 10 to 45 g / m ² . Aggregate production method.
The method according to claim 1, wherein in the step (3)
Wherein the minimum value of the interval of the pair of density adjusting rollers is 0.2 to 0.6 times the thickness of the filter material wound on the first roller.
The method according to claim 1,
In the step (5), the speed of increasing the interval of the pair of density adjusting rollers from the minimum value to the maximum value is 0.0015 to 0.01 mm / s,
Wherein the speed at which the filter material is wound on the second roller in the step (6) is 3 to 25 m / min.
The method according to claim 1,
Wherein the second roller in the step (6) further includes a release preventing portion, and the release preventing portion prevents the release of the filter material wound on the second roller by applying a pressure of 0.1 to 0.4 MPa to the filter material. &Lt; / RTI &gt;
A core portion through which the filtered fluid is discharged; And
And a filter portion formed by winding a filter material having a filtering function around the outer periphery of the core portion,
Wherein the filter medium includes a portion where the density of the filter material is decreased from one end to the other end of the filter material wound around the outer periphery of the core portion.
9. The method of claim 8,
Wherein the filter medium is a single filter medium that does not include a portion cut between one end and the other end of the filter medium.
9. The method of claim 8,
Wherein the first filter material has a first filter material portion having a density decreasing from one end to the other end of the filter material wound on the outer circumference of the core portion,
And a second filter material portion continuous with the first filter material and having a density of the filter material having a lowest density of the first filter material portion.
9. The method of claim 8,
Wherein the filter medium comprises at least one fiber selected from the group consisting of a polyolefin-based, polyester-based, and polyamide-based fiber.
9. The method of claim 8,
Wherein a portion where the density of the filter material is reduced is formed to have a thickness of 50% or more of a thickness of the filter section from the inside to the outside of the filter portion adjacent to the core portion.
12. A filter assembly according to any one of claims 8 to 12, And
An outer case housing the filter assembly; .

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