Method and apparatus for making filter element, including multi-characteristic filter element
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-053/56
B29C-053/80
출원번호
US-0442943
(2006-05-30)
등록번호
US-8231752
(2012-07-31)
발명자
/ 주소
Janikowski, Eric A.
Verdegan, Barry M.
Moy, Jerald J.
Bodasiński, Jacek
Rumiński, Witalis
Gradoń, Leon
Jaroszczyk, Tadeusz
Muse, Robert E.
Rice, Melvin
출원인 / 주소
Cummins Filtration IP Inc.
대리인 / 주소
Andrus, Sceales, Starke & Sawall, LLP
인용정보
피인용 횟수 :
1인용 특허 :
97
초록
Method and apparatus are provided for making a filter element by spinning fibers from one or more dies onto a collector, including designated combinations providing designated filter characteristics.
대표청구항▼
1. A method of making a filter element comprising spinning fibers from a plurality of dies onto a collector in a coordinate system having X, Y, Z axes orthogonal to each other, said X and Y axes defining an X-Y plane transverse to said Z axis, wherein said collector comprises a rotating mandrel rota
1. A method of making a filter element comprising spinning fibers from a plurality of dies onto a collector in a coordinate system having X, Y, Z axes orthogonal to each other, said X and Y axes defining an X-Y plane transverse to said Z axis, wherein said collector comprises a rotating mandrel rotating about said Z axis, and comprising spacing at least a first of said dies from said mandrel along said X axis, namely said first die, and spacing at least a second of said dies from said first die along said X-Y plane, namely said second die, said first and second dies being coplanar in the same said X-Y plane and positioned about said Z axis, and varying fiber diameter along the length of the fiber during fiber production by varying distance between said mandrel and said first die by moving said mandrel and said first die relative to one another in said Y axis during or before said rotating, wherein the fibers spun from said first die are filtration fibers forming a first annular filtration zone, and the fibers spun from said second die are filtration fibers forming a second annular filtration zone, spinning said filtration fibers from each of said first and second dies spaced along said X-Y plane directly onto said rotating mandrel, the method further comprising spinning a first set of fibers of a first filter characteristic from said first die, and spinning a second set of fibers of a second different filter characteristic from said second die. 2. The method according to claim 1 wherein each of said filter characteristics is selected from the group consisting of porosity; wettability; surface energy; fiber diameter; fiber material; and fiber distribution. 3. The method according to claim 1 comprising spinning a first set of fibers in a first filter pattern from a first of said dies, and spinning a second set of fibers in a second different filter pattern from a second of said dies. 4. The method according to claim 1 wherein said spinning step is a fiber spinning step selected from the group consisting of: melt spinning; melt blowing; spun bonding; electrospinning; and air laying. 5. The method according to claim 1 comprising serially spinning fibers from different said dies such that a first set of fibers is spun onto said rotating mandrel from said first die forming said first annular filtration zone of said first set of fibers, and then a second set of fibers is spun onto said rotating mandrel from said second die forming said second annular filtration zone of said second set of fibers. 6. The method according to claim 5 comprising spacing said second die from said first die along said X-Y plane, and wherein said second annular filtration zone is radially outward of said first annular filtration zone and radially aligned with said first annular filtration zone relative to said Z axis including during said spinning. 7. The method according to claim 6 comprising varying at least one parameter from die to die such that at least one filter characteristic varies as a function of radial depth into said filter element. 8. The method according to claim 7 wherein said parameter is selected from the group consisting of: polymer flow rate; polymer temperature; air pressure; air flow rate; air temperature; mandrel axial velocity along said Z axis relative to said dies; mandrel rotational velocity about said Z axis; distance and angle between said dies and said mandrel; and polymer type. 9. The method according to claim 5 comprising, during said spinning and said rotating, translating at least one of said mandrel and said dies along said Z axis. 10. The method according to claim 1 comprising coplanarly aligning third and fourth dies with each other along a second X-Y plane laterally offset from said first and second dies in said first X-Y plane. 11. The method according to claim 10 comprising providing said dies with staggered and different lengths along said Z axis such that said second die overlaps said third and first dies, and such that said third die overlaps said fourth and second dies. 12. The method according to claim 1 comprising effecting said relative movement during said rotating. 13. The method according to claim 1 comprising effecting said relative movement before said rotating. 14. The method according to claim 1 wherein at least one of said dies has a plurality of die openings aligned along a row, and comprising aligning said row parallel to said Z axis. 15. The method according to claim 1 wherein at least one of said dies has a plurality of die openings aligned along a row, and comprising aligning said row along a direction obliquely skewed relative to said Z axis. 16. The method according to claim 1 wherein said first and second dies are spaced from each other in the X-Y plane by 90°. 17. The method according to claim 1 wherein said first and second dies are spaced from each other in the X-Y plane by 60°. 18. The method according to claim 1 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said second die are different polymeric fibers. 19. The method according to claim 1 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said second die are non-polymeric fibers. 20. The method according to claim 1 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said second die are microglass fibers. 21. The method according to claim 20, wherein the fibers spun from the first die have a fiber diameter within a range of 5-20 microns. 22. The method according to claim 1, further comprising effecting relative movement of said mandrel and at least one of said dies along said X axis during or before said rotating. 23. The method according to claim 1, comprising effecting relative movement of said mandrel and at least one of said dies along said Y axis during said rotating. 24. A method of making a filter element comprising spinning fibers from a plurality of dies onto a collector in a coordinate system having X, Y, Z axes orthogonal to each other, said X and Y axes defining an X-Y plane transverse to said Z axis, wherein said collector comprises a rotating mandrel rotating about said Z axis, and comprising spacing at least a first of said dies from said mandrel along said X axis, namely said first die, and spacing at least a second of said dies from said first die along said X-Y plane, namely said second die, said first and second dies being coplanar in the same said X-Y plane and positioned about said Z axis, and varying fiber diameter along the length of the fiber during fiber production by varying distance between said mandrel and said first die by moving said mandrel and said first die relative to one another in said Y axis during or before said rotating, wherein the fibers spun from said first die are filtration fibers forming a first annular filtration zone, and the fibers spun from said second die are filtration fibers forming a second annular filtration zone, spinning said filtration fibers from each of said first and second dies spaced along said X-Y plane directly onto said rotating mandrel, the method comprising serially spinning fibers from different said dies such that a first set of fibers is spun onto said rotating mandrel from said first die forming said first annular filtration zone of said first set of fibers, and then a second set of fibers is spun onto said rotating mandrel from said second die forming said second annular filtration zone of said second set of fibers, the method comprising spacing said second die from said first die along said X-Y plane, and wherein said second annular filtration zone is radially outward of said first annular filtration zone and radially aligned with said first annular filtration zone relative to said Z axis including during said spinning, the method further comprising spacing a third of said dies from said first and second dies along said X-Y plane, namely said third die, and spinning filtration fibers from said third die serially sequentially after said second die, such that a third set of filtration fibers is spun onto said rotating mandrel from said third die forming a third annular filtration zone of said third set of fibers, wherein said third annular filtration zone is radially outward of said second annular filtration zone, the method further comprising spinning a first set of fibers of a first filter characteristic from said first die, spinning a second set of fibers of a second filter characteristic from said second die, and spinning a third set of fibers of a third filter characteristic from said third die. 25. The method according to claim 24 wherein said first and second dies are spaced from each other in the X-Y plane by 90° and said second and third dies are spaced from each other in the X-Y plane by 90°. 26. The method according to claim 24 wherein said first and second dies are spaced from each other in the X-Y plane by 60° and said second and third dies are spaced from each other in the X-Y plane by 60°. 27. The method according to claim 24 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said third die are polymeric fibers. 28. The method according to claim 24 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said third die are different polymeric fibers. 29. The method according to claim 24 wherein said fibers spun from said first die are polymeric fibers, said fibers spun from said second die are microglass fibers, and said fibers spun from said third die are different polymeric fibers. 30. The method according to claim 29, wherein said fibers spun from said first and third dies have a fiber diameter within a range of 5-20 microns. 31. The method according to claim 24, further comprising effecting relative movement of said mandrel and at least one of said dies along said X axis during or before said rotating. 32. The method according to claim 24, comprising effecting relative movement of said mandrel and at least one of said dies along said Y axis during said rotating. 33. A method of making a filter element comprising spinning fibers from a plurality of dies onto a collector in a coordinate system having X, Y, Z axes orthogonal to each other, said X and Y axes defining an X-Y plane transverse to said Z axis, wherein said collector comprises a rotating mandrel rotating about said Z axis, and comprising spacing at least a first of said dies from said mandrel along said X axis, namely said first die, and spacing at least a second of said dies from said first die along said X-Y plane, namely said second die, said first and second dies being coplanar in the same said X-Y plane and positioned about said Z axis, and varying fiber diameter along the length of the fiber during fiber production by varying distance between said mandrel and said first die by moving said mandrel and said first die relative to one another in said Y axis during or before said rotating, wherein the fibers spun from said first die are filtration fibers forming a first annular filtration zone, and the fibers spun from said second die are filtration fibers forming a second annular filtration zone, spinning said filtration fibers from each of said first and second dies spaced along said X-Y plane directly onto said rotating mandrel, the method further comprising serially spinning fibers from different said dies such that a first set of fibers is spun onto said rotating mandrel from said first die forming said first annular filtration zone of said first set of fibers, and then a second set of fibers is spun onto said rotating mandrel from said second die forming said second annular filtration zone of said second set of fibers comprising spacing said second die from said first die along said X-Y plane, and wherein said second annular filtration zone is radially outward of said first annular filtration zone and radially aligned with said first annular filtration zone relative to said Z axis including during said spinning, the method further comprising spacing a third of said dies from said first and second dies along said X-Y plane, namely said third die, and spinning filtration fibers from said third die serially sequentially after said second die, such that a third set of filtration fibers is spun onto said rotating mandrel from said third die forming a third annular filtration zone of said third set of fibers, wherein said third annular filtration zone is radially outward of said second annular filtration zone, the method further comprising varying fiber diameter during said spinning such that fiber diameter decreases from said first annular zone to said second annular zone, and then increases from said second annular zone to said third annular zone, to provide varying fiber diameter along a U-shaped profile in a plot of element depth along an abscissa versus fiber diameter along an ordinate, with minimum fiber diameter at the bight of the U at mid depth, the method further comprising spinning a first set of fibers of a first filter characteristic from said first die, spinning a second set of fibers of a second filter characteristic from said second die, and spinning a third set of fibers of a third filter characteristic from said third die. 34. The method according to claim 33 wherein said first and second dies are spaced from each other in the X-Y plane by 90° and said second and third dies are spaced from each other in the X-Y plane by 90°. 35. The method according to claim 33 wherein said first and second dies are spaced from each other in the X-Y plane by 60° and said second and third dies are spaced from each other in the X-Y plane by 60°. 36. The method according to claim 33 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said third die are polymeric fibers. 37. The method according to claim 33 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said third die are different polymeric fibers. 38. The method according to claim 33 wherein said fibers spun from said first die are polymeric fibers, said fibers spun from said second die are microglass fibers, and said fibers spun from said third die are different polymeric fibers. 39. The method according to claim 38, wherein said fibers spun from said first and third dies have a fiber diameter within a range of 5-20 microns. 40. The method according to claim 33, wherein said fibers spun from said first and third dies have a fiber diameter within a range of 5-20 microns. 41. The method according to claim 33, further comprising effecting relative movement of said mandrel and at least one of said dies along said X axis during or before said rotating. 42. The method according to claim 33, comprising effecting relative movement of said mandrel and at least one of said dies along said Y axis during said rotating. 43. A method of making a filter element comprising spinning fibers from a plurality of dies onto a collector in a coordinate system having X, Y, Z axes orthogonal to each other, said X and Y axes defining an X-Y plane transverse to said Z axis, wherein said collector comprises a rotating mandrel rotating about said Z axis, and comprising spacing at least a first of said dies from said mandrel along said X axis, namely said first die, and spacing at least a second of said dies from said first die along said X-Y plane, namely said second die, said first and second dies being coplanar in the same said X-Y plane and positioned about said Z axis, and varying fiber diameter along the length of the fiber during fiber production by varying distance between said mandrel and said first die by moving said mandrel and said first die relative to one another in said Y axis during or before said rotating, wherein the fibers spun from said first die are filtration fibers forming a first annular filtration zone, and the fibers spun from said second die are filtration fibers forming a second annular filtration zone, spinning said filtration fibers from each of said first and second dies spaced along said X-Y plane directly onto said rotating mandrel, the method further comprising serially spinning fibers from different said dies such that a first set of fibers is spun onto said rotating mandrel from said first die forming said first annular filtration zone of said first set of fibers, and then a second set of fibers is spun onto said rotating mandrel from said second die forming said second annular filtration zone of said second set of fibers comprising spacing said second die from said first die along said X-Y plane, and wherein said second annular filtration zone is radially outward of said first annular filtration zone and radially aligned with said first annular filtration zone relative to said Z axis including during said spinning, the method further comprising spacing a third of said dies from said first and second dies along said X-Y plane, namely said third die, and spinning filtration fibers from said third die serially sequentially after said second die, such that a third set of filtration fibers is spun onto said rotating mandrel from said third die forming a third annular filtration zone of said third set of fibers, wherein said third annular filtration zone is radially outward of said second annular filtration zone, the method further comprising varying porosity during said spinning such that porosity decreases from said first annular zone to said second annular zone, and then increases from said second annular zone to said third annular zone to provide varying porosity along a U-shaped profile in a plot of element depth along an abscissa versus porosity along an ordinate, with minimum porosity at the bight of the U at mid depth, the method further comprising spinning a first set of fibers of a first filter characteristic from said first die, spinning a second set of fibers of a second filter characteristic from said second die, and spinning a third set of fibers of a third filter characteristic from said third die. 44. The method according to claim 43 wherein said first and second dies are spaced from each other in the X-Y plane by 90° and said second and third dies are spaced from each other in the X-Y plane by 90°. 45. The method according to claim 43 wherein said first and second dies are spaced from each other in the X-Y plane by 60° and said second and third dies are spaced from each other in the X-Y plane by 60°. 46. The method according to claim 43 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said third die are polymeric fibers. 47. The method according to claim 43 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said third die are different polymeric fibers. 48. The method according to claim 43 wherein said fibers spun from said first die are polymeric fibers, said fibers spun from said second die are microglass fibers, and said fibers spun from said third die are different polymeric fibers. 49. The method according to claim 43, further comprising effecting relative movement of said mandrel and at least one of said dies along said X axis during or before said rotating. 50. The method according to claim 43, comprising effecting relative movement of said mandrel and at least one of said dies along said Y axis during said rotating. 51. A method of making a filter element comprising spinning fibers from a plurality of dies onto a collector in a coordinate system having X, Y, Z axes orthogonal to each other, said X and Y axes defining an X-Y plane transverse to said Z axis, wherein said collector comprises a rotating mandrel rotating about said Z axis, and comprising spacing at least a first of said dies from said mandrel along said X axis, namely said first die, and spacing at least a second of said dies from said first die along said X-Y plane, namely said second die, said first and second dies being coplanar in the same said X-Y plane and positioned about said Z axis, and varying fiber diameter along the length of the fiber during fiber production by varying distance between said mandrel and said first die by moving said mandrel and said first die relative to one another in said Y axis during or before said rotating, wherein the fibers spun from said first die are filtration fibers forming a first annular filtration zone, and the fibers spun from said second die are filtration fibers forming a second annular filtration zone, spinning said filtration fibers from each of said first and second dies spaced along said X-Y plane directly onto said rotating mandrel, the method further comprising simultaneously spinning fibers from different said dies during a first time increment to form a first annular zone, then varying at least one parameter and simultaneously spinning fibers from said different dies during a second serially sequential time increment to form a second annular zone, said first annular zone comprising first and second subzones, said first subzone having fibers spun from said first die during said first time increment, said second subzone having fibers spun from said second die during said first time increment, said second annular zone having third and fourth subzones, said third subzone having fibers spun from said first die during said second time increment, said fourth subzone having fibers spun from said second die during said second time increment, said first through fourth subzones being radially aligned relative to said Z axis including during said simultaneous spinning during said first time increment and including during said simultaneous spinning during said second time increment, the method further comprising spinning a first set of fibers of a first filter characteristic from said first die, and spinning a second set of fibers of a second different filter characteristic from said second die. 52. The method according to claim 51 wherein said first and second dies are spaced from each other in the X-Y plane by 90°. 53. The method according to claim 51 wherein said first and second dies are spaced from each other in the X-Y plane by 60°. 54. The method according to claim 51 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said second die are different polymeric fibers. 55. The method according to claim 51 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said second die are non-polymeric fibers. 56. The method according to claim 51 wherein said fibers spun from said first die are polymeric fibers and said fibers spun from said second die are microglass fibers. 57. The method according to claim 56, wherein the fibers spun from the first die have a fiber diameter within a range of 5-20 microns. 58. The method according to claim 51, further comprising effecting relative movement of said mandrel and at least one of said dies along said X axis during or before said rotating. 59. The method according to claim 51, comprising effecting relative movement of said mandrel and at least one of said dies along said Y axis during said rotating.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (97)
Ramos Timothy M. ; Steinbrueck Edward A. ; Gieseke Steven Scott ; Finnerty Carolyn J. ; Bishop Wayne R. W., Air cleaner having sealing arrangement between media arrangement and housing.
Mozelack, Brian; Schmitt, Robert J.; Barboza, Steven D.; Jana, Praveen; Nguyen, Son Ngoc; Gschwandtner, Ronald R.; Connor, Robert D.; Yingling, Timothy W., Apparatus for making melt-blown filter cartridges.
Barboza Steven D. ; Hoffman ; Jr. Charles S. ; Kopp Clinton V.,AUX ; Schmitt Robert J. ; Shucosky Anthony C., Apparatus for making melt-blown filtration media having integrally co-located support and filtration fibers.
Pall David B. (Roslyn Estates NY) Harwood Colin F. (Glen Cove NY) Bradley Arthur (Floral Park NY) Brennan Timothy R. (Old Westbury NY), Cylindrical fibrous structures with graded pore size.
Szczepanski Joseph T. (Waconia MN) Aune Thomas M. (Mound MN) Schneider Henry J. (Chino CA), Depth filter cartridge and method and apparatus for making same.
Tadeusz Jaroszczyk ; Jeffrey S. Morgan ; Kent J. Kallsen ; Stephen L. Fallon ; Daniel R. Cady ; Jon S. Wake, Enhanced performance fibrous filter media and extended life fluid filter assembly.
Badeau, Kurt M. A.; Liu, Z. Gerald; Yonushonis, Thomas M.; Haberkamp, William C.; Zoran, Randolph G.; Schukar, Murray R., Exhaust aftertreatment filter with particulate distribution pattern.
Barboza Steven D. (Baltimore MD) Hoffman ; Jr. Charles (Baltimore MD) Kopp Clinton V. (Castle Hill AUX) Schmitt Robert J. (Stewartstown PA) Shucosky Anthony C. (Timonium MD), Filter cartridges having nonwoven melt blown filtration media with integral co-located support and filtration.
Tofsland Kenneth M. (Stoughton WI) Morgan Jeffrey S. (Stoughton WI) Gryttenholm Eric G. (Stoughton WI) Jaroszczyk Tadeusz (Stoughton WI), Liquid-gas separator.
Barboza Steven D. (Baltimore MD) Hoffman ; Jr. Charles S. (Baltimore MD) Kopp Clinton V. (Castle Hill AUX) Schmitt Robert J. (Stewartstown PA) Shucosky Anthony C. (Timonium MD), Melt-blown filtration media having integrally co-located support and filtration fibers.
Brian Mozelack ; Robert J. Schmitt ; Steven D. Barboza ; Praveen Jana ; Son Ngoc Nguyen ; Ronald R. Gschwandtner ; Robert D. Connor ; Timothy W. Yingling, Melt-blown tubular core elements and filter cartridges including the same.
Chown Philip K. (Weybridge GB2) Clarke Simon (Staines GB2) Green Eric C. (Whyteleafe GB2) McFarlane Anthony S. (Lightwater GB2) Medlicott Philip A. C. (Woking GB2) Lawrence Anna C. (Hampton GB2), Method of filtering using an expandable bed fiber and coalescer.
Haynes, Bryan David; McManus, Jeffrey Lawrence; Duellman, Justin Max; Clark, Darryl Franklin; Quincy, III, Roger Bradshaw, Method of increasing the meltblown jet thermal core length via hot air entrainment.
Gryskiewicz Stanley Michael ; Akin Frank Jerrel ; Jackson David Martin ; Sherrod Earle Harry, Method of making an absorbent article including liquid containment beams.
Pall David B. (Roslyn Estates NY) Harwood Colin F. (Glen Cove NY) Bradley Arthur (Floral Park NY) Brennan Timothy R. (Old Westbury NY), Method of making cylindrical fibrous filter structures.
Jones Marvin E. (Grant Township ; Washington County MN) Rousseau Alan D. (Stillwater MN), Oily mist resistant electret filter media and method for filtering.
Ando Katsutoshi (Otsu JPX) Kurata Nobuo (Shiga JPX) Okumura Yoshiharu (Otsu JPX) Sugano Kouji (Otsu JPX), Process for producing a tubular nonwoven fabric and tubular nonwoven fabric produced by the same.
Clayfield Eric J. (Chester GBX) Dixon Arnold G. (Chester GBX) Miller Richard J. L. (Chester GBX), Process for the removal of oil from an oil-in-water dispersion.
Haberkamp, William C.; Janikowski, Eric A.; Ellison, Kyle; Verdegan, Barry Mark; Holm, Christopher E., Composite filter media utilizing bicomponent fibers.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.