DESCRIPTION

Field of the invention

[001] The present invention relates to filter winding apparatuses.

Background of the invention

[002] The prior art discloses various filter winding apparatuses. The Chinese utility model registration publication No. CN21076342U discloses a winding machine for forming a cylindrical filter cartridge. The device comprises a rack, a fixed roller and a pressing roller, an air pressure control system for control of the pressing roller. Similar design is disclosed in the European patent publication No. EP2985065 and in Japanese patent application publication No. JPH05246297A.

[003] Aim of the invention is to design a cylindrical filter winding apparatus that is easy to operate and allows fast adjustment of the apparatus if the configurations of filter layers are changed so that mass customization can be reached.

Summary of the invention

[004] The aim is reached by a design of a cylindrical filter winding apparatus and method of operation said filter winding apparatus.

[005] The filter winding apparatus comprises a frame configured to hold and support all other members of the filter winding apparatus. The filter winding apparatus comprises a winding roller rotationally connected to the frame through its axle. The winding roller consists of two sections - non-movable section and movable section. The winding roller also comprises a fixing groove, preferably along all length of the winding roller. The winding roller further comprises a hydraulic drive unit configured to move the movable section to and away from the central axis of the winding roller increasing or decreasing a circumference of the winding roller. The hydraulic drive unit comprises at least three hydraulic cylinders built in the winding roller and connected between the movable section and non-movable section. At least three hydraulic cylinders are interconnected by a common hydraulic line so that the common control of the hydraulic cylinders may be performed. The movable section is moved by about 3 mm which is sufficient for providing counter pressure to the winded filter layers. A winding motor through any known transmission unit is connected to the winding roller and configured to rotate the winding roller.

[006] The filter winding apparatus comprises a pressure generating unit. The pressure generating unit comprises a lever and pressure roller system. The pressure generating unit comprises a first lever and a second lever. The first lever has a first end and a second end and a middle section therebetween. The second lever has a first end and a second end and a middle section therebetween. It is preferable that both levers are made identical. The middle section of the first lever is hingedly connected to the middle section of the second lever through the central lever hinge forming scissor type connection. A first pressure roller rotationally connected to the first end of the first lever. A second pressure roller rotationally connected to the first end of the second lever. In addition, the pressure generating unit comprises a cylinder having a cylinder body and a piston with a piston rod. The second end of the first lever is hingedly connected to the piston rod and the second end of the second lever is hingedly connected to the cylinder body so that the movement of the piston rod of the cylinder provide a scissor type movement of both levers, in result of which the first pressure roller and the second pressure roller are moved towards or away from the winding roller.

[007] The filter winding apparatus further comprises a support bearing rotationally arranged on the axle of the winding roller and configured to be able to move axial along the axle of the winding roller. The support bearing comprises four additional bearings arranged around the support bearing. The support bearing with its additional bearing provides additional support for winded cylindrical filter.

[008] The filter winding apparatus further comprises a filter preparation station. The station further facilitates preparation of layers for feeding into the filter winding apparatus. The filter preparation station comprises at least six shelfs, preferably eights, arranged one above each other and each shelf is configured to hold at least one layer of a filter to be made. The station comprises a ramp with first and a second end and the first end of the ramp is positioned at the lowest shelf from all shelfs and the second end of the ramp is positioned higher than the first end of the ramp. The highest second end of the ramp is positioned so that it is on approximately the same level with a winding roller of the filter winding apparatus. The filter preparation station further comprises wheels allowing to move the filter preparation station to the filter winding apparatus for loading the layers of the filter to be winded into the filter winding apparatus and away from the filter winding apparatus for loading the next layers of the next filter to be winded.

[009] In another embodiment of the invention the apparatus further comprises second pressure roller cylinder. The cylinder comprises a cylinder body and a piston with a piston rod. The cylinder body is hingedly connected to the frame and the piston rod is hingedly connected to the second end of the second lever, in result of which the movement of the piston rod of the cylinder allows to move the second pressure roller to and from the winding roller.

[010] The present invention also covers a method of manufacture of cylindrical filter using aforementioned filter winding apparatus. The method for manufacture of cylindrical filter comprises the following steps: a) providing a steel mesh having a first end and a second end; b) inserting first end of the steel mesh into a fixing groove of a winding roller; c) turning the winding roller by such a degree that the first end of the steel mesh at the fixing groove forms a fold; d) inserting a welding film between the partly winded steel mesh and the winding roller; e) pressing both rollers against the winding roller so that both rollers are pressed against the steel mesh on the winding roller; f) extending a movable section of the winding roller in direction away from the central axis of the winding roller therefore increasing the circumference of the winding roller; g) continuing rotation of the winding roller with the steel mesh for at least one turn so that the first cylinder of the steel mesh around the winding roller is formed; h) welding of the steel mesh to fix the formed first cylinder of the steel mesh; i) providing a set of filter layers arranged on the base steel mesh; j) welding the second end of the steel mesh with the first end of the base steel mesh of the set of filter layers; k) continuing rotation of the winding roller until all set of the filter layers is winded onto the winding roller; l) welding the second end of the base steel mesh onto already winded base steel mesh forming a multilayer cylindrical filter; and m) releasing the multilayer cylindrical filter from the filter winding apparatus.

[Oi l] The method step of releasing the multilayer cylindrical filter from the filter winding apparatus comprises the following steps: moving the movable section in direction to the central axis of the winding roller decreasing the circumference of the winding roller as well as retracting both rollers from the winding roller; and removing the formed multilayer cylindrical filter from the winding roller.

[012] The layers of the filter are arranged from each other with an offset so that the layers can be wind around the winding roller in uniform manner and form a cylindrical filter. The offset may be in the range of 30 to 70 mm, preferably about 50 mm.

[013] The step of providing a set of filter layers includes providing a set of filter layers comprising an additional layer of steel mesh, at least three layers of steel wool and at least three layers of high silica fibre glass webs. The layer of high silica fibre glass web is folded, forming a double high silica fibre glass web.

Brief description of the drawings

[014] The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments of the invention.

[015] Fig. 1 is a side view of principal schematics of a cylindrical filter winding apparatus.

[016] Fig. 2 is a front view of principal schematics of a cylindrical filter winding apparatus as seen in Fig. 1.

[017] Fig. 3 is a close up view of the cylindrical filter winding apparatus as seen in Fig. 1.

[018] Fig. 4 is a principal schematics of the cylindrical filter winding apparatus as seen in Figs. 1 to 3 together with a filter preparation station (30). [019] Fig. 5 is a close up view of the winding roller (2) with a first end (62) of the steel mesh (61) inserted into a fixing groove (22) of the winding roller (2).

[020] Fig. 6 illustrates a winding roller (2).

[021] Fig. 7 is a cross-section view A- A of the winding roller (2) as seen in Fig. 6, wherein a movable section (23) of the winding roller (2) is in a retracted position.

[022] Fig. 8 is a cross-section view A-A of the winding roller (2) as seen in Fig. 6, wherein a movable section (23) of the winding roller (2) is in a extended position.

[023] Fig. 9 is a side view of principal schematics of a cylindrical filter winding apparatus supplemented with a second pressure roller (10) cylinder (93).

Detailed description of the embodiments

[024] The preferred embodiments of the invention are now described with reference to the figures to illustrate objectives, advantages, and efficiency of the present invention.

[025] Figs. 1 to 5 illustrate a filter winding apparatus comprising a frame (1), a winding roller (2) and a pressure generating unit (3). The winding roller (2) rotationally connected to the frame (1) through its axle (21) and the winding roller (2) further comprising a fixing groove (22). The pressure generating unit (3) comprises a first lever (4) and a second lever (5). The first lever (4) has a first end (41), a second end (42) and a middle section (43) therebetween. The second lever (5) has a first end (51), a second end (52) and a middle section (53) therebetween. The middle section (43) of the first lever (4) is hingedly connected to the middle section (53) of the second lever (5) through the central lever hinge (6) forming scissor type connection. A first pressure roller (8) rotationally connected to the first end (41) of the first lever (4). A second pressure roller (10) rotationally connected to the first end (51) of the second lever (5). The filter winding apparatus further comprises a cylinder (9) having a cylinder body (91) and a piston rod (92). The second end (42) of the first lever (4) is connected to the piston rod (92) and the second end (52) of the second lever (5) is connected to the cylinder body (91) so that the movement of the piston rod (92) of the cylinder (9) provide a scissor type movement of both levers (4; 5), in result of which the first pressure roller (8) and the second pressure roller (10) are moved towards or away (A) from the winding roller (2). The apparatus also comprises a support bearing (11) rotationally arranged on the axle (21) of the winding roller (2) and configured to be able to move axial along the axle (21) of the winding roller (2). The support bearing (11) comprises four additional bearings (12) arranged around the support bearing (11). A winding motor (13) connected to the winding roller (2) through belt transmission and configured to rotate (R) the winding roller (2).

[026] Fig. 4 illustrates the filter winding apparatus together with a filter preparation station (30). The filter preparation station (30) comprises eight shelfs (31) arranged one above each other and each shelf (31) is configured to hold one layer of a filter to be made. The station (30) comprises a ramp (32) with first and a second end. The first end of the ramp (32) is positioned at the lowest shelf from all shelfs (31). The second end of the ramp (32) is positioned higher than the first end of the ramp (32). The filter preparation station (30) further comprises wheels (33) allowing to move (SM) the filter preparation station (30) to the filter winding apparatus for loading the layers of the filter to be winded into the filter winding apparatus and away from the filter winding apparatus for loading the next layers of the next filter to be winded. In preparation of a cylindrical filter the layers (60) are taken out from the shelfs (31) and arranged on the ramp (32) with an offset (69) from each layer. The offset (69) is kept within 30 to 60 mm.

[027] Figs. 6 to 8 illustrates the winding roller (2) in more detail. The winding roller (2) comprises a non-movable section (26), a movable section (23) and a hydraulic drive unit (24). The hydraulic drive unit (24) comprising three hydraulic cylinders (25) built in the winding roller (2) and connected between the movable section (23) and non-movable section (26). The three hydraulic cylinders (25) are interconnected by a common hydraulic line (27). The hydraulic drive unit (24) configured to move (M) the movable section (23) to and away from the central axis (X) of the winding roller (2) increasing or decreasing a circumference of the winding roller (2). The range of the move (M) is within 3 mm.

[028] Another embodiment of the invention is disclosed in Fig. 9. In addition to the apparatus as disclosed in Figs. 1 to 8 further comprises second pressure roller (10) cylinder (93). The cylinder (93) comprises a cylinder body (95) and a piston rod (94). The cylinder body (95) is hingedly connected to the frame (1) and the piston rod (94) is hingedly connected to the second end (52) of the second lever (5), in result of which the movement of the piston rod (94) of the cylinder (93) allows to move (A) the second pressure roller (10) to and from the winding roller (2). This arrangement allows to control the second lever (5) independently from the first lever (4).

[029] While the invention may be susceptible to various modifications and alternative forms, specific embodiments of which have been shown by way of example in the figures and have been described in detail herein, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention includes all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the following claims.