DE102014110340B4 - wire mesh unit - Google Patents

Abstract

Wire mesh unit (1) with at least one wire mesh layer (2) made of warp wires (3) and weft wires (4), the warp wires (3) and the weft wires (4) forming meshes (5) and spanning a mesh surface (6), characterized in that a pore size (7) of at least some of the meshes (5) of the wire mesh unit (5) is changed by a coating (8), the pore size (7) being specifically influenced by the coating (8) and thus set in a defined manner, the coating (8) being selectively formed on the mesh surface (6) and the coating (8) being applied more heavily to at least a first section (11) than to a second section (12).

Description

The present invention relates to a wire mesh unit with at least one wire mesh layer made of warp wires and weft wires, wherein the warp wires and the weft wires form meshes and span a fabric surface.

In particular, the wire mesh unit according to the invention is used as a filter unit for filtration and preferably for fine filtration. For example, the DE 295 07 080 U1 describes a molded part made of at least one layer of wire mesh that can be used in the field of filtration. The molded part is embedded in a hardened coating to prevent individual wires from coming loose from the mesh.

A wire mesh unit according to the invention can be used, for example, to filter the oil flow for an internal combustion engine. It can also be used to filter exhaust gases from combustion processes, for example.

Use in this area requires a seal on the edge of the filter or filter unit to prevent cross-flows or leaks. For this purpose, wire mesh and seals are used together with a holder. The production of such a filter unit is therefore complex.

Typically, the field of application of a wire mesh unit according to the invention is in the field of fine filtration for filtration with pore sizes starting at about 10 or 20 micrometers and ending at 300 micrometers or 400 micrometers.

It is therefore the object of the present invention to provide a wire mesh unit with which a simpler production of a filter unit is possible.

This object is achieved by a wire mesh unit with the features of claim 1 and by a filter unit with the features of claim 18. Preferred developments are the subject of the subclaims. Further advantages and features of the present invention emerge from the general description and the description of the embodiments.

A wire mesh unit according to the invention comprises at least one wire mesh layer made of warp wires and weft wires. The warp wires and the weft wires form meshes and span a mesh surface. A pore size of at least some of the meshes of the wire mesh unit is changed by a coating. The pore size is specifically influenced by the coating and thus set in a defined manner. Furthermore, the coating is selectively formed on the mesh surface, with the coating being applied more heavily on at least a first section than on a second section.

The wire mesh unit according to the invention has many advantages. A significant advantage is that the pore size of the mesh can be specifically influenced after weaving and thus defined. This makes it possible to set very fine and very fine pores even when using relatively thick warp and weft wires, without using correspondingly fine wires.

The wire mesh layer or a wire mesh layer of a wire mesh unit according to the invention can have a wide variety of weave types. The mesh can have open meshes and thus have open through holes perpendicular to the surface. However, it is also possible for the meshes to be tightly woven. The wire mesh layer can be designed as a weft mesh, which only results in skewed open pores, while the wire mesh layer perpendicular to the mesh surface is opaque. This means that the mesh size can be reduced to 0. Due to the three-dimensionality of a wire mesh, a weft mesh also results in open pores with a small opening width, although the open pores are then aligned at an angle to the mesh surface.

In many cases, a large open area or a high proportion of open area in relation to the filter area is required for filter applications. The wire thickness of the warp wires and weft wires can basically be any. Warp wires and weft wires of the same or different thicknesses are possible.

Particularly preferably, in the wire mesh unit according to the invention, the pore size of only some of the meshes of the wire mesh unit is deliberately changed. The pore size of at least some of the meshes can be deliberately reduced to zero so that flow is prevented there.

It is also preferred that the pore size of at least some of the meshes is changed differently than the pore size of other meshes. For example, some pores can be specifically provided with a coating, while the wires of another mesh remain uncoated, so that the original pore size is retained. However, it is also possible that the wires on some meshes are coated with be provided with a stronger coating than the wires of another fabric mesh.

A galvanic process is particularly preferred for coating. This means that the coating is preferably designed as a galvanic coating. However, another type of coating is also possible, for example a paint coating or another plastic coating or the like.

A galvanic coating offers considerable advantages, as the thickness of the coating can be adjusted very precisely and finely by the duration of the galvanic treatment and the other conditions. This means that, for example, in the case of particularly fine wire mesh layers, the mesh size can be reduced from 20 micrometers to 15 micrometers or similar. It is also possible to adjust the pore size of a mesh with an original mesh size of 70 micrometers to 65 micrometers or 60 micrometers or similar.

According to the invention, the coating is applied selectively to the fabric surface or the coating is formed selectively on the fabric surface, with the coating being applied more heavily to at least a first section than to a second section. In this case, no coating at all can be provided in the second section. It is also possible for the wire mesh layer as a whole to have a first coating layer and for sections of the wire mesh layer to have a second selectively applied coating layer.

In particular, the coating is only applied to sections of the wire mesh layer. This opens up many possibilities, as sections of the wire mesh layer have different pore sizes.

In particularly preferred developments, at least some of the meshes are closed by coating material. The coating material is particularly preferably applied in such a way and thickness that the coating enables a seal. As a result, the coating can provide a sealing function through the wire mesh unit in the first section. The coating can also prevent cross-flows. The coating can also enable a tight fit to another component in the transverse direction.

In particular, the meshes are closed by the coating so that there is a pore size of 0. For example, on a certain section of the wire mesh layer, the pore size can be specifically adjusted by, for example, a galvanic coating, and on another section of the wire mesh unit, the pores are closed by the coating so that certain filter areas or filter sections are created.

In preferred developments, the wire mesh unit is compacted in at least one area. For example, the wire mesh unit can be compacted by rolling, local pressing and/or calendering. It is possible and preferred that the local compaction of the wire mesh unit in one area locally closes the pores there.

This means that after the weaving process and the subsequent coating, a small pore size still remains, which is then reduced in the compacted area in such a way that the wire mesh unit offers a closed surface in this area. Such measures enable the wire mesh unit to provide one or more filter sections and at the same time to provide a fluidically tight receiving area or receiving section, with which the wire mesh unit can be tightly fastened.

In preferred developments, the compacted area is in particular punched, partially pressed or pressed and/or provided with the coating. The coated area can be subsequently compacted or the coated area is punched or partially pressed. The compacted area can serve as a seal.

In preferred developments, the coating has two or more coating layers at least in sections. For example, a central filter area can have only one coating layer, while a sealing section has several coating layers, so that the pores of the fabric mesh are completely closed there.

In particular, the wire mesh layer has at least one filter section on the fabric surface. Several filter sections are also possible. The wire mesh unit particularly preferably has open pores on the filter section and closed pores on a holding section adjacent to the filter section. It is possible and preferred that the holding section surrounds the filter section.

Such a design enables a flexible, easy-to-manufacture wire mesh unit in which both a filter section and the holding section required for holding are formed on the mesh surface. provides a flow-tight fabric section.

Preferably, at least one recess is provided on the fabric surface for fastening or aligning the wire mesh layer.

The wire mesh unit can have a material reservoir provided by the coating, which can serve, for example, as a solder reservoir for contacting other components. For example, such a material can be provided for soldering the wire mesh layer to another electrical component.

In preferred developments, the coating has at least one coating layer which consists at least substantially of catalytic materials. In particular, the coating layer or at least one coating layer consists of nickel, chromium, gold, silver, copper, titanium, platinum, palladium or tin. A combination of the materials listed is also possible.

A thickness of the coating is preferably between 1 micrometer and 500 micrometers and particularly preferably between 1 micrometer and 200 micrometers.

In all cases, at least some of the wires in the wire mesh layer preferably consist of at least one metal. Particularly preferably, all devices in the wire mesh layer consist of metal. However, it is also possible for at least some of the wires in the wire mesh layer to consist of a non-metal. Preferably, the wires made of non-metal have an electrically conductive surface coating. Then the wires made of non-metal can also be provided with a galvanic surface coating. The cross-section of the wires can be round or square or designed in some other way. In principle, any contour is possible. For optimally reproducible filter conditions, homogeneous wires are preferably used along their length.

It is possible and preferred that the wire mesh unit comprises a layer composite of at least two wire mesh layers. The two wire mesh layers can be connected to one another using, for example, a galvanic coating. The wire mesh layers of a layer composite can have different mesh parameters and have different mesh sizes, wire diameters, pitches, etc. Two wire mesh layers can also be made of different materials. The orientation of two wire mesh layers to one another can be different. For example, the warp wires of two wire mesh layers can be aligned parallel to one another or at any angle to one another.

In all cases, at least some wires may consist of monofilaments or multifilaments.

With the present invention, the pore size is reduced in a targeted manner by galvanically coating the fabric. Sufficient material is applied in certain areas so that it is possible to create a sealing surface by compacting it. This provides a fine filter surface on the one hand and a dense receiving surface for the wire mesh unit on the other. The effort required to produce a filter unit is significantly reduced because the wire mesh unit is both a receiving surface and a filter.

Coating the wire mesh layer does not fundamentally change the material properties of the mesh wires, but rather specifically adjusts the filter properties. The coating can also provide corrosion protection, for example. An additional separate sealing lip, which in the prior art often has to be molded onto the mesh with plastic or the like, can be omitted with the present invention, since the wire mesh unit can be designed to be locally sealed. The wire mesh unit can be coated with a wide variety of metals in one or more layers.

By applying the coating, the pore size can be reduced in a targeted and reproducible manner, for example to 5 micrometers. The pore is then completely closed by edge compaction. Preferably, the wire mesh layer is produced first and then coated, in particular by galvanization. This can then be followed by pressing or calendering or the like in order to seal holding sections or the like.

The use of such a filter unit is suitable, for example, in the oil flow of the engine in order to reliably filter the fuel.

The selective coating of a wire mesh layer on the mesh surface enables the use as a filter unit, which eliminates the need for a separate holder and a separate seal.

The stability of the wire mesh layer can also be increased by a galvanic surface coating. For example, a nickel layer can be applied to increase stability. and then a copper layer to selectively seal the pores, e.g. after a pressing process.

Preferably, a coating layer is selectively applied which is so soft that after a pressing process the coating layer enables a tight seal. Cross-flows are then also reliably prevented. This means that the wire mesh unit can be used directly as a filter unit. The wire mesh unit provides the holder, the receptacle and the filter. A separate seal is not necessary.

A filter unit according to the invention consists of a wire mesh unit with at least one wire mesh layer made of warp wires and weft wires, the warp wires and the weft wires forming meshes and spanning a mesh surface. A pore size of at least some of the meshes of the wire mesh unit is changed by a coating.

The wire mesh layer of the filter unit has in particular at least one filter section on the mesh surface. Open pores are preferably provided on the filter section. The pores are in particular closed on a holding section surrounding the filter section. The holding section serves to hold the filter unit. At least one recess for fastening or aligning the filter unit is preferably provided on the mesh surface. In particular, the holding section can be compacted as a whole or in certain areas.

In further developments, the wire mesh unit is designed according to one or a combination of several of the previously described embodiments.

The invention can also be used to provide a wire mesh unit with a defined, changed pore size. The pore size depends on the wire diameters of the warp and weft wires. For example, fine pores cannot be achieved with thick wires because the woven wire can only be deformed to a limited extent. In an open, uncoated mesh, the mesh size cannot generally be smaller than the diameter of the woven wire (warp wire or weft wire).

For example, very thin wires are generally used to manufacture fine wire mesh units in order to provide a large open filter surface with defined pore sizes. Wire mesh with a mesh size of 20 micrometers and a wire diameter of 20 micrometers, for example, has a mesh count of 635. This means that there are 635 warp and weft wires per inch of length or width of the wire mesh. Weaving such a fine wire mesh is very complex and takes a lot of time. This is why conventional fine and very fine wire mesh is not cheap to manufacture. If the filter fineness is to be even lower, even thinner wires with a diameter of 16 µm or, for example, 14 µm can be used. However, this increases the manufacturing effort even further. In addition, the manufacturing process is significantly more prone to errors because, for example, with a mesh width of just 100 mm, 2500 individual warp wires have to be fed to the weaving machine in a precisely defined manner. If just one wire is threaded or guided incorrectly, the fabric will have a continuous weaving error and may be unusable. The invention can be used to reduce the pore size in a defined manner without changing the strength or thickness of the warp wires and weft wires. The invention also makes it possible to provide a wire mesh unit with which the filter fineness of ultra-fine fabrics can be increased.

Further advantages and features of the present invention will become apparent from the embodiments which are explained below with reference to the accompanying figures.

• 1 eine schematische Draufsicht auf eine als Filtereinheit ausgebildete Drahtgewebeeinheit;
• 2 einen schematischen Querschnitt durch die Drahtgewebeeinheit nach 1;
• 3 einen stark schematischen Querschnitt durch eine Drahtgewebelage;
• 4 einen weiteren stark schematischen Querschnitt durch eine andere Drahtgewebelage;
• 5 eine stark schematische Draufsicht auf eine Drahtgewebeeinheit; und
• 6 eine weitere schematisch dargestellte Drahtgewebeeinheit mit zwei Drahtgewebelagen.

In the figures show:

• 1 a schematic plan view of a wire mesh unit designed as a filter unit;
• 2 a schematic cross-section through the wire mesh unit according to 1 ;
• 3 a highly schematic cross-section through a wire mesh layer;
• 4 another highly schematic cross-section through another layer of wire mesh;
• 5 a highly schematic plan view of a wire mesh unit; and
• 6 another schematically shown wire mesh unit with two wire mesh layers.

With reference to the figures, embodiments of the invention are explained below, wherein 1 a schematic plan view of a wire mesh unit 1 designed as a filter unit 100. The filter unit 100 or the wire mesh unit 1 here consists of a wire mesh layer 2, which provides a first section 11 and a second section 12 on the mesh surface 6.

The wire mesh unit 1 has a filter section 22 as the first section 11 and a holding section 21 as the second section 12. Here, the wire mesh unit 1 consists of the holding section 21 and the filter section 22. Two recesses 16 are made in the holding section 21 in order to receive the filter unit 100 in a defined manner on another component and to fasten it there by means of screws or the like, for example.

The wire mesh unit 1 basically has an initially homogeneous wire mesh layer 2, which consists of meshes 5 over the entire surface of the mesh 6, which are formed by warp wires 3 and weft wires 4.

After weaving the wire mesh layer 2, the wire mesh layer 2 is locally selectively provided with a coating 8 (cf. 5 ) in order to specifically influence the pore size 7 of the fabric mesh 5 in the first section 11 and the second section 12. Here, so much material is coated in the holding section 21 that after the subsequent compaction process in the second section 12, the pore size 7 is reduced to 0, so that the holding section 21 is designed to be fluidically tight.

Such a filter unit 100 is very advantageous because it practically consists of only one component manufactured in one piece, namely the wire mesh layer 2, which is selectively coated. The second section is then compacted.

The pores 9 on the filter section 22 are open, while the dashed-circled pores 10 in the holding section 21 are closed.

2 shows a sectioned side view of the filter unit 100 according to 1 The filter unit 100 consists of a wire mesh unit 1. The section 12 as a holding section 21 is compacted so that a thickness of the wire mesh layer 2 in the section 12 is reduced by preferably 10% to 40%. The compaction further increases the sealing effect. In addition, the rigidity in the section 12 is increased. At least one recess 16 can be formed on the holding section 21 in order to facilitate screwing or fastening to other components. Two recesses 16 can be used to determine the orientation of the filter unit.

3 shows a schematic cross-section through a wire mesh layer 2, with the warp wires shown in hatched lines. In the example shown here, wires 25 made of non-metal and wires 26 made of metal are provided, which are alternately provided as warp wires. However, it is also possible for all warp wires to be made of metal or possibly also of non-metal. If a galvanic coating is to be applied, it is advantageous if non-metallic wires are first provided with a metallic surface coating.

In the outer areas of the 3 The second section 12 is located in each of the wire mesh layers 2 shown, to which a coating layer 14 has been galvanically applied to the wire mesh layer 2. The first section 11 is provided in the central area, which serves, for example, as a filter section 22 and in which open pores 9 are provided. In order to prevent galvanic coating in the first section, a varnish or other mass that prevents galvanic deposition can be applied there before the galvanic bath.

4 shows a further variant of a wire mesh layer 2, wherein here in the lateral second section 12 two separate coating layers 14 and 15 are applied as coating 8. Here too, the central area with the first section 11 is formed without coating.

5 shows a highly schematic plan view of another wire mesh unit 1 according to the invention, which is used as a filter unit 100.

The wire mesh unit 1 consists of a wire mesh layer 2, which comprises warp wires 3 and weft wires 4. In the central area, a first section 11 is provided as a filter section 22. Open pores 9 are provided on the meshes 5 in the filter section 22.

In the holding section 21 which is outer here and surrounds the filter section 22, closed pores 10 are provided which were closed by the application of the coating 8 and/or by a subsequent post-treatment.

As a result, the wire mesh layer 2 serves as a filter layer. The filter unit 100 can be attached to the holding section 21, wherein the holding section 21 is sealed. Further sealing is generally not required.

In 5 the filter section 22 is shown with two differently designed pores, namely on the one hand with pores 9 in which the associated fabric mesh is provided with a surface coating with a thickness of 18, so that the remaining pore size 7 is specifically adjusted. In addition, the filter section 22 here has completely uncoated pores 9, the pore size 7 of which is correspondingly larger.

However, it is also possible that no coating 8 or a smaller coating 8 is applied in the area of the filter section 22, so that a correspondingly larger pore size 7 remains.

The individual wires 3, 4 of the wire mesh layer 2 can be designed as monofilaments. However, it is also possible to use multifilaments 24, as shown in the bottom right of 5 is indicated as an example. The entire filter surface or the entire wire mesh layer can consist of multifilament wires.

6 finally shows a further variant of a wire mesh unit 1 according to the invention, which consists of two wire mesh layers 2. The two wire mesh layers are connected to one another via the coating 8. This creates a layer composite 20. In the central area, a filter section 22 is again provided, which is surrounded towards the edge by a holding section 21.

Overall, the present invention provides a flexibly applicable wire mesh unit 1, which can be used in particular as a filter unit 100.

List of reference symbols:

1

wire mesh unit

2

wire mesh layer

3

wire, warp wire

4

wire, weft wire

5

fabric mesh

6

tissue surface

7

pore size

8

coating

9

pore, opened

10

pore, closed

11

first section

12

second section

13

coating material

14

coating layer

15

coating layer

16

recess

17

material reservoir

18

thickness

19

surface coating

20

layered composite

21

stopping section

22

filter section

23

filter section

24

multifilament

25

wire (non-metal)

26

wire (metal)

100

filter unit

Claims (18)

Wire mesh unit (1) with at least one wire mesh layer (2) made of warp wires (3) and weft wires (4), the warp wires (3) and the weft wires (4) forming meshes (5) and spanning a mesh surface (6), characterized in that a pore size (7) of at least some of the meshes (5) of the wire mesh unit (5) is changed by a coating (8), the pore size (7) being specifically influenced by the coating (8) and thus set in a defined manner, the coating (8) being selectively formed on the mesh surface (6) and the coating (8) being applied more heavily to at least a first section (11) than to a second section (12). Wire mesh unit after claim 1 , wherein the coating (8) is designed as a galvanic coating. Wire mesh unit (1) according to one of the preceding claims, wherein the coating is applied only in sections to the wire mesh layer (2). Wire mesh unit (1) according to one of the preceding claims, wherein at least some meshes (5) are closed by coating material (13). Wire mesh unit (1) according to one of the preceding claims, wherein the wire mesh unit (2) is compacted in at least one region. Wire mesh unit (1) according to one of the preceding claims, wherein the compacted region is punched, partially pressed or pressed and is provided with the coating (8). Wire mesh unit according to one of the preceding claims, wherein the coating (8) has at least partially a plurality of coating layers (14, 15). Wire mesh unit (1) according to one of the preceding claims, wherein the wire mesh layer (2) on the fabric surface (6) has at least one filter section (22, 23). Wire mesh unit (1) according to one of the preceding claims, wherein open pores (9) are formed on the filter section (22) and the pores (10) are formed closed on a holding section (21) surrounding the filter section. Wire mesh unit (1) according to one of the preceding claims, wherein at least one recess (16) for fastening or aligning the wire mesh layer (2) is provided on the mesh surface (6). Wire mesh unit (1) according to one of the preceding claims, comprising a solder reservoir (17) provided by the coating (8). Wire mesh unit (1) according to one of the preceding claims, wherein the coating (8) has at least one coating layer (14) which consists at least substantially of catalytic materials and in particular of nickel, chromium, gold, silver, copper, titanium, platinum, palladium or tin. Wire mesh unit (1) according to the preceding claim, wherein a thickness (18) of the coating (8) is between 1 µm and 500 µm. Wire mesh unit (1) according to the preceding claim, wherein at least some wires (26) of the wire mesh layer (2) consist of a metal. Wire mesh unit (1) according to one of the two preceding claims, wherein at least some wires (25) of the wire mesh layer (2) consist of a non-metal and/or have an electrically conductive surface coating (19). Wire mesh unit (1) according to one of the preceding claims, wherein at least two wire mesh layers (2) are connected to form a layer composite (20). Wire mesh unit (1) according to one of the preceding claims, wherein at least some wires consist of monofilaments or multifilaments (24). Filter unit (100) comprising at least one wire mesh unit (1) according to one of the preceding claims.

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