The manufacturing process of sub-HEPA (High-Efficiency Particulate Air) air filters is a complex and intricate endeavor, encompassing multiple crucial steps to guarantee the final product's performance and quality. Below is a detailed introduction to the manufacturing process of sub-HEPA air filters:
I. Preliminary Preparation
Needs Analysis: Determine the specific specifications and performance parameters of the filter based on factors such as the operating environment, airflow volume, and filtration efficiency requirements.
Material Selection:
Filter Media: Choose materials with high filtration efficiency, low resistance, and good wear resistance, such as polypropylene fibers and glass fibers, which are processed into filter membranes through melt-blown technology.
Frame Materials: Select high-strength aluminum profiles or iron wires to construct the frame, supporting the filter media and ensuring stability.
Sealing Materials: Opt for high-quality sealants or sealing strips to ensure the filter's sealing performance.
II. Structural Design
Layout Design: Conduct a rational layout design based on the needs analysis results, ensuring the device's ventilation and sealing properties.
Filter Media and Frame Design: Design the dimensions, shapes, and quantity of filter media according to their characteristics and the filter's specifications. Additionally, design the frame's structure and connection methods to ensure the filter media is securely fixed to the frame.
III. Production and Manufacturing
Machining of Aluminum Profiles and Iron Wires:
Cut aluminum profiles and iron wires using aluminum cutting machines and manual cutting tables.
Straighten and bend aluminum profiles and iron wires with straightening machines, manual bending machines, and manual punches.
Weld aluminum profiles and iron wires using welding machines to form the inner and outer frames.
Filter Media Processing:
Cut filter media into appropriate sizes.
Fold filter paper into a corrugated shape using medium-efficiency filter media folding machines or high-efficiency filter paper folding machines to enhance filtration effectiveness.
Weld multiple layers of filter paper together, often using ultrasonic welding due to their plastic nature.
Assembly:
Install the processed filter paper into the formed inner frame.
Roll-press aluminum foil into corrugations using an aluminum foil corrugating machine and assemble it with the filter paper within the inner frame to reinforce the filter's support strength.
Install other internal components, such as partition plates and sealing strips.
Gluing and Fixing:
For filters requiring higher sealing performance, apply sealant (e.g., M-313 sealant) to the filter's frame joints and where the filter paper meets the frame.
Mix the sealant in a mixer and manually apply it to the filter, allowing it to cure naturally.
IV. Quality Inspection
Visual Inspection: Check the filter's appearance for flatness, damage, and stains.
Performance Testing: Conduct tests on the filter's filtration efficiency, resistance, and sealing performance to ensure all specifications meet design requirements. Special attention is given to filtration efficiency, as sub-HEPA filters must effectively trap large particles, dust, smoke, and other pollutants from the air.
V. Packaging and Labeling
Package qualified filters and label them with information such as product name, specifications, production date, and manufacturer for traceability and management.
VI. Usage and Maintenance
Installation: Follow the installation instructions to correctly install the filter in the intended environment.
Maintenance: Regularly inspect and maintain the filter, including cleaning the filter media and replacing damaged components, to ensure long-term stable operation.
In summary, the manufacturing process of sub-HEPA air filters involves preliminary preparation, structural design, production and manufacturing, quality inspection, packaging and labeling, as well as usage and maintenance. Each step requires rigorous quality and performance control to ensure the filter's filtration efficiency and service life.
Hot Tags: sub-hepa (high-efficiency particulate air filters, China sub-hepa (high-efficiency particulate air filters manufacturers, suppliers, factory, High Efficiency Air Filter without Partition, Microporous PP Folded Filter Element, Y Type Pipeline Filter, Medium Alkali Free Expanded Filter Material, Membrane Covered Dust Removal Filter, Gearbox Filter Element Hydraulic Oil Filter