JP3301227B2 - Filter manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a filter made of nonwoven fabric.

[0002]

2. Description of the Related Art An intake system of an internal combustion engine such as an automobile engine is provided with an air filter for removing dirt, dust and the like contained in the intake air. The air filter includes a housing including a case and a cap, and a filter mounted in the housing.

[0003] The above-mentioned filter comprises a filter element formed by folding a filter medium made of non-woven fabric into a shape called pleated, corrugated, or pleated, and a resin for holding the outer periphery of the filter element and assisting the mounting of the filter in a housing. It consists of a frame. Further, a seal member made of rubber is provided on the outer periphery of the resin frame in order to secure a sealing property between the resin frame and the housing. That is, the filter can be mounted on the housing by the resin frame and the seal member.

[0004] A conventional method for manufacturing the above-mentioned filtration element will be described below. First, a filter medium fiber made of polyester, rayon, or the like is laminated on a sheet-like base fabric manufactured by a spunbonding method described below. The base cloth on which the filter medium fibers are laminated is subjected to a fiber bonding process by needle punch, and the fibers are entangled between the base cloth and the filter medium fibers, and the filter medium fibers are bonded to each other. Next, the base cloth and the filter medium fibers are impregnated with a binder and dried.
Thereby, a sheet-like filter medium is obtained. Next, the filter medium is fold-folded and cut to a desired length. Then, a resin frame and a sealing member molded in a separate process are assembled to the filtration element to form a filter.

[0005]

However, in the above filter, the filter element, the resin frame, and the seal member must be manufactured as separate parts made of different materials. Further, the process of manufacturing the filter element as the material of the filter element and the step of forming the filter element from the filter medium are completely different steps. For this reason, the production of the conventional filtration element is complicated and time-consuming. For the above reasons, the manufacturing cost increases.

Further, when a filter element is formed from a filter medium, the fiber is compressed inside the bent portion, so that air cannot pass through, and the filtering performance is reduced.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method of manufacturing a filter which can be manufactured at low cost, is made of the same material, and has excellent filtration performance.

[0008]

SUMMARY OF THE INVENTION The present invention relates to a filter medium fiber to be obtained.
Consists only, using a mold having a corrugated mold surface along the shape of one side of the filter corrugated body, wavy forming die
Supply and attach only the filter media fibers to the surface of the filter media
A filter medium fiber supplying step of forming a first intermediate composed of only fibers, a fiber bonding step of coupling filter medium fibers in the first intermediate to each other to form a second intermediate composed of only filter medium fibers , Press the intermediate from above and below,
A method for producing a corrugated body filter comprising only filter medium fibers, comprising a forming step of forming a desired corrugated body filter shape (first method).

The corrugated surface of the molding die is a portion where the filter media fibers are laminated to form a first intermediate composed of only the filter media fibers. The shape is a convex portion or a concave portion along the shape of one side surface of the corrugated filter to be obtained.
For example, when the method for supplying the filter medium fibers described later is a wet method, the mold surface becomes a concave portion, and when the method is a dry method, it becomes a convex portion.

Next, the method for supplying the filter medium fibers is roughly classified into a wet method and a dry method. The wet method is almost the same as the papermaking method. That is, the filter medium fibers are uniformly suspended in water, and the fibers are scooped with the above-mentioned mold to form a first intermediate on the mold surface.

The dry method includes, for example, an air raid method and a card method. In the air laid method, a fiber mass as a raw material is defibrated to generate fibers. After the fibers are scattered in the air, the fibers are collected on a molding die by an air current and molded. The card method is a method of using a carding machine to collect fibers formed from a fiber mass on a forming die and forming the fibers.

In the above-mentioned filter medium fiber supplying step, a base cloth may be previously formed on a molding die by a spun bond method or a melt blow method, and the filter medium fibers may be laminated on the base cloth. In this case, since the strength of the first intermediate is improved by the base cloth, handling when the first intermediate is removed from the mold becomes easy. Therefore, the first intermediate can be easily moved to a mold described later, and the workability is improved.

The spunbonding method is a method in which high-temperature filter medium fibers are directly accumulated from a spinning machine and supplied to a forming die. At this time, the filter medium fibers are in a semi-molten state, so that the filter medium fibers fuse at the contact points with each other to form a nonwoven fabric. The melt blow method is a method in which a filter medium fiber generated from a spinning machine is blown off by an air current and collected in a molding die. As described above, since the filter medium fibers are in a semi-molten state, they come into contact with each other to form a nonwoven fabric.

In the above-mentioned filter medium fiber supplying step,
By sequentially supplying a plurality of types of different filter media fibers, a density gradient type nonwoven fabric can be formed. Thereby, the filtration performance of the filter is improved. As the filter medium fiber, for example, polyester, polypropylene, rayon, glass, acetate and the like are used.

The fiber bonding step is a step of integrally bonding the fibers in the first intermediate made of only the filter medium fibers, for example, by intertwining the filter medium fibers that are merely laminated. The fiber bonding method in the above step is performed by mechanical bonding .

The above-mentioned mechanical connection means that the fibers in the first intermediate are entangled by a mechanical action and entangled with each other. In the case of using a needle to entangle the fibers, there are a needle punch method, a spunlace method using a jet stream, a water jet punch method, and a stitch bond method in which the fibers are sewn with a filament thread. Among the various joining methods described above, the spunlace method and the water jet method are most preferable. This is because the jet water stream can be jetted from multiple directions in order to uniformly and integrally bond the fibers of each part of the filter having the unevenness.

[0017]

[0018]

The forming step is a step of completely connecting the filter medium fibers and forming a first intermediate consisting only of the filter medium fibers into a filter shape. In the above forming process, the same shape of the filter
A press mold having a wavy cavity is prepared, and a second intermediate is arranged in the cavity. Then, the second intermediate is subjected to a heat press treatment. As a result, the fibers of the filter medium in the intermediate body are bonded to each other to form a non-woven fabric. Therefore, a completed filter can be obtained.

It is preferable that the mold is a porous body. In this case, various fluids such as air and water used when supplying the filter medium fibers can freely pass through the mold, and only the filter medium fibers can be efficiently laminated on the mold. Examples of the porous body include a net-like body such as a wire net, a perforated plate having a large number of fine holes, and a coarse filter cloth.

As an example of the filter manufactured by the above-described manufacturing process, a filter having a plurality of corrugated bags and a collar provided on the outer periphery of the filter are provided. In addition, there is a filter in which the base material of the brim portion is made of the same nonwoven fabric.

Next, a method of manufacturing a filter different from the first method will be described below. That is, this manufacturing method
A corrugation processing step of forming a sheet consisting only of the filter medium fibers into a corrugated body, a side closing step of pressing both sides of the corrugated body to form a large number of corrugated bags, and joining the filter medium fibers of the corrugated body and fiber bonding step, it since only the filter media fiber, characterized by comprising further a forming step of forming the shape of the filter corrugated body desired by pressing the corrugated member in the vertical direction
This is a method of manufacturing a wavy filter (second method).

The above-mentioned sheet of filter medium fibers is a sheet in which filter medium fibers are accumulated in a flat plate shape by, for example, an air laid method or a card method, and is not subjected to the above-mentioned various fiber bonding steps. The wavy processing step is performed by, for example, bending the sheet. In the side part closing step, the corrugated side part is pressed with, for example, a roller or the like, and both side parts of the corrugated body are closed with the filter medium fibers.

Hereinafter, the fiber bonding step and the forming step are the same as those in the first method. Also in this manufacturing method, it is preferable that the bonding of the filter medium fibers in the fiber bonding step be performed by mechanical bonding , as in the first method described above. According to the present manufacturing method, a filter of a corrugated body, which has a large number of corrugated bags and is made of only filter media fibers having excellent filtration performance, can be produced easily and inexpensively from the same material.

Further, a method of manufacturing a filter different from the above-described manufacturing method will be described below. That is, this manufacturing method
A cutting step of cutting a sheet made of only the filter medium fiber into a filtering section and a brim section; a wavy processing step of processing the filtering section into a wavy body; and integrally bonding the brim section to a peripheral edge of the wavy body. A step of bonding a brim portion, a fiber bonding step of bonding the filter material fibers of the corrugated body, and a forming step of pressing the corrugated body in a vertical direction to form a filter of a desired corrugated body. Waves consisting only of filter media fibers
In the method for manufacturing a filter for a body (third method).

That is, in this manufacturing method, each part of the filter is separately formed from a sheet of the filter medium fiber, and these are joined to form a first intermediate. In the present manufacturing method, when the corrugated bag of the filter to be obtained has a corrugated body and a side plate, the side plate is bonded to the side surface of the corrugated body in the brim bonding step. Perform the operation.

The above cutting step is performed by a cutting tool such as a cutter. In addition, the bonding process of the brim portion uses a bonding method in which an adhesive, hot melt, and fibers are heat-welded. Less than,
The fiber bonding step and the forming step are the same as those in the first and second methods. Also, in the present manufacturing method, it is preferable that the bonding of the filter medium fibers in the fiber bonding step is performed by mechanical bonding , as in the above-described first and second methods. According to the present manufacturing method, a filter of a corrugated body, which has a large number of corrugated bags and is made of only filter media fibers having excellent filtration performance, can be produced easily and inexpensively from the same material.

[0028]

[Operation and Effect] The filter medium fiber of the first method of the present invention is used.
The method of manufacturing a filter composed of only a corrugated body comprises a filter medium fiber supply step, a fiber bonding step, and a molding step, wherein the filter medium fiber supply step has a corrugated mold surface along one side of a desired filter. By using a molding die and supplying filter media fibers to the molding die, a first intermediate of a filter consisting of only the filter media fibers is formed.

That is, according to the present method, as in the conventional example, each part of the filter made of a different base material is created as a separate part.
Then, it is not a method of assembling these into a filter. According to the present method, a filter composed of only the filter medium fibers can be manufactured by forming the first intermediate integrated in the shape of the filter to be obtained by the filter medium fibers. Therefore, the manufacturing process of the filter is extremely simplified, and the manufacturing cost is reduced.

In the present method, after the filter medium fiber is formed into the approximate shape of the corrugated filter, a fiber bonding step is performed on the filter medium fiber. For this reason, in the obtained filter, the fiber structure of the bent portion becomes uniform, and the bag-like side portion can be effectively used for filtration, so that the filtration performance can be improved. The same effect can be obtained in the second and third methods.

As described above, according to the present invention, it is possible to provide a filter manufacturing method which can be manufactured at low cost, is made of the same material, and has excellent filtration performance.

[0032]

【Example】Reference Example 1 Reference example FIGS. 1 to 5 show a method of manufacturing a filter according to the present invention.
This will be described with reference to FIG. That is, as shown in FIG.
Of the filter 1 (see FIG. 5) along the shape of one side
Using a mold 2 having a surface, the surface of the mold 2 has three types
And supply filter media fibers 11, 12, 13
Filter medium fiber supplying step of forming the first intermediate body 101 by attaching
I do.

Next, as shown in FIGS. 1 and 2, a fiber bonding step of forming the second intermediate 102 by bonding the filter media fibers 11, 12, 13 in the first intermediate 101 to each other is performed. This fiber bonding step uses two bonding methods as described later. Then, as shown in FIG. 2, finally, a molding step of pressing the second intermediate body 102 from above and below to form the filter 1 into a desired shape is performed. Hereinafter, these will be described in detail.

First, the filter medium fiber supply step will be described. As shown in FIG.
A mold 2 having the same shape as the lower surface side (inside) of (see FIG. 5) and made of a metal net is prepared. Next, FIG.
As shown in the figure, three different filter media fibers 11, 12, 1
3 are sequentially laminated on the molding die 2 by using an air raid method. In the air laid method, a fiber mass as a raw material is defibrated to generate fibers. After the fibers are scattered in the air, the fibers are collected on a molding die 2 by an air current and formed.

At this time, the finest filter media fibers 11 are
Next, the thickest filter medium fibers 13
Is laminated on the upper layer. The filter medium fiber 11 is composed of 30% (weight%, the same applies hereinafter) of rayon having a thickness of 1.5 denier and 70% of rayon having a thickness of 2 denier, and the supply amount per unit area to the mold 2 is 80 to 100 g / m ^2. It is.

The filter medium fibers 12 are made of 70% polyester having a thickness of 1.5 denier and 30% polyester having a thickness of 2.5 denier.
%, The supply amount to the mold 2 is 40 to 60 g / m ^2.
It is. The filter medium fiber 13 is made of 60% polyester of 2 denier and 40% of 6 denier polyester.
The amount supplied to the mold 2 is 25 to 45 g / m ² .

Thus, the first intermediate 101 is formed. As shown in an enlarged view of FIG. 3, the first intermediate body 101 is formed by sequentially laminating filter medium fibers 11, 12, and 13, and is in a soft state.
It is placed on the mold 2 as it is.

Next, the fiber bonding step and the molding step will be described. The fiber bonding step in this example is a combination of mechanical bonding and adhesive bonding. First, as shown in FIG. 1C, the first intermediate body 101 is mechanically bonded by a water jet punch method as a first bonding method. That is, the first intermediate 101
The jet water flow 19 is applied so that the jet density becomes 35 to 45 nozzles / cm ² . As a result, the filter medium fibers 11, 12, and 13 are entangled with each other, and the second intermediate 1
02. Note that FIG.
FIG. 2 shows an enlarged cross-sectional view of the second intermediate body 102.

Next, with respect to the second intermediate 102, 2
Adhesive bonding is performed as the second bonding method. That is, FIG.
As shown in (A), a water-soluble acrylic resin as the adhesive 18 is sprayed on the second intermediate 102. After that, the second intermediate body 102 is dried and removed from the mold 2.

Finally, as shown in FIG. 2B, the second intermediate body 102 containing the acrylic resin is placed in the molds 21 and
Using 2, the hot press is performed on the second intermediate from above and below. The mold cavity 20 has the same shape as the filter 1 to be obtained. The filter 1 having a large number of corrugated bag portions 15 (FIG. 5) is obtained by the hot pressing. After completion of the heat press, as shown in FIG.
Remove filter 1 from 1 and 22.

Next, FIG. 5 shows a filter 1 manufactured by the manufacturing method of this embodiment. The filter 1 of the present embodiment is formed by integrally forming a frame part on the outer periphery of the so-called filtration element itself, which retains its shape, with the same material, and is collectively referred to as a filter including the filtration element and the frame. The filter 1 includes a filtering unit 150 including a plurality of corrugated bags 15.
And a flange 153 as a frame disposed on the outer peripheral edge of the filtering unit 150. The base material of the wavy bag portion 15 and the brim portion 153 is made of a nonwoven fabric made of the same polyester fiber or the like.

The corrugated bag portion 15 in the filtering section 150 includes a corrugated plate 151 and a side plate 152, and the corrugated bag portion 15 and the brim portion 153 are integrally formed. In the filter 1, a fluid flows from below the wavy bag portion 15 upward to perform filtration.

Next, the operation and effect of this embodiment will be described. The method of manufacturing the filter of this example includes a filter medium fiber supply step, a fiber bonding step, and a molding step. In the filter medium fiber supply step, a molding die having a mold surface along one side of a desired filter is used. By supplying the filter medium fiber to the mold, a first intermediate of a filter made of the filter medium fiber is formed.

That is, the present embodiment is not a method in which each part of a filter made of a different base material is formed as a separate part and then assembled into a filter as in the conventional example. In this example, a filter consisting only of the filter medium fibers can be manufactured by forming the first intermediate integrated in the shape of the filter to be obtained by the filter medium fibers. Therefore, the manufacturing process of the filter is extremely simplified, and the manufacturing cost is reduced.

In this embodiment, the filter medium fiber is subjected to a fiber bonding process after the filter medium fiber is formed into a desired shape of the filter. Therefore, the obtained filter is
The internal fiber structure becomes uniform, and the bag-like side part can be effectively used for filtration, so that filtration performance can be improved.

Therefore, according to this embodiment, it can be manufactured at low cost, is made of the same material, and has excellent filtration performance.
A method for manufacturing a filter can be provided.

The molding die 2 used in manufacturing the filter of the present embodiment is made of a metal net. Therefore, when the water jet punch and the water-soluble acrylic resin are sprayed, no extra liquid remains in the first intermediate and the second intermediate. This shortens the drying time of the second intermediate. Further, the filter 1 of the present embodiment has a density gradient because it is made of filter medium fibers having different thicknesses. Therefore, at the time of filtration, the filtration fluid is subjected to a filtering action such that the filtration fluid is coarse at first and fine at the end. Therefore, the filter manufactured by the manufacturing method of this example has excellent filtration performance.

Example1  In this example, as shown in FIG.
To form a base cloth on the mold in advance, and put the filter media fiber on the base cloth.
And thenReference Example 1Through the same manufacturing process as
Reference Example 1This is to produce a filter having the same shape as the above.

That is, the manufacturing process of the present embodiment includes a corrugating step of forming a sheet of filter medium fiber into a corrugated body, and a side closing step of pressing both sides of the corrugated body to form a large number of corrugated bags. A fiber bonding step of bonding the filter material fibers of the corrugated body, and a forming step of pressing the corrugated body vertically to form a desired filter shape. Hereinafter, these will be described in detail.

In the filter medium fiber supplying step of this example, first, as shown in FIG. 6A, a molding die 2 similar to that of Reference Example 1 is prepared. Then, a filter medium fiber composed of 100% of polyester is supplied onto the molding die 2 by a melt blow method at a supply amount of 50 to 150 g / m ² .

The above-mentioned melt blow method is a method in which a filter medium fiber generated from a spinning machine is blown off by an air current and accumulated in a forming die. At this time, the filter medium fibers are in a semi-molten state, so that the filter medium fibers are fused and integrated at the contact points with each other. Therefore, as shown in FIG.
The base cloth 14 is formed thereon. Then, as shown in FIG. 6C, the filter medium fibers 12 and 13 are supplied onto the base cloth 14 to obtain the first intermediate 104, as in Reference Example 1 . Others are the same as in Reference Example 1 .

In the case of this example, the strength of the first intermediate body 104 is improved by the base cloth 14. Therefore, the first intermediate 1
04 can be easily removed from the mold 2. Therefore, the first intermediate body 14 can be easily moved to the mold, and the workability is improved. Others have the same functions and effects as those of the first embodiment .

Example2  In this example, as shown in Fig. 7, the first intermediate
After shaping the body,Reference Example 1Through the same process as
Reference Example 1To manufacture a filter having the same shape as that shown in FIG.
It is. That is, the manufacturing process of this example is performed by using a sheet of filter medium fiber.
Process to form a wavy body, and both sides of the wavy body
Side closing step of pressing a portion to form a number of wavy bag portions
And a fiber bonding step of bonding the filter material fibers of the wavy body
And pressing the corrugated body vertically to fill the desired
And a forming step of forming into the shape of a tab.

The above-mentioned sheet uses the same filter medium fibers as in Example 1, and is formed by stacking these in a flat plate shape as shown in FIG. 7 (A). That is, the three different filter media fibers, on the sheet creation conveyor 49 moves, the thinnest filter material fibers 11 in the lower layer, then thicker filter media fibers 12 in the middle layer, the thickest filter material fibers 13 in the upper layer, Reference Example 1 The layers are sequentially laminated using the air laid method in the same manner as described above. Thus, a sheet 400 having a three-layer structure is obtained. Note that reference numerals 41 and 4 in FIG.
Reference numerals 2 and 43 denote fiber masses as raw materials for the respective filter medium fibers 11, 12, and 13; 490, a supply conveyor; and 48, a fiber feeder.

The lower filter medium fiber 11 is made of 30% rayon having a thickness of 1.5 denier and 70% rayon having a thickness of 2 denier, and the supply amount per unit area is 80 to 100 g / m ^2.
It is. The filter medium fiber 12 in the middle layer is made of 70% of 1.5 denier polyester, 2.5 denier of polyester 3
From 0%, the supply amount is 40 to 60 g / m ² . The upper filter medium fiber 13 is made of 2-denier polyester 6
The feed rate is 25 to 45 g / m ^2, which is made from 0%, 40% polyester of 6 denier.

Next, in the corrugating step, first, as shown in FIG. 7B, the sheet 400 is put into the corrugating machine 31. As a result, the sheet 401
Is crimped as a whole to form a wavy body 401. afterwards,
The wavy body 401 is cut into a desired length. The corrugating machine 31 is composed of a pair of rotating machines 310 having formed plates 313 standing upright on a belt 315 at appropriate intervals.

As shown in FIG. 7C, the side closing process is performed on both sides 4 of the corrugated body 401 cut to a desired length.
03 is pressed with a roller 32 to make it flat. Thereby, the side part 403 of the corrugated body 41 is closed. On the lower surface of the closed side portion, a brim portion 153 of the filter 1 shown in FIG. 5 is formed.

Therefore, the first intermediate having the desired general shape of the filter can be formed from the above steps. When the side portion 403 is closed, the corrugated body 4
01 is still in a soft state, so it is easily deformed,
The corrugated bag 15 (FIG. 5) and the brim portion 153 are formed.
Others are the same as in Reference Example 1 . Also refer to the effects
Same as Example 1 .

Example3  In this example, as shown in FIG.
After forming the interstitial body,Reference Example 1Go through the same process as
Thus, a filter having the same shape as in the first embodiment (see FIG. 5) is manufactured.
Things. That is, the manufacturing process of the filter of this example is
Cutting process for cutting a sheet of material fiber into a filtering part and a brim part
And a wavy processing step of processing the filtering section into a wavy body.
A collar for integrally bonding the collar to the periphery of the corrugated plate
Fiber for bonding the filter media fibers of the corrugated body
In the joining step, press the corrugated body up and down
And a forming step of forming into a filter shape.

As in the case of the second embodiment, the above-mentioned sheet is obtained by collecting filter medium fibers in a flat plate shape. That is, three types of different filter media fibers are sequentially laminated using the air laid method, with the thinnest fiber in the lower layer, the next thicker fiber in the middle layer, and the thickest fiber in the upper layer.

In the cutting step, both sides of the sheet 400 are cut by a cutter as shown in FIG. Thus, the sheet 400 is separated into a center sheet 405 and two side sheets 406.

In the corrugating step, as shown in FIG. 7B, the center sheet 405 is put into a corrugating machine 31 similar to the second embodiment. As a result, the central sheet 405 is entirely folded and becomes a corrugated body 407.
Thereafter, the corrugated body 407 is cut into a desired length. The two side sheets 406 are also cut to the same length.

In the above-mentioned brim bonding step, FIG.
As shown in (2), the two side sheets 406 are bonded to both sides of the cut corrugated body 407 with an adhesive.
At this time, the side sheet 406 partially protrudes from the side surface of the wavy body 407. This part is naturally woven into the corrugated body during a fiber bonding step, a forming step, and the like that are performed thereafter. Therefore, the first intermediate having the desired general shape of the filter can be formed from the above steps. Others are the same as in Reference Example 1 . Also,
The operation and effect are the same as those of the first embodiment .

Example4  The filter manufacturing method of this example is to supply the filter media fibers to the mold.
To do this, a wet method similar to the papermaking method is used.
It is. That is, in the manufacturing method of this example, first,
It has a concave mold surface along one side of the filter to be obtained.
Prepare a mold to be used. The above mold was used in the examples1When
Similarly, it is composed of a metal net. Also, filter media fibers
Prepare a dispersed aqueous solution.

Then, the mold is put into the aqueous solution. Thereafter, the mold is raised and dewatered to obtain a first intermediate formed on the mold surface of the mold.

Thereafter, in the same manner as in Reference Example 1 , a fiber bonding step of bonding the filter media fibers of the first intermediate to each other to form a second intermediate, and pressing the second intermediate from above and below. , A forming step of forming into a desired filter shape is performed. This embodiment also has the same function and effect as the first embodiment .

The embodiment described above is a filter in which a frame is formed on the outer periphery thereof at the same time as the so-called filtration element is formed. A filter that can be accommodated in a resin frame may be manufactured by each of the manufacturing methods of the above embodiments. Also,
The collar as a frame around the outer periphery of the filter is effective for fixing the filter or preventing leakage of the fluid, but a seal member such as a sponge may be provided on the collar.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a method for manufacturing a filter in Reference Example 1 .

FIG. 2 is an explanatory view of the method for manufacturing a filter, following FIG. 1;

FIG. 3 is an enlarged explanatory view of a first intermediate in Reference Example 1 .

FIG. 4 is an enlarged explanatory view of a second intermediate in Reference Example 1 .

FIG. 5 is a perspective view of a filter obtained in Reference Example 1 .

FIG. 6 is an explanatory diagram of a filter manufacturing method according to the first embodiment.

FIG. 7 is a diagram illustrating a method for manufacturing a filter according to a second embodiment.

FIG. 8 is an explanatory diagram of a method for manufacturing a filter according to a third embodiment.

[Explanation of symbols]

1. . . Filter, 101. . . First intermediate, 10
2. . . Second intermediate, 11, 12, 13. . . Filter media fibers, 15. . . Corrugated bag, 151. . . Corrugated plate, 15
2. . . Side plate, 153. . . Collar part, 2. . . Mold, 31. . . Wavy processing machine,

Continuation of the front page (72) Inventor Tetsuro Okazono 1-1-1, Showa-cho, Kariya-shi, Aichi Japan Inside Denso Co., Ltd. (56) References JP-A-58-214313 (JP, A) (58) Fields investigated ( Int.Cl. ⁷ , DB name) B01D 39/00-39/20

Claims (9)

(57) [Claims] Claims: 1. A filter medium comprising only a filter medium fiber to be obtained.
Is, using a mold having a corrugated mold surface along the shape of one side of the filter corrugated body, only the filter media fiber is adhered to supply only the filter media fibers wavy surface of the forming die
Comprising a filter media fiber supply process for forming a first intermediate, by bonding together the filter media fibers in the first intermediate filtration
A fiber bonding step of forming a second intermediate consisting only of material fibers ; and pressing the second intermediate from above and below to form a desired wave.
Corrugated member production method of filter consisting only of the filter media fiber characterized more becomes possible and forming step of forming the filter shape of the Jo body. 2. The method of claim 1, in the filter media supply process, by sequentially supplying a plurality of types of filter media fibers, the filter media fiber characterized by forming a first intermediate body made of a plurality of types of filter media fiber layer A method for manufacturing a wavy body filter comprising only 3. The method according to claim 1, wherein the bonding of the filter medium fibers in the fiber bonding step is performed by a mechanical method.
I since only the filter media fiber and performs a binding
A method for manufacturing a wavy filter. 4. The method according to claim 1, wherein:
The above-mentioned mold is a filter medium fiber characterized by being a porous body
A method for manufacturing a wavy body filter comprising only 5. A corrugated processing step of forming a sheet made of only filter media fibers into a corrugated body, a side closing step of pressing both sides of the corrugated body to form a large number of corrugated bags, and fiber bonding step of bonding the filter media fibers, only the filter media fiber characterized more becomes possible and forming step of forming the shape of the full <br/> filter wavy body desired by pressing the corrugated member in the vertical direction A method for producing a wavy filter. 6. The method for manufacturing a filter according to claim 5, wherein the bonding of the filter medium fibers in the fiber bonding step is performed by mechanical bonding . 7. A cutting step of cutting a sheet made of only the filter medium fiber into a filtering section and a brim section; a wavy processing step of processing the filtering section into a wavy body; and forming the brim section around the periphery of the wavy body. A collar bonding step of integrally bonding, a fiber bonding step of bonding the filter material fibers of the corrugated body, and pressing the corrugated body in a vertical direction to form a desired corrugated filter shape A method for producing a corrugated body filter comprising only filter media fibers, comprising a molding step. 8. The method according to claim 7, wherein in the step of bonding the brim portion, a side plate is bonded to a side surface of the wavy body . 9. The method according to claim 7, wherein the bonding of the filter medium fibers in the fiber bonding step is performed by a mechanical method.
I since only the filter media fiber and performs a binding
A method for manufacturing a wavy filter.