JPH1190150A - Production of filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently produce a filter with a filter member arranged in a frame by placing an expandable resin on the peripheral part of the member, expanding the resin and integrating the frame with the filter member by the expanded resin. SOLUTION: A filter member 10 is arranged between the upper die 11a and lower die 11b having a pleated surface, and the upper die 11a and lower die 11b are closed to pleat the member 10. As the member 10 is inserted in the pleating die 11, the peripheral part of the member 10 is impregnated with a soln. of the expandable resin contg. a foaming agent. Subsequently, the expandable resin impregnating the member 10 is expanded by the general method such as heating. When the pleating die 11 is opened after the resin is expanded, the pleated filter member 10 with the peripheral part surrounded by the expanded resin 12 is obtained. The desired filter 1 is produced by working the resin 12 at the peripheral part of the member 10 into a frame 3.

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, and more particularly to a method for manufacturing a filter in which a filter portion is disposed in a frame.

[0002]

2. Description of the Related Art Airborne substances such as molds and mites, and various odor components such as tobacco odor and pet odor are contained in the air. Such floating substances and odorous components often have a bad influence on the health condition of the human body or give a discomfort to the human body. For this reason, recently, there is an increasing demand for an air purifier for removing suspended matters and odor components in the air, and for a gas treatment device such as an air conditioner having such an air purifying function.

By the way, the above-mentioned gas processing apparatus is usually
It has a built-in filter to remove suspended matter and odor components contained in the air. In such a filter, for example, a frame is attached to a peripheral portion of a filter portion in which a sheet of activated carbon-containing paper, polyester nonwoven fabric, glass fiber paper, or the like is formed into a pleated shape. When manufacturing such a filter, first, the above-mentioned sheet is formed into a pleated shape using a so-called pleated loom. Then, the pleated sheet is placed in a separately prepared frame, and the peripheral portion of the sheet is fixed to the inner peripheral surface of the frame using an adhesive.

[0004]

In the above-described method for manufacturing a filter, the process of arranging and fixing the sheet in the frame is performed manually, and thus it is difficult to increase the productivity and suppress the production cost.

An object of the present invention is to efficiently manufacture a filter in which a filter portion is disposed in a frame.

[0006]

SUMMARY OF THE INVENTION A method of manufacturing a filter according to the present invention is for manufacturing a filter having a filter portion disposed in a frame. This manufacturing method includes a step of arranging a foamable resin around the filter member and a step of foaming the foamable resin.

[0007] Here, the filter member includes, for example, a sheet-shaped substrate with activated carbon fibers planted thereon or a sheet containing activated carbon. The filter member is formed, for example, in a pleated shape.

Another method for manufacturing a filter according to the present invention is a method for manufacturing a filter in which a pleated filter portion is disposed in a frame. This manufacturing method
A step of forming a sheet-shaped filter member into a pleated shape using a pleated mold, and, in a state where the filter member is formed into a pleated shape using a pleated mold, a foamable resin is formed around the filter member. The method includes a step of disposing and a step of foaming the foamable resin.

[0009]

In the manufacturing method of the present invention, when the foamable resin disposed around the filter member is foamed, a frame is formed integrally with the foamed resin around the filter member. According to such a manufacturing method of the present invention, it is not necessary to manually attach the filter member to the inner peripheral surface of the frame body as in the related art, so that it is possible to efficiently manufacture a target filter. it can.

In another manufacturing method of the present invention, when the foamable resin disposed around the filter member is foamed, the frame is integrally formed with the foamed resin around the filter member. It is formed. Here, since the foamable resin is foamed in a state in which the filter member is formed in a pleated shape by the pleated mold, the filter member formed in the pleated shape is formed from the foamable resin while maintaining the pleated shape. Is fixed in the frame body.

[0011]

1 and 2 (II-I in FIG. 1).
With reference to (I sectional view), a filter manufactured according to an embodiment of the present invention will be described. In the figure, a filter 1 is formed in a substantially rectangular plate shape, and mainly includes a filter section 2 and a frame 3 arranged around the filter section 2.

The filter portion 2 is a sheet-like member formed in a pleated shape, and as shown in FIG. 3 (an enlarged view of a part III in FIG. 2), the base material 4 and the active material implanted in the base material 4 And carbon fibers 5. Here, the base material 4 is made of a flexible material having air permeability and capable of being formed into a pleated shape. Examples of such a material include a porous resin sheet, a nonwoven fabric, various woven fabrics and knitted fabrics. On the other hand, the activated carbon fibers 5 have a large number of pores and are densely implanted on both surfaces of the base material 4. In addition,
The activated carbon fiber 5 used here is not particularly limited, and is, for example, various types such as a coal type, a petroleum type, a phenol resin type, a polyacrylonitrile resin type, and a cellulose type. In FIG. 3, for convenience of understanding,
The length of the activated carbon fiber 5 is emphasized as compared with the thickness of the substrate 4.

The frame 3 is made of a foamed resin, and is fixed to the periphery of the filter portion 2. Here, examples of the foamed resin include a polystyrene resin, a polyethylene resin, and a polypropylene resin.
It should be noted that such a foamed resin may have a low resin strength if the foaming ratio is too high, and may have a poor sealing property as the frame 3 if the foaming ratio is too low. Those set to 2 to 40 times are preferable, and those set to 2 to 10 times are more preferable.

Next, a method of manufacturing the above-described filter 1 according to one embodiment of the present invention will be described. First, a sheet-like filter member 10 as shown in FIG. 4 is prepared. The filter member 10 used here is one in which activated carbon fibers 5 are densely implanted on both surfaces of the above-described base material 4.

Next, the filter member 10 is formed into a pleated shape using a pleated mold 11 as shown in FIG.
Here, the upper mold 11a and the lower mold 11 having a pleated mold surface are shown.
b, the filter member 10 is disposed, and the upper mold 11a and the lower mold 11b are closed. Thereby, the filter member 1
0 is sandwiched between the upper mold 11a and the lower mold 11b as shown in FIG.

Next, a solution of the above-described foamed resin containing a foaming agent is impregnated into a peripheral portion of the filter member 10 while the filter member 10 is sandwiched between the above-described pleated mold 11. As a method of impregnating the foamed resin solution, for example, a method of applying a foamed resin solution to the periphery of the filter member 10 or a method of dipping the pleated mold 11 with the filter member 10 sandwiched in the foamed resin solution Etc. can be adopted.

Next, with the filter member 10 still sandwiched between the pleated molds 11, the filter member 10
The foamable resin impregnated into the foam is foamed. As a method for foaming the foamable resin, a general method such as heating can be employed.

After the foaming resin is foamed in this way, when the pleat mold 11 is opened, as shown in FIG. 7, the filter member 10 is formed into a pleated shape and the peripheral portion is surrounded by the foaming resin 12. Is obtained. When the foamable resin 12 at the periphery of the filter member 10 is processed into a frame 3 shape as shown in FIG.
Is obtained. In addition, as a processing method of the foamable resin 12, for example, various processing methods usually applied to the foamable resin, such as cutting and cutting, can be adopted.

In the manufacturing method as described above, it is not necessary to separately prepare the pleated filter portion 2 and the frame 3 and join them by hand, so that the filter 1 can be manufactured efficiently. Further, the manufacturing cost can be effectively suppressed.

[Other Embodiments] (1) In the above embodiment, the filter member 10 is formed in a pleated shape, but the present invention is not limited to this.
For example, the present invention can be similarly implemented when the peripheral portion of the flat sheet-like filter member 10 is impregnated with a foamed resin solution and foamed. In this case, a filter in which a flat filter portion is surrounded by the frame is obtained.

(2) In the above-described embodiment, the periphery of the filter member 10 is impregnated with the solution of the foamed resin while the filter member 10 is formed in a pleated shape by the pleating die 11, but the present invention is not limited to this. It is not limited to. For example, the present invention can be similarly implemented when a filter member formed in a pleated shape using a pleated loom or the like in advance and the peripheral portion of the filter member is impregnated with a solution of a foamed resin and foamed. .

(3) In the above-described embodiment, the case where the filter 1 is made of the base material 4 on which the activated carbon fibers 5 are planted is described, but the present invention is not limited to this. For example, as shown in FIG. 8 (a diagram corresponding to FIG. 3 according to the above-described embodiment), the activated carbon-containing paper 21 and the polyester The present invention can be carried out in the same manner even when the present invention is made of a laminate with the nonwoven fabric 22.

When such a laminate is used, the activated carbon-containing paper 21 is, for example, 60 parts by weight of activated carbon fiber,
A paper made by mixing a mixture of 20 parts by weight of hemp pulp and 20 parts by weight of polyester fiber to a weight of 70 g / m ² is preferably used. On the other hand, as the polyester nonwoven fabric 22, one provided with dust removal and deodorization properties by performing electret treatment is preferably used.

When the filter 1 provided with the filter portion 2 made of the above-described laminate is manufactured by the method of the present invention, the filter member 10 used in the above-described embodiment is replaced with the above-described laminate of the laminate. Use a sheet.
Such a sheet can be obtained by bonding the activated carbon-containing paper 21 and the polyester nonwoven fabric 22 by thermal bonding.

[0025]

The method for producing a filter according to the present invention comprises:
Since a foamable resin is arranged around the filter member and the foamable resin is foamed, a filter having a filter portion arranged in a frame can be efficiently manufactured.

In another method of manufacturing a filter according to the present invention, the filter member is formed into a pleated shape, and in that state, a foaming resin is arranged around the filter member and foamed. It is possible to efficiently manufacture a filter in which the filter parts in a shape of a circle are arranged.

[Brief description of the drawings]

FIG. 1 is a perspective view of a filter manufactured according to an embodiment of the present invention.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is an enlarged view of a part III in FIG. 2;

FIG. 4 is a view showing one process of the embodiment.

FIG. 5 is a view showing another process of the embodiment.

FIG. 6 is a view showing still another step of the embodiment.

FIG. 7 is a view showing still another step of the embodiment.

FIG. 8 is a diagram corresponding to FIG. 3 in another embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Filter 2 Filter part 3 Frame 10 Filter member 12 Foamable resin

Claims (5)

[Claims] 1. A method for manufacturing a filter having a filter portion disposed in a frame, comprising: a step of disposing a foamable resin around a filter member; and a step of foaming the foamable resin. And a method for producing a filter. 2. The method for producing a filter according to claim 1, wherein said filter member is obtained by implanting activated carbon fibers on a sheet-like substrate. 3. The method according to claim 1, wherein the filter member includes activated carbon-containing paper. 4. The method for producing a filter according to claim 1, wherein the filter member is formed in a pleated shape. 5. A method for manufacturing a filter in which a pleated filter portion is disposed in a frame, comprising: forming a sheet-shaped filter member into a pleated shape using a pleated die; While the filter member is being formed into the pleated shape using a pleated mold, a step of arranging a foamable resin around the filter member, and a step of foaming the foamable resin, A method for producing a filter comprising: