JP2002001039A - High performance air filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a high performance air filer having such advantages that its waste can be reduced volumewise and the weight of the filter can be diminished while keeping a required strength as an air filter for a clean room, and further, an air leakage is effectively prevented from occurring while cutting a material cost. SOLUTION: This high performance air filter is structured of a filter frame in which a filter pack consisting of a filter medium folded in a zigzag fashion, each of the foldings being spaced through a separator by a ribbon material, is airtightly housed. A reinforcement is brought into contact with the side face of the filter pack and the side face of the filter pack is fixed with the reinforcement using a sealant. Thus, the filter pack and the reinforcement are sealed in one piece and the filter frame is formed by the help of the sealant.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a method for reducing waste,
The present invention relates to a high-performance air filter for weight reduction and the like.

[0002]

2. Description of the Related Art In a high performance air filter, since the sealing property between a filter pack and a filter frame has been regarded as important, how to dispose of the filter after use has been little considered. Did not. For example, in the case of air filters for the FFU system, which is currently the mainstream of clean rooms, an aluminum frame is used as a frame material to protect the shape and strength of the filter material in order to protect the weak filter material. Since the tangent line between the filter and the aluminum frame is sealed with a sealant made of urethane resin or the like, it is almost impossible to separate the filter pack and the aluminum frame after use. The main method is landfilling, which has resulted in an increase in the amount of waste. Also, when installing an air filter by the FFU method, the number of installation steps is one fan unit.
Since there is only one air filter per unit, it is desired to reduce the weight of the air filter, including work behind the ceiling. However, conventional air filters require the use of frame materials. There was a limit to weight reduction. By the way, Japanese Patent Application Laid-Open No. 59-4413 discloses an air filter aimed at reducing the amount of waste and reducing the weight of the air filter. In this air filter, the filter pack is sealed with a peripheral frame that simply joins the filter pack. Such an air filter is usually placed above the air filter by a FU (fan unit).
In the case of adopting the FFU system in which the FU is used, there is a problem that the FU cannot withstand the weight of the FU and may be broken or otherwise damaged.

[0003]

According to the present invention, it is possible to reduce the amount of waste and to reduce the weight, and also to have the necessary strength as an air filter for a clean room, and to effectively prevent air leakage. It is another object of the present invention to provide a high-performance air filter capable of reducing material costs.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and a high-performance filter according to the present invention is obtained by folding a filter medium into a zigzag shape as described in claim 1 and folding each of the folded media. What is claimed is: 1. A high-performance air filter in which a filter pack in which a space is interposed between separators or a ribbon material is air-tightly housed in a filter frame, wherein a reinforcing material is in contact with a side surface of the filter pack, The filter pack and the reinforcing material are integrally sealed by fixing the side surface of the filter pack together with the reinforcing material with a sealant, and a filter frame is formed by the sealant. The high-performance air filter according to the second aspect is the high-performance air filter according to the first aspect, wherein the filter pack is accommodated in a reinforcing member formed in a box-shaped body having a front opening, thereby reducing the size of the filter pack. A reinforcing material abuts on a side surface, and the side surface of the filter pack is fixed together with the reinforcing material with a sealant, whereby the filter pack and the reinforcing material are integrally sealed, and a filter frame is formed by the sealant. Is formed. According to a third aspect of the present invention, there is provided the high performance air filter according to the first or second aspect, wherein a flange portion is integrally formed over the entire circumference of an opening surface of the filter frame. . The high-performance air filter according to a fourth aspect is the high-performance air filter according to any one of the first to third aspects, wherein an opening surface of the filter frame is formed to have a narrow width, and a gasket function is also provided. It is characterized by the following.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION A high-performance filter of the present invention is obtained by folding a filter medium in a zigzag shape, and sealingly holding a filter pack in which each folded space is interposed with a separator or a ribbon material in a filter frame in an airtight manner. A high-performance air filter, wherein a reinforcing material is abutted on a side surface of the filter pack, and the side surface of the filter pack is fixed together with the reinforcing material with a sealant, whereby the filter pack and the reinforcing material are separated from each other. In addition to being integrally sealed, a filter frame is formed by the sealant.

The structure of the high performance air filter of the present invention, the materials used, and the method of manufacturing the same will be described. The filter pack is manufactured by a well-known method, that is, by folding a filter medium in a zigzag shape, and keeping a space between the folded spaces via a separator or a ribbon material. Here, as the filter medium, a resin film such as a wet nonwoven fabric or a dry nonwoven fabric made of glass fiber, synthetic fiber, or the like, or PTFE can be used. As the separator, a metal foil such as an aluminum foil or a separator made of a synthetic resin can be used. As the ribbon material, a hot melt resin or the like can be used in addition to a polyolefin resin or a polyamide resin.
As the reinforcing material to be brought into contact with the side surface of the filter pack, a sealing agent spreads to the front and back of the reinforcing material, and the filter pack and the reinforcing material are fixed with the sealing material so that both are integrally sealed. If so, a perforated body, a porous body, a liquid penetrant, and any other material may be used, but among them, a perforated plate-like body such as a net-like body such as a lath net or a punching plate is preferable. Can be used. By using such a reinforcing material, it is possible to easily integrally seal the filter pack and the reinforcing material with a sealant,
The required strength can be provided to the air filter, and the weight of the air filter can be reduced. The reinforcing material may be brought into contact with a portion other than the side surface of the filter pack, that is, the front surface or the back surface. The reinforcing member may have a separate reinforcing member having a predetermined shape corresponding to each side surface, which may be individually abutted for each side surface. If the reinforcing material is brought into contact with the side surface of the filter pack by housing the filter pack, the filter pack can be easily and accurately positioned with respect to five surfaces other than the front (or back) surface. Since the reinforcing member can be abutted, it is convenient in that the manufacturing process of the air filter can be simplified. As the sealant, a two-part urethane resin or an epoxy resin, which is a liquid having fluidity at first and then has a curability, can be used.

The formation of the filter frame can be performed, for example, as follows. That is, a sealing agent is poured into a predetermined mold, and a filter pack in which a reinforcing material is in contact with the sealing agent is set at a stage where the fluidity has not been lost.
After the sealant has cured, remove it from the mold
A filter pack is obtained with one side fixed with a sealant. Next, the same process is performed on the opposite side surface of the side surface fixed with the seal material, and then the same process is performed on the remaining two side surfaces. An air filter housed in the airtight can be obtained. The mold is made of a heat-resistant material made of metal such as stainless steel or resin such as Teflon (registered trademark), and it is desirable to use a mold release agent applied to the inner surface thereof.

[0008]

(Embodiment 1) An embodiment of a high-performance air filter of the present invention will be described using a high-performance mini-pleated air filter for an FFU system having an outer dimension of 570 mm in height, 1170 mm in width and 62 mm in depth as an example. FIG. 1A is a front view thereof,
FIG. 1 (b) is a rear view thereof, and FIG. 1 (c) is A in FIG. 1 (b).
FIG. In the figure, reference numeral 5 denotes a filter pack (mini-pleated type pack) in which a glass fiber filter material 1 is folded in a zigzag shape, and each of the folded spaces is held by a ribbon material 2 made of a polyolefin resin. The filter pack 5 is housed in a reinforcing member 4 made of a 4 × 8 mm lath net having a thickness of 0.8 mm and formed in a box-like body with a front opening, so that the back surface of the filter pack 5 is removed. A lath net as a reinforcing material is in contact with the two surfaces. The filter frame 3 is fixed to the side surface of the filter pack together with the lath net with a sealant made of a two-component urethane resin, so that the filter pack and the lath net are integrally sealed and a plate-shaped seal is formed. It is formed by the agent.
With this configuration, the filter pack 5 is housed in the filter frame 3 in an airtight manner.

This high performance air filter can be easily manufactured as follows. First, the filter material 1 made of glass fiber is folded in a zigzag shape, a polyolefin resin is applied to a predetermined position in order to maintain the space between the folded spaces, the ribbon material 3 is formed, and the filter pack 5 is manufactured. The filter pack is accommodated in a reinforcing member 4 made of a lath net formed in a box-like body having a front opening. Next, a sealing agent 3 ′ made of a two-part urethane resin is poured into a molding die 6 having a predetermined shape, and is formed into a box-shaped body having a front opening prepared in advance at a stage where fluidity is not lost. Set the filter pack housed in the lath net. After the sealant has hardened, it is removed from the mold to obtain a filter pack having one side fixed with the sealant. Even if there is a lath net, the fluid sealant passes through the mesh of the lath net and spreads sufficiently to the back surface, so the side of the filter pack is firmly fixed with the lath net with the sealant and integrally sealed, A part of the filter frame is formed of the plate-shaped cured sealant (see FIG. 2A).
Subsequently, as shown in FIGS. 2 (b), 2 (c) and 2 (d), the remaining three side surfaces are subjected to the same process as in FIG. The pack and the lath net are integrally sealed, and the filter frame 3 is formed by the sealant. The filter pack 5 is housed in the filter frame 3 in an airtight manner.

The high-performance air filter manufactured in this manner does not use an aluminum frame or the like unlike the conventional air filter, so that the amount of waste can be reduced and the weight can be reduced. Further, if an air filter is manufactured without reinforcing with a reinforcing material and a FU (fan unit) is mounted thereon, the air filter cannot withstand the weight of the FU and breaks such as crushing. In the air filter, since the reinforcing material is in contact with the side surface of the filter pack,
Even if U is placed, no damage such as crushing occurs. Further, the cost of the material can be reduced.

(Embodiment 2) Next, the external dimensions are 570
Another embodiment of the high-performance air filter of the present invention will be described with an example of a high-performance mini-pleated air filter for a pressure method (gel specification) having a size of 1 mm × width 1170 mm × depth 75 mm. FIG.
3A is a front view, FIG. 3B is a bottom view, FIG.
FIG. 3C is a sectional view of a portion B in FIG. This air filter is characterized in that the flange portion 7 is integrally formed over the entire periphery of the opening surface of the filter frame 3. When the air filter is installed by a pressurizing method (gel specification), the collar portion is necessary because a part of the frame of the air filter is buried in the silicon gel filled in the groove of the air filter mounting frame to make the air filter airtight. It is a member. In the conventional air filter, the brim portion was formed by folding the brim portion into a design in advance when molding the mold of the aluminum frame, but in the air filter of the present invention, the sealant was cured until it was cured. Since it is a liquid, a brim portion can be formed using this property, for example, as follows. That is, first, a liquid sealing agent made of a two-liquid urethane resin was poured into a mold having a predetermined shape, and at a stage where the fluidity was not lost, the liquid sealing agent was formed into a box-shaped body having a front opening prepared in advance. Set the filter pack housed in the lath net. Next, the sealant is removed from the mold at the stage of semi-curing, and the member 7 'for forming the brim portion is buried at a predetermined position. In addition, since the air filter is mounted on the air filter mounting frame as a member for forming the flange portion, it is desirable to use a strong metal plate such as aluminum, stainless steel, or a steel plate. Therefore, in this embodiment, the thickness is 2 mm.
Aluminum plate was used. Next, after the sealant has cured,
An air filter in which a member for forming a brim portion is buried in a molding die having a predetermined shape, the member is covered with a sealant, and a filter pack having a brim portion having one side fixed with a sealant Get. Subsequently, by performing a similar process on the remaining three side surfaces, an air filter in which the flange portion 7 is integrally formed over the entire periphery of the opening surface of the filter frame 3 can be manufactured.

(Embodiment 3) External dimensions are 570 mm in height.
Still another embodiment of the high-performance air filter of the present invention will be described using a high-performance mini-pleated air filter (with a gasket function) for a FFU system having a width of 1170 mm and a depth of 62 mm as an example. 4A is a front view, FIG. 4B is a bottom view, and FIG. 4C is a cross-sectional view of a portion C in FIG. 4B. In this embodiment, when the filter frame is formed by the sealant, the filter frame gasket portion 8 is formed so that the shape of the filter frame itself has a gasket function. That is, conventionally, the gasket function was provided by attaching a sponge made of chloroprene, EPDM, or the like to the frame surface at the end of the air filter manufacturing process. By using a molding die 9 (see FIG. 5) in which the opening surface can be formed with a narrow width, the opening surface of the filter frame is formed with a sealing agent to have a narrow and uniform flat surface. The filter frame itself made of a sealant has a gasket function for effectively preventing air leakage.

[0013]

According to the high performance air filter of the present invention,
Since an aluminum frame or the like is not used unlike the conventional air filter, the amount of waste can be reduced and the weight can be reduced. In addition, since the reinforcing material is in contact with the filter pack, the filter pack has the necessary strength as an air filter for a clean room, and since the frame is formed by a sealant, air leakage can be effectively prevented. it can. Further, the cost of the material can be reduced.

[Brief description of the drawings]

FIG. 1 (a) is a front view of one embodiment of a high performance air filter of the present invention. (B) The rear view. (C) Detailed view of the part A in FIG. 1 (b).

FIG. 2 is a manufacturing process diagram of one embodiment of the high performance air filter of the present invention.

FIG. 3 (a) is a front view of another embodiment of the high performance air filter of the present invention. (B) The bottom view. (C) Sectional view of section B in FIG. 3 (b).

FIG. 4 (a) is a front view of another embodiment of the high performance air filter of the present invention. (B) The bottom view. (C) Sectional drawing of the C section of FIG.4 (b).

FIG. 5 is an overall perspective view of a molding die provided with a gasket function according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 filter medium 2 ribbon material 3 filter frame (hardened sealant) 3 ′ sealant (liquid) 4 reinforcing material 5 filter pack (filter medium + ribbon material) 6 molding die 7 brim 7 ′ member for forming brim 8 Filter frame gasket part 9 Mold with gasket function

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Nakao Yoshikawa 415 Sakunodani, Yuki City, Ibaraki Prefecture F-term in the Yuki Plant of Nippon Inorganic Corporation 4D058 JA14 JB05 JB24 JB25 JB48 KA01 KA08 KA12 KA14 KC32 KC62 SA04

Claims (4)

[Claims] 1. A high-performance air filter in which a filter medium is folded in a zigzag shape, and a filter pack in which each of the folded spaces is interposed by a separator or held by a ribbon material is hermetically accommodated in a filter frame, A reinforcing material is brought into contact with a side surface of the filter pack, and the side surface of the filter pack is fixed together with the reinforcing material with a sealant, whereby the filter pack and the reinforcing material are integrally sealed, and the sealing is performed. A high-performance air filter characterized in that a filter frame is formed by an agent. 2. The filter pack is accommodated in a reinforcing member formed in a box-like body having a front opening, so that the reinforcing member abuts on a side surface of the filter pack, and the side surface of the filter pack is joined with the reinforcing member. The high performance air filter according to claim 1, wherein the filter pack and the reinforcing material are integrally sealed by fixing with a sealant, and a filter frame is formed by the sealant. . 3. The high-performance air filter according to claim 1, wherein a collar portion is integrally formed over the entire periphery of the opening surface of the filter frame. 4. The high performance air filter according to claim 1, wherein an opening surface of the filter frame is formed to have a narrow width, and the filter frame has a gasket function.