JP2003071221A - Integrally molded filter unit and production method therefor - Google Patents
Integrally molded filter unit and production method thereforInfo
- Publication number
- JP2003071221A JP2003071221A JP2001269290A JP2001269290A JP2003071221A JP 2003071221 A JP2003071221 A JP 2003071221A JP 2001269290 A JP2001269290 A JP 2001269290A JP 2001269290 A JP2001269290 A JP 2001269290A JP 2003071221 A JP2003071221 A JP 2003071221A
- Authority
- JP
- Japan
- Prior art keywords
- filter
- holding frame
- filter medium
- mold
- filter unit
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Landscapes
- Filtering Materials (AREA)
- Filtering Of Dispersed Particles In Gases (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、フィルター保持枠
の射出成型と同時に、別に用意されたフィルター部を同
時接着させて、気体処理装置への装着性に優れ、軽量、
かつ低圧損失、高捕集効率のフィルターユニットを製造
するものである。TECHNICAL FIELD The present invention relates to injection molding of a filter holding frame and simultaneously adhering a separately prepared filter portion, which is excellent in mountability to a gas treatment device and is lightweight.
It also manufactures a filter unit with low pressure loss and high collection efficiency.
【０００２】[0002]
【従来の技術】近年、空気清浄機、およびそのような空
気清浄機を備えたエアーコンディショナーなどの気体処
理装置に対する需要が増えている。2. Description of the Related Art In recent years, there has been an increasing demand for air purifiers and gas treatment devices such as air conditioners equipped with such air purifiers.
【０００３】上述の気体処理装置は、通常、空気中に含
まれる浮遊物や臭気成分を除去するためのフィルターを
内蔵している。このようなフィルターは、活性炭等の吸
着剤、高分子不織布や織布、ガラス繊維などからなるシ
ートまたは、シートをプリーツ状に加工されたフィルタ
ー部をフィルター保持枠に取りつけられ、フィルターユ
ニットとして用いられている。The above-described gas treatment device usually has a built-in filter for removing suspended matters and odorous components contained in the air. Such a filter is used as a filter unit in which a sheet made of an adsorbent such as activated carbon, a polymer non-woven fabric or a woven fabric, or a glass fiber, or a pleated filter part is attached to a filter holding frame. ing.
【０００４】フィルターユニットの製造方法としては，
予めシートまたはプリーツ状に加工されたフィルター部
を準備し、また別に用意したフィルター保持枠に組みこ
み、接着剤で固定する方法、係止ツメやネジ、バネで固
定する方法が行われていた。このため、工数が多く、製
造効率が悪化するという問題があった。最近では、特開
平１０−２６３３４８号公報に示されるように、フィル
ター保持枠の周囲にパッキンを用いて成型加工する方
法、特開平１１−９０１５０号公報のようにフィルター
保持枠に発泡樹脂を用いる方法などが知られている。し
かし,これらの方法は生産性の効率化に主眼を置かれ,フ
ィルターユニットそのものの強度や重量など、またフィ
ルターとしての性能、特性については、なんら言及され
ていない。また、製造効率が良く，且つ，高強度で軽量
なフィルターユニットを製造する方法として，フィルタ
ー保持枠の成型と同時に予め別工程で準備されたフィル
ター部を接着させる一体成型方法がある。As a method of manufacturing the filter unit,
A method of preparing a filter portion processed into a sheet or a pleat shape in advance, incorporating it into a separately prepared filter holding frame and fixing it with an adhesive, and fixing with locking claws, screws, and springs has been performed. Therefore, there is a problem that the number of steps is large and the manufacturing efficiency is deteriorated. Recently, as shown in JP-A-10-263348, a method of molding using a packing around the filter holding frame, and a method of using a foamed resin for the filter holding frame as in JP-A-11-90150. Are known. However, these methods focus on improving the efficiency of productivity, and do not mention the strength and weight of the filter unit itself, and the performance and characteristics of the filter. Further, as a method of manufacturing a filter unit having high manufacturing efficiency, high strength and light weight, there is an integral molding method in which a filter portion prepared in a separate step is bonded at the same time as molding of the filter holding frame.
【０００５】しかし、一体成型法に於いても、特にフィ
ルター部に活性炭等の吸着剤が含有されている場合、そ
の吸着剤の機能を少しでも発揮させるべくフィルター部
の表面積を大きくしたり、保持枠との接着する部分を少
しでも少なくして、捕集効果をあげ、且つ、フィルター
成型加工性を向上させるためフィルター濾材と保持枠と
の接着にいろいろな工夫が凝らされている。しかし、例
えば、フィルター部の表面積を最大限に利用するため
に、保持枠端部まで活性炭を装填したものがあるが、フ
ィルター濾材の端部から活性炭が金型掴み部に脱落して
バリを生じたり、あるいは金型破損を引き起こすという
問題があった。また、濾材端部には活性炭を装填せずバ
リや金型破損を防止する方法があるが、フィルターとし
ての有効表面積が減少するため、フィルター性能が低下
するという問題があった。さらに、金型構造を工夫し、
枠内側の掴み部に樹脂流入部を数ミリ設けることにより
バリや活性炭脱落を防止する方法があるが、先述したも
のと同様、フィルターとしての有効表面積が減少するた
め、フィルター性能が低下するという問題があった。ま
た、気体処理装置に装着されるフィルター保持枠は、装
着性に優れ、軽いことが望ましいが、枠の厚みを薄くし
て軽量化するとその分強度が低下して気体処理装置への
装着時にねじれや破壊を生じ、取り扱いにくい問題があ
った。However, even in the integral molding method, especially when the filter portion contains an adsorbent such as activated carbon, the surface area of the filter portion is increased or retained so that the function of the adsorbent can be exerted even a little. Various measures have been taken to bond the filter medium to the holding frame in order to improve the collecting effect by reducing the part to be bonded to the frame as much as possible and to improve the filter molding processability. However, for example, in order to maximize the surface area of the filter part, there is one in which activated carbon is loaded up to the end of the holding frame.However, activated carbon falls off from the end of the filter medium into the mold gripping part, causing burrs. However, there was a problem of causing mold damage. Further, there is a method of preventing burr and die damage by not loading activated carbon on the end of the filter medium, but there is a problem in that the filter surface performance is lowered because the effective surface area of the filter is reduced. Furthermore, devising the mold structure,
There is a method to prevent burrs and activated carbon from falling off by providing a resin inflow part on the grip part inside the frame for several millimeters, but like the one described above, the effective surface area as a filter decreases, so the problem that the filter performance decreases was there. Also, it is desirable that the filter holding frame installed in the gas treatment device is excellent in wearability and light in weight, but if the thickness of the frame is made thinner and the weight is reduced, the strength is reduced accordingly and the filter holding frame is twisted when mounted in the gas treatment device. However, there was a problem that it was difficult to handle.
【０００６】[0006]
【発明が解決しようとする課題】本発明は、保持枠用の
樹脂を溶融射出してフィルターユニットを成型する時
に、フィルター濾材の破損をなくし、かつ濾材の有効面
積を大きくして捕集効率を高めるとともに、フィルター
装着性および生産効率を高めたフィルターユニットの成
型方法である。DISCLOSURE OF THE INVENTION According to the present invention, when a resin for a holding frame is melt-injected to mold a filter unit, damage to the filter medium is eliminated and the effective area of the filter medium is increased to improve the collection efficiency. This is a method of molding a filter unit, which enhances the filter mountability and the production efficiency as well.
【０００７】[0007]
【課題を解決するための手段】本発明は、図５に示す金
型を用いてフィルター濾材と保持枠を接合するフィルタ
ーユニットの成型方法である。図５の１７はフィルター
濾材が型逃がし部、１８は掴み部、１９は掴み部の距離
を示す。本発明は逃がし部のクリアランスＡがフィルタ
ー部の濾材厚みに対して８０〜１１５％、好ましくは１
００〜１１０％、掴み部のクリアランスＢを２５〜４５
％、好ましくは３５〜４０％、掴み部の距離Ｃを０．５
〜５ｍｍ、好ましくは１〜３ｍｍとすることにより、濾
材の表面積が大きく、一体成型性の良好なフィルターを
提供するものであり、さらに、フィルターにリブを付与
することにより、フィルター保持枠の側面（濾材配列方
向）の補強およびフィルター装着時の歪みを防止し、取
り扱い性にも優れたフィルターを提供するものである。
ここでクリアランスとはフィルター濾材部を挟み込む金
型間つまりキャビ側とコア側の距離である。掴み部とは
フィルター濾材部の中で保持枠との境界に位置し，その
他のフィルター濾材部，つまり逃がし部よりクリアラン
スが小さくなっている部分である。この掴み部，逃がし
部を設けることによって溶融した熱可塑性樹脂が濾材部
に流れ込むこと無く，また濾材構造が破壊される事無く
成型される。このＡ，Ｂ，Ｃを調整してフィルター部末
端に活性炭が担持されていても、容易に保持枠と接着が
可能となり、本発明にいたった。The present invention is a method of molding a filter unit in which a filter medium and a holding frame are joined using a mold shown in FIG. Reference numeral 17 in FIG. 5 indicates the mold releasing portion of the filter medium, 18 indicates the grip portion, and 19 indicates the distance of the grip portion. In the present invention, the clearance A of the relief portion is 80 to 115% of the thickness of the filter medium of the filter portion, preferably 1
0 to 110%, clearance B of grip is 25 to 45
%, Preferably 35 to 40%, and the grip portion distance C is 0.5.
By providing the filter having a size of -5 mm, preferably 1-3 mm, it is possible to provide a filter having a large surface area of the filter medium and good moldability. Furthermore, by providing a rib to the filter, the side surface of the filter holding frame ( The present invention provides a filter which is excellent in handleability by reinforcing the filter medium arrangement direction) and preventing distortion when the filter is attached.
Here, the clearance is the distance between the molds that sandwich the filter medium, that is, the distance between the cabinet side and the core side. The grip portion is a portion of the filter medium portion located at the boundary with the holding frame and having a smaller clearance than the other filter medium portions, that is, the relief portions. By providing the grip portion and the relief portion, the molten thermoplastic resin is molded without flowing into the filter medium portion and without destroying the filter medium structure. Even if activated carbon was carried on the end of the filter part by adjusting A, B, and C, it was possible to easily adhere to the holding frame, which led to the present invention.
【０００８】クリアランスＡを８０〜１１５％、好まし
くは１００〜１１０、クリアランスＢを２５〜４５％、
好ましくは３５〜４５％、掴み部の距離Ｃを０．５〜５
ｍｍ、好ましくは１〜３ｍｍとすることにより、金型に
溶融した樹脂を流した場合、濾材への溶融した樹脂の染
み出しがなく、フィルター濾材を最大限に利用すること
ができる。クリアランスＡを８０％以下とした場合はフ
ィルター濾材が圧縮・破壊され圧力損失が増大し、１１
５％以上した場合は、フィルター部のプリーツ形状が変
形したり皺が発生する。またクリアランスＢを２５％以
下とした場合もフィルター濾材が圧縮・破壊され圧力損
失が増大し、４０％以上とした場合はフィルター部へ樹
脂が流出しバリが発生する。更に掴み部の距離Ｃを０．
５ｍｍ以下とした場合もフィルター部へ樹脂が流出しバ
リが発生し、５ｍｍ以上した場合はフィルター部の面積
が減少しフィルター性能が低下する。The clearance A is 80 to 115%, preferably 100 to 110, and the clearance B is 25 to 45%.
Preferably 35 to 45%, the distance C of the grip portion is 0.5 to 5
When the molten resin is poured into the mold by setting the thickness to mm, preferably 1 to 3 mm, there is no exudation of the molten resin to the filter medium, and the filter medium can be used to the maximum extent. When the clearance A is set to 80% or less, the filter medium is compressed and destroyed, and the pressure loss increases.
When it is 5% or more, the pleated shape of the filter portion is deformed or wrinkles occur. Also, when the clearance B is 25% or less, the filter medium is compressed and destroyed to increase the pressure loss, and when it is 40% or more, the resin flows out to the filter portion to cause burrs. Further, the distance C of the grip is 0.
Even when the thickness is 5 mm or less, the resin flows out to the filter portion to cause burrs, and when it is 5 mm or more, the area of the filter portion is reduced and the filter performance is deteriorated.
【０００９】フィルター保持枠の側面（濾材配列方向）
の厚みを、薄くすることは困難とされていた。フィルタ
ー保持枠の濾材幅方向の両側から金型に流れ込んだ溶融
した樹脂は、フィルター保持枠の側面（濾材配列方向）
の中央部にて合流する。この時、リブ部分に相当する金
型の隙間を薄くすると、射出成型時にショートが発生
し、不良品発生の原因となっていた。ショートとは樹脂
がフィルター保持枠の成型金型全体に行き渡らず、一部
隙間を残して冷却固化し、そのため成型品の一部に強度
斑を生じ、その結果そこの部分の保持枠の一部が欠ける
現象のことを指す。しかし、リブを設けることによっ
て、ショートの発生もなくなり不良品の発生も減少し
た。またフィルター保持枠全体の強度が増し、全体のゆ
がみもなくなり、気体処理装置に装着する時のねじれの
問題も解消した。リブ、ゲートが無い場合は、金型内で
溶融した樹脂の流れが不均一となり、温度斑が生じて、
この結果冷却速度も異なり、冷却固化したフィルター保
持枠の側面部に強度斑を生じ、ショートの原因になって
不良が発生していた。[0009] Side surface of the filter holding frame (filter element arrangement direction)
It was difficult to reduce the thickness of the. The molten resin that has flowed into the mold from both sides of the filter holding frame in the filter medium width direction is the side surface of the filter holding frame (filter medium arranging direction).
Meet at the central part of. At this time, if the gap of the mold corresponding to the rib portion is made thin, a short circuit occurs during injection molding, which causes defective products. A short circuit means that the resin does not reach the entire mold for the filter holding frame and solidifies by cooling with a gap left between them, which causes uneven strength in a part of the molded product, resulting in a part of the holding frame in that part. Refers to the phenomenon of lack of. However, by providing the ribs, the occurrence of short circuits disappeared and the occurrence of defective products also decreased. In addition, the strength of the entire filter holding frame has been increased, the overall distortion has been eliminated, and the problem of twisting when mounted in the gas treatment device has been solved. If there are no ribs or gates, the flow of molten resin in the mold will be non-uniform, causing temperature unevenness,
As a result, the cooling rate was also different, and strength unevenness was generated on the side surface of the cooled and solidified filter holding frame, causing a short circuit and causing a defect.
【００１０】本発明に関わるリブの巾は保持枠側面の巾
に対して、１０％以上９０％以下、好ましくは、１５〜
４０％である。また、リブの厚みは、保持枠側面の厚み
に対して１０〜７０％、好ましくは２０〜５０％であ
る。特にリブの巾が、保持枠側面の巾に対して、１０％
以下であれば強度が得られず、また、９０％以上であれ
ば、補強効果はあるが、側面厚みが大きくなったのと同
じことであり、軽量化を図ることはできない。このリブ
をつけることにより、金型のフィルター保持枠の側面
（濾材配列方向）の隙間（厚み）を２．００５ｍｍ以下
好ましくは、１．５０４ｍｍ以下とすることにより、側
面の厚みは、２ｍｍ以下、好ましくは１．５ｍｍ以下が
可能となった。The width of the rib according to the present invention is 10% or more and 90% or less of the width of the side surface of the holding frame, and preferably 15 to 15.
40%. Further, the thickness of the rib is 10 to 70%, preferably 20 to 50% with respect to the thickness of the side surface of the holding frame. Especially, the rib width is 10% of the width of the side surface of the holding frame.
If it is below, strength cannot be obtained, and if it is 90% or more, there is a reinforcing effect, but this is the same as the increase in side face thickness, and it is not possible to reduce the weight. By providing this rib, the clearance (thickness) on the side surface (filtering medium arranging direction) of the filter holding frame of the mold is 2.005 mm or less, preferably 1.504 mm or less, so that the side surface has a thickness of 2 mm or less, It is possible to reduce the thickness to 1.5 mm or less.
【００１１】フィルターユニットの気体処理装置への装
着時のねじれとは、フィルターユニットの挿入時にかか
る力によって生じる一時的な変形を意味し、これを下記
（１）式で示して、代用特性とした。即ち、濾材幅方向
の保持枠の一方の側面を固定し、対面の保持枠の一端に
濾材面に対して垂直方向から力を加えた時、保持枠が歪
んで動いた距離（Ａ）を保持枠の巾（Ｂ）で割った値に
１００を乗じてねじれ率とした。
ねじれ率＝（Ａ）／（Ｂ） ×１００％ （１）
この値は、小さい程剛直であり、変形しにくいことを示
し、気体処理装置への装着が簡易であることを意味す
る。１５０％以下好ましくは、１３０％以下であれば、
処理装置への装着時には何ら支障はない。The twist when the filter unit is attached to the gas treatment device means a temporary deformation caused by a force applied when the filter unit is inserted. This is shown by the following formula (1) and is used as a substitute characteristic. . That is, one side of the holding frame in the width direction of the filter medium is fixed, and when a force is applied to one end of the facing holding frame in the direction perpendicular to the filter medium surface, the holding frame holds the distance (A) that is distorted and moved. The value obtained by dividing by the width (B) of the frame was multiplied by 100 to obtain the twist rate. Twist rate = (A) / (B) × 100% (1) This value indicates that the smaller the value, the more rigid and the less likely it is to deform, and that it is easy to install in the gas treatment device. 150% or less, preferably 130% or less,
There is no hindrance when mounted on the processing device.
【００１２】[0012]
【発明の実施の形態】本発明に用いる濾材は、活性炭や
ゼオライト等の吸着剤含有シート、高分子不織布、ガラ
ス繊維、多孔性の樹脂シート、各種の織物、編物などか
らなるシートまたは、それをプリーツ状などに成型加工
されたものからなる。本発明の保持枠に用いることので
きる熱可塑性樹脂としては、アクリル系樹脂、フェノー
ル系樹脂、シリコン系樹脂、ポリオレフィン系樹脂、ポ
リウレタン系樹脂、エポキシ樹脂、ポリエステル系樹
脂、塩化ビニル系樹脂、メラミン系樹脂、酢酸ビニル系
樹脂、ポリスチレン系樹脂などの熱可塑性樹脂、スチレ
ン系熱可塑性エラストマー、ウレタン系熱可塑性エラス
トマー、オレフィン系熱可塑性エラストマー、ポリエス
テル系熱可塑性エラストマー、ポアミド系熱可塑性エラ
ストマー、塩ビ系熱可塑性エラストマー、フッ素系熱可
塑性エラストマー、などの熱可塑性エラストマーなど溶
融射出成型ができるものなら何でも良い。本発明によっ
てできるフィルターユニット全体を図１に示した。ま
た、フィルター部を図２に示した。一体成型する時に用
いる金型を図３乃至図４に示した。図４中の１４に示し
た溝はできたフィルター枠部の側面外側（濾材配列方
向）のリブに相当する。また、図４中の１６は、フィル
ター枠部の濾材巾方向面に位置するゲートに相当する。
このリブ、ゲートを設けることにより、射出成型時の溶
融した樹脂の流動性が上がり,短時間に金型全体に溶融
した樹脂が行き渡り,また、金型の隙間全体に均一に圧
がかかり、隙間なく樹脂が行き渡る。通常金型への溶融
した樹脂の流れ込みは１５から20秒で完了する。この
後、金型内の冷却に３０〜３５秒を要する。冷却後、金
型を上下にはがして、目的とするフィルターユニットが
得られる。BEST MODE FOR CARRYING OUT THE INVENTION The filter medium used in the present invention is a sheet containing an adsorbent such as activated carbon or zeolite, a polymer nonwoven fabric, glass fiber, a porous resin sheet, various woven fabrics, knitted fabrics, or the like. It is made of pleats. Examples of the thermoplastic resin that can be used in the holding frame of the present invention include acrylic resins, phenolic resins, silicone resins, polyolefin resins, polyurethane resins, epoxy resins, polyester resins, vinyl chloride resins, and melamine resins. Resin, vinyl acetate-based resin, thermoplastic resin such as polystyrene-based resin, styrene-based thermoplastic elastomer, urethane-based thermoplastic elastomer, olefin-based thermoplastic elastomer, polyester-based thermoplastic elastomer, poamide-based thermoplastic elastomer, vinyl chloride-based thermoplastic Any material capable of melt injection molding such as an elastomer and a thermoplastic elastomer such as a fluorine-based thermoplastic elastomer may be used. The entire filter unit made by the present invention is shown in FIG. The filter section is shown in FIG. A mold used for integral molding is shown in FIGS. 3 to 4. The groove indicated by 14 in FIG. 4 corresponds to a rib on the outside of the side surface of the formed filter frame (in the direction of the filter medium arrangement). Further, 16 in FIG. 4 corresponds to a gate located on the surface of the filter frame portion in the filter medium width direction.
By providing these ribs and gates, the fluidity of the molten resin during injection molding is increased, the molten resin is spread over the entire mold in a short time, and pressure is evenly applied to the entire gap between the molds. Instead, the resin spreads. The flow of molten resin into the mold is usually completed in 15 to 20 seconds. After that, it takes 30 to 35 seconds to cool the inside of the mold. After cooling, the mold is peeled up and down to obtain the desired filter unit.
【００１３】さらに濾材を固定し，保持枠を形成する金
型の概略図を図５に示した。逃がし部のクリアランスＡ
をフィルター部の濾材厚みに対して８０〜１１５％、掴
み部のクリアランスＢを２５〜４５％、掴み部の距離Ｃ
を０．５〜５ｍｍ、好ましくは１〜３ｍｍとしてキャビ
とコアを圧着させることにより、溶融した保持枠用の樹
脂の濾材への染み出しもなく、完全に溶着される。この
結果、濾材中の活性炭の脱落や濾材の破壊もなく濾材と
保持枠とが接着され、活性炭を含んだ濾材が保持枠に直
接接合することができる。そして、活性炭を含んだ濾材
の有効面積が大きくなり、フィルター性能に大きく寄与
することが可能となった。また、濾材の破損、破壊もな
く、さらに活性炭の飛散もないことから、保持枠との一
体成型が可能となり、１つ１つのバッチ生産だけでな
く、連続生産も可能となり、工程が簡略化され工程での
不良率を低減させることもでき、コスト低減にも寄与で
きるものである。Further, a schematic view of a mold for fixing the filter medium and forming a holding frame is shown in FIG. Clearance A of the relief section
Is 80 to 115% of the filter material thickness of the filter portion, the clearance B of the grip portion is 25 to 45%, and the distance C of the grip portion is
Is 0.5 to 5 mm, preferably 1 to 3 mm, and the mold and the core are pressure-bonded to each other, so that the molten resin for the holding frame does not exude to the filter medium and is completely welded. As a result, the filter medium and the holding frame are bonded to each other without dropping off the activated carbon in the filter medium or breaking the filter medium, and the filter medium containing the activated carbon can be directly bonded to the holding frame. Then, the effective area of the filter medium containing activated carbon is increased, and it is possible to greatly contribute to the filter performance. Moreover, since the filter medium is not damaged or destroyed, and the activated carbon is not scattered, it is possible to perform integral molding with the holding frame, which enables continuous production as well as individual batch production, which simplifies the process. It is possible to reduce the defective rate in the process and also contribute to cost reduction.
【００１４】また、保持枠部の金型の隙間を小さくする
ことができ、即ち、出来たフィルター保持枠の厚みを小
さくすることができる。さらに驚くべきことに、固化し
た樹脂がフィルター保持枠の側面（濾材配列方向）を補
強することにもなり、出来たフィルターの強度を著しく
向上させることが可能となった。Further, the gap between the molds of the holding frame portion can be reduced, that is, the thickness of the filter holding frame thus formed can be reduced. Further, surprisingly, the solidified resin also reinforces the side surface of the filter holding frame (filter element arranging direction), and the strength of the resulting filter can be significantly improved.
【００１５】以下、本発明の一体成型フィルターの実施
例及び比較例を記載するが本発明はこの実施例に限定さ
れるものではなく、本明細書の趣旨を逸脱しない範囲で
変更することができるものである。Examples and comparative examples of the integrally molded filter of the present invention will be described below, but the present invention is not limited to these examples and can be modified within a range not departing from the gist of the present specification. It is a thing.
【００１６】以下実施例における評価、測定方法を下記
に示す。フィルター部に用いる濾材の性能については以
下の試験により実施したものとする。
［濾材厚み］測定加重７ｇｆ／ｃｍ2、測定端子２５ｍ
ｍφの厚み計により測定した。
［剛軟度］ＪＩＳ Ｌ １０９６ ８．１９ Ｂ法によ
り測定した。
［圧縮弾性率］ＪＩＳ Ｌ １０９６ ８．１８により
測定した。
［フィルター部有効面積］フィルターユニットにおける
フィルター部の濾材有効面積。ＪＩＳ Ｌ １０９６
８．１８により測定した。
［濾材トルエン効率］８０ｐｐｍのトルエンを使ったワ
ンパスの除去性能を測定した。風速２３ｃｍ／ｓにおけ
る上流側と下流側の濃度を島津製炭化水素系によって測
定。次式より除去効率を算出した。
トルエン除去効率＝（下流側濃度／上流側濃度）×１００ ［％］
［濾材圧力損失］風速４８ｃｍ／ｓにおける濾材の通気
抵抗を測定した。
［樹脂使用量］保持枠に要した樹脂量。
［成型性不良率］射出成型２０００ショットした時に発
生した不良個数より下記式により算出した。ここで不良
とは保持枠部のバリ，ショートおよび濾材破れ，変形を
指す。
成型不良率＝不良個数／２０００ショット×１００％
［トルエン除去効率］８０ｐｐｍのトルエンを使ったワ
ンパスの除去性能を測定した。風量３００ｍ3／ｈｒに
おける上流側と下流側の濃度を島津製炭化水素系によっ
て測定。次式より除去効率を算出した。
トルエン除去効率＝（下流側濃度／上流側濃度）×１００ ［％］
［圧力損失］風量６００ｍ3／ｈｒにおけるフィルター
ユニットの通気抵抗を測定した。
［ねじれ率］濾材幅方向の一方の保持枠を固定し、対面
の保持枠の一端に濾材面に対して垂直方向から荷重３ｋ
ｇをかけ、保持枠の歪んで動いた距離を測り、保持枠側
面の巾で割った値に１００を乗じて求めた。
［装着性］気体処理装置の架台に装着するときの操作に
おいて、フィルターユニットを持って、一回の挿入で装
着できるものを、操作性良好とし、二回以上の繰り返し
が必要な場合を操作性不良と判定した。The evaluation and measurement methods in the examples are shown below. The performance of the filter material used in the filter part shall be determined by the following tests. [Filtration material thickness] Measurement load 7 gf / cm 2 , measurement terminal 25 m
It was measured with a thickness meter of mφ. [Bending flexibility] Measured according to JIS L 1096 8.19 B method. [Compressive Elastic Modulus] Measured according to JIS L 1096 8.18. [Effective area of filter section] The effective area of the filter medium of the filter unit. JIS L 1096
It was measured according to 8.18. [Filter material toluene efficiency] One-pass removal performance using 80 ppm of toluene was measured. The upstream and downstream concentrations at a wind speed of 23 cm / s were measured using a Shimadzu hydrocarbon system. The removal efficiency was calculated from the following formula. Toluene removal efficiency = (downstream concentration / upstream concentration) × 100 [%] [filter material pressure loss] The ventilation resistance of the filter material at a wind speed of 48 cm / s was measured. [Amount of resin used] The amount of resin required for the holding frame. [Moldability defect rate] It was calculated by the following formula from the number of defects generated after 2000 shots of injection molding. Here, the term "defective" refers to burr, short circuit, breakage, and deformation of the holding frame. Molding defect rate = number of defectives / 2000 shots × 100% [toluene removal efficiency] One-pass removal performance using 80 ppm of toluene was measured. The upstream and downstream concentrations at an air volume of 300 m 3 / hr were measured using a Shimadzu hydrocarbon system. The removal efficiency was calculated from the following formula. Toluene removal efficiency = (downstream concentration / upstream concentration) × 100 [%] [pressure loss] The ventilation resistance of the filter unit at an air flow rate of 600 m 3 / hr was measured. [Twist rate] One holding frame in the width direction of the filter medium is fixed, and a load of 3k is applied to one end of the holding frame facing the filter medium from the direction perpendicular to the filter medium surface.
It was calculated by multiplying g, measuring the distorted movement distance of the holding frame, and dividing the value by the width of the side surface of the holding frame and multiplying by 100. [Attachability] In the operation of attaching to the frame of the gas treatment device, the one that can be attached by one-time insertion with the filter unit is considered to have good operability, and operability is required when it needs to be repeated twice or more. It was judged to be defective.
【００１７】[0017]
【実施例】実施例１
フィルター部として、濾材厚み１．１ｍｍ、幅方向の剛
軟度２２〜２６ｋｇ・ｃｍ、厚み方向の圧縮弾性率４５
〜５０％、濾材トルエン除去効率５０％以上、濾材圧力
損失９０Ｐａ以下の活性炭含有シートを、ヒダ高さ３９
ｍｍ、ヒダ間隔が９ｍｍでヒダ折りした後、濾材幅１０
５．５ｍｍにカットした。予め用意された図４に示す金
型のインサート部すなわちフィルター部１５に該濾材を
挿入した。この金型の逃がし部クリアランスＡは濾材厚
みに対して１０５％即ち１．１６ｍｍ，掴み部クリアラ
ンスＢは４０％即ち０．４４ｍｍ，掴み部の距離Ｃは
１．５ｍｍとした。該金型に該濾材を挿入して、射出成
型機により２１５℃に溶融したポリプロピレン樹脂（Ｃ
＆ＣＴＥＣＨ製）を、図３の金型の樹脂導入部８より５
０ｋｇｆ／ｃｍ2の圧力をかけて６点のゲートから図４
に示す金型の隙間１７に流し込んだ。この時、金型への
注入時間は１５秒とし、注入後冷却に３５秒かけた。こ
の後、金型を上下に分離して、フィルターユニットを取
り出した。これにより、ユニット外形寸法１０６ｍｍ×
２２２ｍｍ×４０ｍｍ、フィルター部寸法１０３ｍｍ×
２１６ｍｍ×３９ｍｍ、ヒダ間隔９ｍｍ、フィルター保
持枠の形状としては、保持枠厚み１．５ｍｍ、リブ厚み
０．５ｍｍ、リブ幅６ｍｍのフィルターユニットのフィ
ルターユニットを得た。このフィルターユニットのフィ
ルターとしての特性を測定した。また、このフィルター
ユニットを気体処理装置の架台に装着する時の装着性を
判定した。Example 1 As a filter part, the filter medium has a thickness of 1.1 mm, a bending resistance in the width direction of 22 to 26 kg · cm, and a compression elastic modulus of 45 in the thickness direction.
˜50%, filter medium toluene removal efficiency 50% or more, filter medium pressure loss 90 Pa or less, activated carbon containing sheet, fold height 39
mm, the crease spacing is 9 mm, and after folding, the filter medium width is 10
It was cut to 5.5 mm. The filter medium was inserted into the insert portion of the mold shown in FIG. 4 prepared in advance, that is, the filter portion 15. The relief clearance A of the mold was 105% or 1.16 mm with respect to the thickness of the filter medium, the grip clearance B was 40% or 0.44 mm, and the grip distance C was 1.5 mm. Insert the filter medium into the mold, and melt the polypropylene resin (C
& CTECH) from the resin introduction part 8 of the mold of FIG.
Applying a pressure of 0 kgf / cm 2 from the gate of 6 points,
It was poured into the gap 17 of the mold shown in. At this time, the injection time into the mold was 15 seconds, and the cooling after injection took 35 seconds. Then, the mold was separated into upper and lower parts and the filter unit was taken out. As a result, the unit external dimensions 106 mm ×
222mm x 40mm, filter size 103mm x
A filter unit having a size of 216 mm × 39 mm, a fold interval of 9 mm, and a shape of the filter holding frame having a holding frame thickness of 1.5 mm, a rib thickness of 0.5 mm, and a rib width of 6 mm was obtained. The characteristics of the filter unit as a filter were measured. In addition, the mountability when the filter unit was mounted on the frame of the gas treatment device was determined.
【００１８】実施例２
フィルター部は実施例１と同様のものを使用した。フィ
ルターユニットの成型方法も実施例１と同じとしたが、
金型構造を逃がし部クリアランスＡを濾材厚みに対して
１０３％即ち１．１３ｍｍ，掴み部クリアランスＢを３
５％即ち０．３９ｍｍ，掴み部の距離Ｃを３ｍｍとし
た。Example 2 The same filter part as in Example 1 was used. The molding method of the filter unit was the same as in Example 1, but
The clearance A of the relief part of the mold structure is 103% of the filter medium thickness, that is, 1.13 mm, and the clearance B of the gripping part is 3
5%, that is, 0.39 mm, and the distance C of the grip portion was 3 mm.
【００１９】比較例１
フィルター部は実施例１と同様のものを使用した。フィ
ルターユニットの成型方法も実施例１と同じとしたが、
リブを設けなかった。金型構造を逃がし部クリアランス
Ａを濾材厚みに対して１００％即ち１．１ｍｍとし，掴
み部は設けなかった。また金型の樹脂の流れ込み部の厚
みを変え，保持枠厚みを３ｍｍとした。Comparative Example 1 The same filter unit as in Example 1 was used. The molding method of the filter unit was the same as in Example 1, but
No ribs were provided. The clearance A of the relief portion of the mold structure was set to 100% of the filter medium thickness, that is, 1.1 mm, and the grip portion was not provided. In addition, the thickness of the holding frame was set to 3 mm by changing the thickness of the resin inflow part of the mold.
【００２０】比較例２
フィルター部は実施例１と同様のものを使用した。フィ
ルターユニットの成型方法も実施例１と同じとしたが、
リブを設けず、金型構造を逃がし部クリアランスＡを濾
材厚みに対して７０％即ち０．７７ｍｍとし，掴み部ク
リアランスＢを４０％即ち０．４４ｍｍ、掴み部の距離
Ｃを１．５ｍｍとした。また、金型の樹脂の流れ込み部
の厚みを変え，保持枠厚みを３ｍｍとした。Comparative Example 2 The same filter part as in Example 1 was used. The molding method of the filter unit was the same as in Example 1, but
Without providing ribs, the clearance A of the relief portion of the mold structure was 70% or 0.77 mm with respect to the thickness of the filter medium, the clearance B of the grip portion was 40% or 0.44 mm, and the distance C of the grip portion was 1.5 mm. . Also, the thickness of the resin inflow portion of the mold was changed to make the holding frame thickness 3 mm.
【００２１】以上のようにして得られた、フィルターユ
ニットを用いてフィルターとしての性能評価を行なっ
た。結果を表１に示した。The filter unit thus obtained was used to evaluate the performance as a filter. The results are shown in Table 1.
【００２２】[0022]
【表１】 [Table 1]
【００２３】[0023]
【発明の効果】以上のように、合成樹脂からなるフィル
ター保持枠を射出成型する際の金型の掴み部，逃がし部
のクリアランス，および掴み部の距離を限定する事によ
って，濾材の破損や成型時のバリ，ショート等の不良を
無くし，かつ濾材の有効面積が大きく捕集効率が大きな
フィルターユニットを得ることができた。さらにねじれ
率が小さいので、気体処理装置への装着性が良好であ
る。As described above, when the filter holding frame made of a synthetic resin is injection-molded, the holding portion of the mold, the clearance of the relief portion, and the distance between the holding portions are limited, whereby the filter medium is damaged or molded. It was possible to obtain a filter unit that eliminates defects such as burrs and shorts at the time, has a large effective area of the filter medium, and has a large collection efficiency. Furthermore, since the twist rate is small, the mountability to the gas treatment device is good.
【図１】（ａ）はこの発明における製造方法により作製
したフィルターユニットの斜視図例。（ｂ）は該フィル
ターユニットの濾材幅方向側正面図例。FIG. 1A is an example of a perspective view of a filter unit manufactured by a manufacturing method according to the present invention. (B) is a front view example of the filter medium width direction side of the filter unit.
【図２】フィルター部となるプリーツ濾材の斜視図例。FIG. 2 is an example of a perspective view of a pleated filter medium serving as a filter unit.
【図３】本発明に係る成型金型の全体断面図例。FIG. 3 is an example of an overall sectional view of a molding die according to the present invention.
【図４】本発明に係る成型金型の下金型展開上面概略図
例。FIG. 4 is an example of a schematic top view of a lower mold development of a molding mold according to the present invention.
【図５】本発明に係る成型金型の下金型の斜視図例。FIG. 5 is an example of a perspective view of a lower die of a molding die according to the present invention.
【符号の説明】 １ ゲート ２ リブ ３ 保持枠側面（濾材配列方向） ４ 保持枠側面（濾材幅方向） ５ フィルター部乃至フィルター濾材 ６ リブ幅 ７ リブ厚み ８ 溶融樹脂の流動経路 ９ 成型金型上下合わせ面 １０ セレーション部 １１ 上金型（固定側金型） １２ 下金型（可動側金型） １３ ランナー部 １４ リブを形成する金型コア １５ 成型金型における濾材挿入部 １６ ゲート １７ 掴み部 １８ 逃がし部 １９ 掴み部の距離[Explanation of symbols] 1 gate 2 ribs 3 Side of the holding frame (filter element arrangement direction) 4 Side of holding frame (filter width direction) 5 Filter part or filter media 6 rib width 7 Rib thickness 8 Flow path of molten resin 9 Mold die top and bottom mating surfaces 10 Serration part 11 Upper mold (fixed mold) 12 Lower mold (Movable mold) 13 Runner section 14 Mold core forming ribs 15 Filter media insertion part in molding die 16 gates 17 Grasping part 18 Relief department 19 Grip distance
フロントページの続き Ｆターム(参考） 4D019 AA01 BA04 BA13 BB02 BB03 BC05 CB01 CB04 CB06 4D058 JA14 JB24 JB25 KA01 KA14 KA23 KA25 SA20 TA03 4F206 AD17 AH03 AR12 JA07 JB12 JF05 JL02 JN34 JQ81 Continued front page F-term (reference) 4D019 AA01 BA04 BA13 BB02 BB03 BC05 CB01 CB04 CB06 4D058 JA14 JB24 JB25 KA01 KA14 KA23 KA25 SA20 TA03 4F206 AD17 AH03 AR12 JA07 JB12 JF05 JL02 JN34 JQ81
Claims (2)
部に担持される活性炭がフィルター保持枠部まで装填さ
れ、かつ下記（１）式で示されるねじれ率が１５０％以
下であることを特徴とするフィルターユニット。 ねじれ率 ＝ （Ａ）／（Ｂ） × １００％ （１） （ここで（Ａ）とは、濾材幅方向の保持枠の一方の側面
を固定し、対面の保持枠の一端に濾材面に対して垂直方
向から力を加えた時の保持枠が歪んで動いた距離、
（Ｂ）は保持枠の巾）1. A filter unit characterized in that the activated carbon carried on the filter part is loaded up to the filter holding frame part, and the twist ratio shown by the following formula (1) is 150% or less. Twist rate = (A) / (B) x 100% (1) (Here, (A) means that one side of the holding frame in the width direction of the filter medium is fixed and one end of the holding frame facing the filter medium surface is used. The distance that the holding frame was distorted and moved when a force was applied from the vertical direction,
(B) is the width of the holding frame)
いて、該フィルターユニットの金型における逃がし部の
クリアランスＡが濾材厚みに対して８０〜１１５%、掴
み部のクリアランスＢが濾材厚みに対して２５〜４５
%，且つ，掴み部の距離Ｃが０．５〜５ｍｍであること
を特徴とするフィルターユニットの製造法。2. The filter unit according to claim 1, wherein the clearance A of the relief portion of the mold of the filter unit is 80 to 115% with respect to the thickness of the filter medium, and the clearance B of the gripping portion is 25 with respect to the thickness of the filter medium. ~ 45
%, And the distance C of the grip portion is 0.5 to 5 mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001269290A JP2003071221A (en) | 2001-09-05 | 2001-09-05 | Integrally molded filter unit and production method therefor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001269290A JP2003071221A (en) | 2001-09-05 | 2001-09-05 | Integrally molded filter unit and production method therefor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2003071221A true JP2003071221A (en) | 2003-03-11 |
Family
ID=19095139
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2001269290A Withdrawn JP2003071221A (en) | 2001-09-05 | 2001-09-05 | Integrally molded filter unit and production method therefor |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2003071221A (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5150966A (en) * | 1974-10-31 | 1976-05-06 | Kozo Sugiura | NETSUYOJUZAINI KANAAMIRUIOINSAATOSURU HOHO |
| JPS63268607A (en) * | 1987-04-28 | 1988-11-07 | Munekata Kk | Die for integrally molded air filter |
| JPS63287521A (en) * | 1987-05-19 | 1988-11-24 | Shuji Harada | Dust net for air cleaner and production thereof |
| JP2001239121A (en) * | 2000-03-02 | 2001-09-04 | Toyobo Co Ltd | Filter unit and method for manufacturing the same |
-
2001
- 2001-09-05 JP JP2001269290A patent/JP2003071221A/en not_active Withdrawn
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5150966A (en) * | 1974-10-31 | 1976-05-06 | Kozo Sugiura | NETSUYOJUZAINI KANAAMIRUIOINSAATOSURU HOHO |
| JPS63268607A (en) * | 1987-04-28 | 1988-11-07 | Munekata Kk | Die for integrally molded air filter |
| JPS63287521A (en) * | 1987-05-19 | 1988-11-24 | Shuji Harada | Dust net for air cleaner and production thereof |
| JP2001239121A (en) * | 2000-03-02 | 2001-09-04 | Toyobo Co Ltd | Filter unit and method for manufacturing the same |
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