JP2004263440A

JP2004263440A - Manufacturing method for drain outlet filter and manufacturing device

Info

Publication number: JP2004263440A
Application number: JP2003054995A
Authority: JP
Inventors: Madoka Yamashita; 円山下; Naoki Ohashi; 直樹大橋
Original assignee: Kobayashi Pharmaceutical Co Ltd
Current assignee: Kobayashi Pharmaceutical Co Ltd
Priority date: 2003-02-28
Filing date: 2003-02-28
Publication date: 2004-09-24
Anticipated expiration: 2023-02-28
Also published as: JP4392550B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a drain outlet filter equipped with a circular installation section and a shell-like wall having a rise section upward from the installation section and a closed upper surface capable of maintaining drainage capacity for a long period of time while maintaining high catching ability of foreign matter and a manufacturing device. <P>SOLUTION: A projected type 95 having a projected section 95a corresponding to an inside shape of the shell-like wall 10a and a circular type 90 having an inside diameter corresponding to the circumference of the lower end of the shell-like wall 10a are used, and while maintaining the projected type 95 in a molding temperature, the circular type 90 is applied to one surface of a sheet body m3 consisting of a thermoplastic foaming resin having a three dimensional net structure, the projected type 95 is applied to the other surface, and the sheet body m3 is paralleled with the projected type 95 to mold it in a shell-shape by passing the sheet m3 and the projected type 95 through an opening section of the circular type 90. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、排水口用フィルタの製造方法及び製造装置に関し、より詳細には、浴室の洗い場、洗面場、流し台、屋外の洗い場、排水中に異物の混入を伴う場所などに設けられた排水口に設置される排水口用フィルタの製造方法及び製造装置に関する。
【０００２】
【従来の技術】
上記排水口では、排水管の詰まりや汚染を防止するため、排水中のゴミや毛などの異物を捕捉し、排水とは別に廃棄することが望ましい。このため、上記排水口に装着する種々の排水口用フィルタが提案されている。
【０００３】
例えば、特開平８−４９２７４号公報（特許文献１）には、合成繊維のパイル織りにより基材表面から無数の針状体を突出させたシート状の排水口用フィルタが示されている。この排水口用フィルタは、裏面の粘着材層により排水口の目皿に貼着され、排水に含まれる毛などを表面の針状体に絡ませて捕捉するようになっている。これと同様に針状体（剛毛）を備えたシート状の排水口用フィルタが、実用新案第３０４２５１６号（特許文献２）、実開昭６０−１８９３０５号公報（特許文献３）にもそれぞれ記載されている。
【０００４】
また、実開平６−３０２７０号公報（特許文献４）には、排水口の目皿の下面に沿わせて組込み可能なシート状の排水口用フィルタ、及び目皿を包み込む袋状の排水口用フィルタが示されている。このように排水口の目皿に重ねて組み込む、或いは目皿を包み込む排水口用フィルタが、特開平６−２８５３０９号公報（特許文献５）、実開平７−１５８７２号公報（特許文献６）、及び特開平１０−２５２１１５号公報（特許文献７）にそれぞれ記載されている。
【０００５】
実開昭６１−１７３４０１号公報（特許文献８）及び実開昭６２−９４１６４号公報（特許文献９）には、目皿の周縁から下方へ吊り下げて設置されるネット状の排水口用フィルタが記載されている。
【０００６】
実開昭６３−１７３３０５号公報（特許文献１０）には、ドーム状に隆起したフィルタの外周部を囲むように粘着面を設けた排水口用フィルタが記載されている。そして、特開平８−２９６２６５号公報（特許文献１１）には、目皿の中央上方から目皿を覆うように放射状に広がる複数のゴミ取り部材を有する排水口用フィルタが記載されている。
【０００７】
さらに、特開平９−２２５２１４号公報（特許文献１２）には、排水口直下の排水管に挿入されて用いられる三次元網目構造からなる略円柱形の排水口用フィルタが記載されている。
【０００８】
【特許文献１】
特開平８−４９２７４号公報（第３頁）
【０００９】
【特許文献２】
実用新案第３０４２５１６号（第３頁）
【００１０】
【特許文献３】
実開昭６０−１８９３０５号公報（第３頁）
【００１１】
【特許文献４】
実開平６−３０２７０号公報（第３頁）
【００１２】
【特許文献５】
特開平６−２８５３０９号公報（第４頁）
【００１３】
【特許文献６】
実開平７−１５８７２号公報（第４頁）
【００１４】
【特許文献７】
特開平１０−２５２１１５号公報（第４頁）
【００１５】
【特許文献８】
実開昭６１−１７３４０１号公報（第４頁）
【００１６】
【特許文献９】
実開昭６２−９４１６４号公報（第４頁）
【００１７】
【特許文献１０】
実開昭６３−１７３３０５号公報（第４頁）
【００１８】
【特許文献１１】
特開平８−２９６２６５号公報（第４頁）
【００１９】
【特許文献１２】
特開平９−２２５２１４号公報（第４頁）
【００２０】
【発明が解決しようとする課題】
しかしながら、上記特許文献１〜７及び１２に記載の排水口用フィルタでは、排水を受けるフィルタ部分の形状は排水口の開口部や排水管内に設置される平板状のものであり、その面積は排水口や排水管の径と同程度となっている。そのため、この限られた面積内を排水が通過し、フィルタ部分がすぐに目詰まりしてしまうという欠点があった。
【００２１】
また、特許文献８及び９に記載の排水口用フィルタのように、目皿の下方に網部を垂下させるものの場合には、水分を含む異物を捕らえる網部が空気の流通し難い目皿の下方に設置されるため、雑菌が繁殖しやすく不衛生であるという問題があった。
【００２２】
また、特許文献１０に記載の排水口用フィルタでは、フィルタの網目が単層であるため異物を逃しやすいという欠点があった。そのため、同じフィルタを複数枚重ねる形態も図示されているが、この場合も異物の捕捉能力、特に小さいゴミ等の異物を捕捉する能力は個々の単層フィルタにより決定されるので、大幅な改善を期待することはできない。さらに複数枚重ねることによりコストが嵩む、フィルタの清掃がより面倒になるなどの問題が発生する。
【００２３】
特許文献１１に記載の排水口用フィルタにおいても、同様に異物の捕捉能力が低いという問題がある。この場合、フィルタは網目ではなく櫛歯状となっているので、さらに異物の捕捉能力が低くなってしまう。
【００２４】
上記のように、従来の排水口用フィルタには、高い異物の捕捉能力を保ちつつ、排水能力を長期間維持することはできなかった。
【００２５】
本発明者は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えていることを特徴とする排水口用フィルタによれば、高い異物の捕捉能力を保ちつつ、排水能力を長期間維持し得ることを見い出した。
【００２６】
また、本発明は、上記構成を有する排水口用フィルタを製造するための排水口用フィルタの製造方法及び製造装置を提供することを目的とする。
【００２７】
【課題を解決するための手段】
本発明に係る排水口用フィルタの製造方法は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えており、前記設置部は、前記殻状壁が排水口を覆う位置をとるように、前記排水口又はその近傍に接し得る排水口用フィルタの製造方法であって、前記殻状壁の内面形状に対応する凸部を有する凸型と、前記殻状壁の下端外周に対応する内径を有する環状型とを用い、前記凸型を成形温度に保ちつつ、三次元網目構造を有する熱可塑性発泡樹脂からなるシート体の一方の面に前記環状型、他方の面に前記凸型を当てがい、該シート体及び前記凸型を該環状型の開口部に通すことにより前記シート体を前記凸型に沿わせて殻状に成形することを特徴とする。
【００２８】
上記製造方法によれば、殻状壁の内面形状に対応する凸部を有する凸型と、殻状壁の下端外周に対応する内径を有する環状型という簡単な装置により、殻状壁の殻形状を得ることができ、上記排水口用フィルタを製造することができる。
【００２９】
また、三次元網目構造を有するシート体を凸型に沿わせることにより、シート体の内側における網目が外側における網目よりも網目の開口が小さくなるようシート体を変形させ、この状態でシート体に成形熱を加えて網目を固定することができる。これにより、前記三次元網目構造からなる部分の内側における網目が、外側における網目よりも網目の開口が小さい排水口用フィルタを容易に製造することができる。
【００３０】
また、本発明に係る他の排水口用フィルタの製造方法は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えており、前記設置部は、前記殻状壁が排水口を覆う位置をとるように、前記排水口又はその近傍に接し得る排水口用フィルタの製造方法であって、前記殻状壁の内面形状に対応する凸部を有する雄型と、前記殻状壁の外面の形状に対応する凹陥部を有する雌型とを用い、前記雄型を成形温度に保ち、前記雌型を成形温度より低くしつつ、三次元網目構造を有する熱可塑性発泡樹脂からなるシート体を前記雄型と前記雌型とで挟むことにより殻状に成形することを特徴とする。
【００３１】
上記製造方法によれば、殻状壁の内面形状に対応する凸部を有する雄型と、前記殻状壁の外面の形状に対応する凹陥部を有する雌型という簡単な装置により、殻状壁の殻形状を得ることができ、上記排水口用フィルタを製造することができる。
【００３２】
また、前記凸型及び環状型を使用する場合に比し、シート体を両側から雄型及び雌型により挟んで成形するので、成形精度が向上する。この場合も、三次元網目構造を有するシート体を凸型に沿わせることにより、シート体の内側における網目が外側における網目よりも網目の開口が小さくなるようシート体を変形させ、この状態でシート体に成形熱を加えて網目を固定することができる。これにより、前記三次元網目構造からなる部分の内側における網目が、外側における網目よりも網目の開口が小さい排水口用フィルタを容易に製造することができる。
【００３３】
また、本発明に係るさらに他の排水口用フィルタの製造方法は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えており、前記設置部は、前記殻状壁が排水口を覆う位置をとるように、前記排水口又はその近傍に接し得る排水口用フィルタの製造方法であって、前記殻状壁の内面形状に対応する凸部又は前記殻状壁の外面形状に対応する凹部からなる成形面と、該成形面に開口する多数の吸気用小孔とを備えた成形型を用い、前記三次元編目構造部材を成形温度に加熱し、押え部材により前記三次元編目構造部材及び低通気性シートを、前記成形面を覆うように位置決めし、前記成形型の吸気用小孔からの吸気により前記成形面と前記低通気性シートとの間を減圧することにより前記三次元編目構造部材を前記成形面に沿わせて殻状に成形することを特徴とする。
【００３４】
本発明に係る排水口用フィルタの製造装置は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えており、前記設置部は、前記殻状壁が排水口を覆う位置をとるように、前記排水口又はその近傍に接し得る排水口用フィルタの製造装置であって、前記殻状壁の内面形状に対応する凸部を有する凸型と、前記殻状壁の下端外周に対応する内径を有する環状型とを備え、前記三次元網目構造の部材に殻状壁成型用の熱を付与する加熱部が、前記凸型に備えられていることを特徴とする。
【００３５】
上記製造装置によれば、上記製造方法を実施することができる。
【００３６】
また、本発明に係る他の排水口用フィルタの製造装置は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えており、前記設置部は、前記殻状壁が排水口を覆う位置をとるように、前記排水口又はその近傍に接し得る排水口用フィルタの製造装置であって、前記殻状壁の内面形状に対応する凸部を有する雄型と、前記殻状壁の外面の形状に対応する凹陥部を有する雌型とを備え、前記三次元網目構造の部材に殻状壁成型用の熱を付与する加熱部が、前記雄型に備えられていることを特徴とする。
【００３７】
上記製造装置によれば、上記製造方法を実施することができる。
【００３８】
また、本発明に係るさらに他の排水口用フィルタの製造装置は、環状の設置部と、該設置部から上方への立ち上がり部及び閉じた天面を有した殻状壁とを備え、該殻状壁が三次元網目構造からなる部分を備えており、前記設置部は、前記殻状壁が排水口を覆う位置をとるように、前記排水口又はその近傍に接し得る排水口用フィルタの製造装置であって、前記殻状壁の内面形状に対応する凸部又は前記殻状壁の外面形状に対応する凹部からなる成形面、及び該成形面に開口する多数の吸気用小孔を備えた成形型と、前記三次元編目構造部材を成形温度にするための加熱部と、前記三次元編目構造部材及び低通気性シートを、前記成形型の成形部を覆うように位置決めする押え部材と、前記成形型の吸気用小孔を吸引源に接続するための接続部とを備えたことを特徴とする。
【００３９】
【発明の実施の形態】
以下、本発明に係る実施形態について、添付図面を参照しつつ詳細に説明をする。
【００４０】
図１（ａ）は、本発明の実施形態に係る排水口用フィルタの製造方法により製造された排水口用フィルタの斜視図であり、図１（ｂ）は図１（ａ）に示した領域Ａ、図１（ｃ）は領域Ｂにおける排水口用フィルタの断面をそれぞれ示している。図２（ａ）は、該排水口用フィルタの使用状態を示した図であり、図２（ｂ）は図２（ａ）に示した領域Ｃにおける排水口用フィルタの断面を示している。
【００４１】
図示のように、本発明の実施形態に係る排水口用フィルタ１０は、環状の設置部１０ｂと、設置部１０ｂから上方への立ち上がり部及び閉じた天面を有したドーム型の殻状壁１０ａと、殻状壁１０ａの天面付近で殻状壁１０ａと結合された廃棄用吊り上げ部材１４とを備えている。
【００４２】
殻状壁１０ａは、この例では三次元網目構造からなる部分１０ｃで全体を形成されている。このような三次元網目構造は、ポリウレタン、ポリエチレン、ポリプロピレン、ポリスチレン、ポリ塩化ビニール、若しくはポリエチレンテレフタレート又はこれらの共重合体（例えば発泡ポリエチレン／ポリスチレン共重合樹脂等）、或いはこれらの混合物からなる樹脂、或いは、メラニン樹脂、生分解性樹（脂肪族ポリエステル樹脂）等の種々の樹脂の発泡処理、又は発泡処理及び破泡処理等により得ることができる。これらの中でも望ましい網目（セル）の大きさを得る点と安定性（耐水性）等の点から、ポリウレタンフォームの破泡処理により形成することが望ましく、ポリエチレンフォーム等も破泡処理により形成することもできる。ポリウレタンフォームはポリオールの種類によりエステルタイプ及びエーテルタイプのいずれにも形成可能である。エステルタイプのものでは、空隙の大きさが多様となり、伸縮性、強度、耐摩耗性、耐熱性、耐油性、耐候性の面で有利である。エーテルタイプのものは、弾力性に優れ、多様な材料が選択でき、通常エステルタイプのものより安価である。
【００４３】
本発明の実施形態では、図１（ｂ）に示すように三次元網目構造からなる部分１０ｃの外側が複数の突出繊維端１０ｄを有する起毛状とされている。また、該部分１０ｃの内側における網目は、該部分の外側における網目よりも網目の開口が小さくなっている。三次元網目構造における網目（セル）の大きさ（密度）は、排水を透過させる主要部分の最も密な部分において、２５ｍｍ当たり（ＪＩＳＫ６４００設定）４〜３０個となるように製造することが望ましい。３０個より多くなると水の透過が非常に悪くなって目詰まりも急速となり、４個より少なくなると、異物の捕捉能力が低下する。この観点から、より望ましくは８〜２５個、さらに望ましくは１０〜２０個となるように製造することが望ましい。
【００４４】
本実施形態においては、設置部１０ｂは、図１（ｃ）に示すように、設置部１０ｂは平面状に形成されている。このような形状は、例えば、殻状壁１０ａの底部を熱溶融させ平面状に固化させることによって形成される。設置部１０はこの平面状の形状によって、図２（ａ）に示すように排水口２０の周縁部２０ａに適合するように接する。
【００４５】
廃棄用吊り上げ部材１４は、殻状壁１０ａと結合されていればよく、殻状壁１０ａの天面付近でなく側面や設置部１０ｂ等に設けられていてもよく、或いは省略することもできる。また、この廃棄用吊り上げ部材１４は、摘み部と殻状壁１０ａへの連結部とを備えておればよく、殻状壁に挿通する端部に幅方向に広がる戻り止め部を設ける等、様々な形態が可能である。
【００４６】
このように構成された本発明の実施形態に係る排水口用フィルタ１０は、図２（ａ）に示すように設置部１０ｂにより排水口２０の周縁部２０ａに設置されて使用される。排水口２０に流れる排水は殻状壁１０ａを通過することとなり、三次元網目構造部分１０ｃが、排水中に含まれるゴミや毛などの異物Ｘを捕捉する。また、排水口の上方に設置されるため、水切れが良く衛生的である。
【００４７】
本発明の実施形態に係る排水口用フィルタ１０によれば、三次元網目構造部分１０ｃによって、排水中の異物Ｘを該構造中に立体的に分散させて捕捉することができるので、異物Ｘを捕捉しても該構造中に排水経路となる空隙を残留させ易い。したがって、高い異物の捕捉能力を保ちつつ、排水能力を長期間維持することができる。
【００４８】
また、設置部からの立ち上がり部及び閉じた天面を有した立体的な殻状壁１０ａが三次元網目構造部分１０ｃを備えているので、排水と最もよく接する部分が目詰まり等で排水能力を低下させても、殻状壁１０ａの他の部分からの排水が確保される。したがって、この点からも高い排水能力を長期間維持することができる。
【００４９】
さらに本実施形態では、三次元網目構造部分１０ｃの外側は、網目構造の網目の連続が切断された起毛状となっているので、排水中の異物Ｘを起毛状の部分に絡め取ることができ、より高い異物の捕捉能力を得ることができる。また、図２（ｂ）に示すように、殻状壁１０ａのドーム形状に基づいて、三次元網目構造部分１０ｃの内側における網目が、外側における網目よりも網目の開口が小さくなっているので、大きい異物Ｘ１を三次元網目構造の外側で捕捉し、小さい異物Ｘ２を内側で捕捉するというように、異物Ｘの捕捉位置をより立体的に分散させることができる。したがって、排水能力をより長期間維持することができる。
【００５０】
上記のような排水口用フィルタ１０は、その設置部１０ｂに粘着材層が設けられていても良い。これにより、排水口又はその近傍に粘着を伴って適合することができる。
【００５１】
粘着材層は、ゴム系、アクリル系、ユリア樹脂系、メラニン樹脂系、フェノール系、エポキシ樹脂系、ウレタン樹脂系、シリコーン系などの種々の樹脂で構成され得る。これらは、溶剤系、水性系のいずれでも良く、感圧接着タイプとすることができる。設置部と対象表面との間の分子間力で密着状態を維持するものでも良い。また、上記実施形態のように粘着材層を省略することもできる。
【００５２】
また、粘着材層は設置部１０ｂに沿って環状に設けることができ、或いは設置部１０ｂの複数箇所に離散的に、或いは１箇所だけに設けることもできる。尚、粘着性が強い素材を用いる場合には、使用時まで粘着性を保護するため、粘着材層は剥離紙等で覆われていることが好ましい。
【００５３】
また、殻状壁１０ａの天面付近に薬剤載置用凹部が設けられていても良い。これにより薬剤載置用凹部の中に薬剤を設置することができる。薬剤としては、洗浄剤、香料、消臭剤、脱臭剤、殺菌剤、除菌剤、抗菌剤等を用いることができ、これにより、排水中の異物を除去しつつ、設置した薬剤の作用を得ることができる。
【００５４】
図３（ａ）及び（ｂ）は、本発明により製造し得る他の形態に係る上記排水口用フィルタを排水口に設置した状態を模式的に示した断面図である。
【００５５】
図３（ａ）に示すように、排水口用フィルタ１０Ａは、環状の設置部１０Ａｂと、該設置部１０Ａｂから上方への立ち上がり部及び閉じた天面を有した殻状壁１０Ａａとを備えている。設置部１０Ａｂは、該殻状壁１０Ａａの殻状下端部を径方向内側に折り曲げ、その先端を再び下方へ折り曲げた形状となっている。図示のように、排水口用フィルタ１０Ａは、設置部１０Ａｂの先端部を排水口２０に挿入するようにして適合させることができる。
【００５６】
図３（ｂ）に示すように、さらに他の形態に係る排水口用フィルタ１０Ｂは、環状の設置部１０Ｂｂと、該設置部１０Ｂｂから上方への立ち上がり部及び閉じた天面を有した殻状壁１０Ｂａとを備えており、設置部１０Ｂｂは殻状壁１０Ｂａ下部から径方向外側に突出したフランジ部を備えている。
【００５７】
図示のように、排水口用フィルタＢは、設置部１０Ｂｂが排水口２０Ｅの周縁部２０Ｅａに載置されて適合している。この排水口用フィルタ１０Ｂによれば、設置部１０Ｂｂのフランジ部により、排水口２０Ｅの周縁部２０Ｅａとの接触面積が増し、排水口用フィルタ１０Ｂを安定して設置することができる。
【００５８】
設置部は、三角形その他の多角形状、又は円形、星形等、種々の環状の形態とすることができる。
【００５９】
殻状壁は、設置部から上方への立ち上がり部及び閉じた天面を有した種々の形状とすることができ、例えば、ドーム状、有蓋筒状、錘体状等とすることができる。ドーム型のものには、真円状に形成されたものだけでなく、卵状、楕円状、又はその組み合わせ等、全体として丸味を帯びた殻形状が含まれる。
【００６０】
次に本発明に係る排水口用フィルタの製造方法及び製造装置の例について説明する。
【００６１】
図４（ａ）は、三次元網目構造を有するシート体の基となるブロック体の製造方法を模式的に示した側面図であり、図４（ｂ）は、該ブロック体からシート体を裁断する様子を模式的に示した斜視図である。
【００６２】
まず図４（ａ）に示すように、ポリウレタンフォームの発泡体ｍ１を形成するために、原料タンク５０からポリオール、イソシアネート等を導出し、水、触媒（アミン触媒、金属触媒）、界面活性剤等を添加して、これらを反応装置６０内で混合し、該装置内のプロペラにより攪拌して反応させる。発泡体ｍ１は反応装置６０先端の排出口から排出され、ローラ７０から引き出される搬送用紙上に載積されて引き延ばされる。この場合の反応温度は望ましくは７０℃以上、より望ましくは１５０〜２００℃、さらに望ましくは１７０〜１８０℃である。また、加熱時間は、望ましくは１．５〜５分間、より望ましくは２〜４分間である。
【００６３】
この反応ではポリオールとイソシアネートとが結合してウレタン結合を形成すると共に、イソシアネートと水とが反応して二酸化炭素を発生させる泡化反応が起こる。該反応は搬送用紙上においても継続し、発泡体ｍ１は搬送用紙上で膨張しつつコンベヤで搬送される。
【００６４】
上記膨張が収まると発泡体ｍ１は破泡手段（図示せず）によって破泡される。この破泡処理には、発泡体ｍ１に振動を与える振動装置、発泡体ｍ１に突風を吹き付けるガス噴射機、発泡体ｍ１に圧力を加えるプレス機など、様々な破泡手段を用いることができる。破泡処理を受けた発泡体ｍ１は、破泡されて残留した発泡構造の骨組みによって三次元網目構造をなす。三次元網目構造における網目（セル）の大きさは、上述のように主要部分の最も密な部分において、２５ｍｍ当たり（ＪＩＳＫ６４００設定）４〜３０個、より望ましくは８〜２５個、さらに望ましくは１０〜２０個となるように製造することが望ましい。セルの大きさは、材料や添加する界面活性剤等の種類、二酸化炭素の発生量に影響を与える反応装置６０内での攪拌速度などの反応条件を変化させることにより調節することができる。
【００６５】
コンベヤで搬送された発泡体ｍ１は、裁断機８０の手前の搬送経路、又は裁断機８０に設けられた成形スリット（図示せず）に通されて略直方体状に成形される。その後、発泡体ｍ１は裁断機８０で複数のブロック体ｍ２へと裁断され、さらに、図４（ｂ）に示すように、ブロック体ｍ２から複数のシート体ｍ３へと裁断される。この裁断時にシート体ｍ３のカットされた表面は起毛状態となる。上記破泡処理をこれらの裁断処理の後に行うこともできる。
【００６６】
図５（ａ）〜（ｅ）は、本発明の実施形態に係る排水口用フィルタの製造工程を模式的に示した断面図である。本発明の実施形態に係る排水口用フィルタは、上記のように、排水口又はその近傍に接する環状の設置部１０ｂと、設置部１０ｂから上方への立ち上がり部及び閉じた天面を有した殻状壁１０ａとを備えている。
【００６７】
まず図５（ａ）に示すように、殻状壁の内面形状に対応する凸部９５ａを有する凸型９５と、殻状壁１０ａの下端外周に対応する内径のリング部９０ａを有する環状型９０とを用い、適当な搬送手段（図示せず）により凸型９５と環状型９０との間にシート体ｍ３を搬送する。尚、本実施形態では凸型９５に管部９５ｘが設けられており、管部９５ｘには電熱線が挿入され、且つ伝熱のための油が充填されている。これにより、電熱線からの熱を凸型（雄型）９５Ａに伝導させることができ、冷却時には電熱線への電力供給を遮断するようになっている。或いは、必要に応じて温度調節器等により加熱又は冷却された水などの流体を管部９５ｘに通して温度を制御することもできる。尚、管部９５ｘは、形状が損なわれない程度に凸形状に沿わせて設けられていることが望ましい。
【００６８】
次いで凸型９５を成形温度に保ちつつ、図５（ｂ）に示すように、三次元網目構造を有する熱可塑性発泡樹脂からなるシート体ｍ３の一方の面に環状型９０、他方の面に凸型９５を当てがい、シート体ｍ３及び凸型９５を環状型９０におけるリング部９０ａの開口部に通すことによりシート体ｍ３を凸型９５に沿わせて殻状に加熱成形する。このとき環状型９０はリング部９０ａでシート体ｍ３を押さえつけるので、三次元網目構造からなる部分の外側が熱で軟化乃至溶融するのを防いで、該外側を上記裁断時の起毛状に維持することができる。また、三次元網目構造を有するシート体を凸型９５に沿わせることにより、シート体ｍ３の内側における網目が外側における網目よりも網目の開口が小さくなるようシート体ｍ３を変形させ、この状態でシート体ｍ３に成形熱を加えて網目を固定することができ、これにより、三次元網目構造からなる部分の内側における網目が、外側における網目よりも網目の開口が小さい排水口用フィルタを容易に製造することができる。
【００６９】
環状型９０におけるリング部９０ａ底面と凸型９５の凸部９５ａを囲む平面との間に挟まれる部分では、シート体ｍ３が加熱圧縮され平板部１００ｂが形成される。
【００７０】
本実施形態のように、ポリウレタンフォームを用いる場合、上記成形温度は望ましくは軟化点である１６０℃以上、融点である２５０℃以下、より望ましくは１５０〜２４０℃、さらに望ましくは１８０〜２２０℃である。
【００７１】
上記加熱成形により、図５（ｃ）に示すように、環状型９０を取り除くと、凸型９５上には殻状壁１００ａとプレスにより圧縮された平板部１００ｂを備えた殻状体ｍ４が残る。
【００７２】
次に、図５（ｄ）に示すように、殻状体ｍ４を載置した凸型９５を裁断型９２直下に搬送する。裁断型９２は、凸型９５との組み合わせ時に凸部９５ａ周縁に当たるリング状刃９２ａを備えている。次いで、図５（ｅ）に示すように、殻状体ｍ４から殻状の排水口用フィルタ１０を切り出す。この切り出しは殻状壁の外周縁に沿って行ってもよいが、排水口用フィルタ１０の設置部１０ｂにおけるフランジ部が殻状壁１０ａ外周面から少し突出するように平板部１００ｂを裁断することもできる。これにより、設置部１０ｂの平坦部が増し、設置部１０ｂが排水口の周縁の略水平面に適合しやすくなる、また上述した粘着材層１２を用いる場合には、粘着材層１２を設置部１０ｂに設け易くなる。尚、必要に応じて、殻状壁１０ａに上述した廃棄用吊り上げ部材１４を取り付けることができる。さらに、凸型を下に配置することにより、成形時の加熱効率が高くなり、成形物である排水口フィルタの保形性も良好となるので好ましい。
【００７３】
図３（ａ）に示したような段部を伴った縮径部を設置部に設けるには、凸型を該設置部を含めて排水口用フィルタの内面形状に沿う形状とし、環状型を径の拡大・収縮が可能な構造とし、凸型の最大径部を通過した後に該環状型を収縮させるようにすればよい。径の拡大・収縮可能な環状型は、例えば耐熱性ゴム等の弾性体により形成することができる。或いは、環状型を周方向に複数に分割し、相互間の距離を増減させることにより径の収縮を可能にすることもできる。成形後は縮径部の途中で切断して排水口用フィルタを得る。
【００７４】
以上のように上記製造方法によれば、殻状壁１０ａの内面形状に対応する凸部９５ａを有する凸型９５と、殻状壁１０ａの下端外周に対応する内径を有する環状型９０という簡単な装置により、殻状壁１０ａの殻形状を得ることができる。
【００７５】
図６（ａ）〜（ｅ）は、本発明の他の実施形態に係る排水口用フィルタの製造工程の一部を模式的に示した断面図である。
【００７６】
図６（ａ）に示すように、図５に示した実施形態におけるリング部９０ａを有する環状型９０に代えて、殻状壁１０ａの外面の形状に対応する凹陥部９１ａを有する雌型９１を用いる。この場合、雌型９１を成形温度より低くしておく。本実施形態では雌型９１に水や冷却用チラーなどの不凍結剤を有する流体を流すための管部９５ｙが設けられており、これにより雌型９１の温度を低くすることができるようになっている。或いは、必要に応じて温度調節器等により加熱又は冷却された水などの流体を管部９５ｙに通して温度を制御することもできる。これにより、三次元網目構造からなる部分の外側が熱で軟化乃至溶融するのを防いで、該外側を上記裁断時の起毛状に維持することができる。尚、管部９５ｙは、形状が損なわれない程度に凹形状に沿わせて設けられていることが望ましい。
【００７７】
図６に示す工程は、図５の工程における凸型９５及び環状型９０を各々雄型９５及び雌型９１に置き換えて同様に行われるので、説明は省略する。
【００７８】
図７（ａ）〜（ｃ）は、本発明のさらに他の実施形態に係る排水口用フィルタの製造工程の一部を模式的に示した断面図である。
【００７９】
図７（ａ）に示すように、図５に示した実施形態におけるリング部９０ａを有する環状型９０、及びリング状刃９２ａを有する裁断型９２に代えて、雄型９５との組み合わせ時に、雄型９５の凸部９５ａとの間に殻状の空隙を形成する凹陥部９３ａと、雄型９５の凸部９５ａ周縁に当たるリング状刃９３ｂとを備えた裁断雌型９３を用いることもできる。これにより、加熱圧縮成形と排水口用フィルタ１０の切り出しとを同時に行うことができる。これは図５に示したリング部９０ａを用いる方法にも適用することができる。
【００８０】
また、シート体ｍ３を用いず、直接ポリオール、イソシアネート、水、触媒（アミン触媒、金属触媒）、界面活性剤等の原材料を、図６に示したような雄型９５と雌型９１との間の間隙に注入し、熱風炉を通して排水口用フィルタを成形することもできる。
【００８１】
また、上記実施形態ではポリウレタンフォームを用いる場合について説明したが、ポリウレタンフォームの代わりにポリエチレンフォームを用いる場合は、主原料（低密度ポリエチレン等）と有機系発泡助剤などの添加剤とを用い、図４に示したような方法でシート体ｍ３を形成し、上記実施形態と同様にして加熱成形を行う。
【００８２】
しかし、ポリエチレンフォームの場合、耐熱温度がポリウレタンの１／２〜１／３であるため、上記の方法で熱成形ができない。そこで、保温容器のようなものの中で４０℃〜５０℃程度にシート体ｍ３を温めておき、図６に示したような雄型９５及び雌型９１を使ってプレス成形するとよい。
【００８３】
或いは、殻状壁を真空成形により形成することもできる。この場合は、凸型（雄型）９５及び雌型９１のいずれかの型に吸気用小孔を設け、殻状壁の内面形状に対応する凸部又は殻状壁の外面形状に対応する凹部からなる成形面、及び該成形面に開口する多数の吸気用小孔を備えた成形型を形成する。そして、シート体ｍ３を成形温度に加熱して軟化させておき、凸型（雄型）９５及び雌型９１の内、吸気用小孔を備えた方の型に載せ、さらに該型に対して反対側のシート体ｍ３表面に、実質的に空気を透過難い変形可能な低通気性シートを載せておく。シート体ｍ３及び低通気性シートを、押え部材によって前記成形型の成形部を覆うように位置決めした後、成形型の吸気用小孔を吸引源に接続するための接続部によって、該型の凸部又は凹部とシート体ｍ３との間の空間を急激に減圧状態とすることにより成形及び冷却する。
【００８４】
低通気性シートは、実質上通気性のない非通気性シートとするのが望ましいが、吸気用小孔からの吸引により三次元編目構造部材を成形面に沿わせるように変形する程度に通気性が低いものでもよい。
【００８５】
押え部材は、成形面の周辺部において三次元編目構造部材及び低通気性シートを押さえる環状のもの、或いは、成形面との間に三次元編目構造部材及び低通気性シートを挟み得るように成形面に沿う形状の凹部又は凸部を備えたものとすることができる。
【００８６】
図８（ａ）は、他の形態に係る管部を備えた凸型（雄型）の断面図であり、図８（ｂ）及び（ｃ）は、さらに他の形態に係る管部を備えた凸型（雄型）の断面図である。
【００８７】
図８（ａ）に示した凸型（雄型）９５Ａでは、凸型（雄型）９５Ａがその下部に台部９７Ａを備えており、管部９５Ａｘは台部９７Ａに設けられている。台部９７Ａは平板状に形成されており、管部９５Ａｘには電熱線が挿入され、且つ伝熱のための油が充填されている。これにより、電熱線からの熱を凸型（雄型）９５Ａに伝導させることができる。冷却時には電熱線への電力供給を遮断するとよい。また、温度調節器等により加熱又は冷却された水などの液体を管部９５Ａｘに通して温度を制御することもできる。
【００８８】
図８（ｂ）及び（ｃ）に示した凸型（雄型）９５Ｂでは、凸型（雄型）９５Ｂが第１部材９５ＢＡと第２部材９５ＢＢとで構成されており、管部９５Ｂｘは第１部材９５ＢＡに設けられた溝部９５ＢＡｘと第２部材９５ＢＢに設けられた溝部９５ＢＢｘとを組み合わせることにより形成される。
【００８９】
【発明の効果】
本発明によれば、殻状壁の内面形状に対応する凸部を有する凸型、及び殻状壁の下端外周に対応する内径を有する環状型、或いは、殻状壁の内面形状に対応する凸部を有する雄型、及び殻状壁の外面の形状に対応する凹陥部を有する雌型という簡単な装置により、上記殻形状の排水口用フィルタを製造することができる。
【図面の簡単な説明】
【図１】（ａ）は、本発明の製造方法及び製造装置により製造された排水口用フィルタの斜視図であり、（ｂ）は（ａ）に示した領域Ａ、（ｃ）は領域Ｂにおける排水口用フィルタの断面をそれぞれ示している。
【図２】（ａ）は、図１に示す排水口用フィルタの使用状態を示した図であり、（ｂ）は（ａ）に示した領域Ｃにおける排水口用フィルタの断面を示している。
【図３】（ａ）及び（ｂ）は、本発明の方法又は装置により製造し得る排水口用フィルタを排水口に設置した状態を模式的に示した切断端面図である。
【図４】（ａ）は、三次元網目構造を有するシート体の基となるブロック体の製造方法を模式的に示した側面図であり、（ｂ）は、該ブロック体からシート体を裁断する様子を模式的に示した斜視図である。
【図５】（ａ）〜（ｅ）は、本発明に係る排水口用フィルタの製造工程の一例を模式的に示した切断端面図である。
【図６】（ａ）〜（ｅ）は、本発明に係る排水口用フィルタの製造工程の他の例を模式的に示した切断端面図である。
【図７】（ａ）〜（ｃ）は、本発明に係る排水口用フィルタの製造工程のさらに他の例を模式的に示した切断端面図である。
【図８】（ａ）は、他の形態に係る管部を備えた凸型（雄型）の切断端面図であり、（ｂ）及び（ｃ）は、さらに他の形態に係る管部を備えた凸型（雄型）の切断端面図である。
【符号の説明】
１０排水口用フィルタ
１０ａ殻状壁
１０ｂ設置部
１０ｃ三次元網目構造からなる部分
１０ｄ突出繊維端
１４廃棄用吊り上げ部材[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method and an apparatus for manufacturing a drain filter, and more particularly, a drain provided in a bathroom washing place, a washbasin, a sink, an outdoor washing place, a place where foreign matter is mixed in drainage, and the like. TECHNICAL FIELD The present invention relates to a method and an apparatus for manufacturing a drainage filter installed in a container.
[0002]
[Prior art]
In order to prevent clogging and contamination of the drain pipe, it is preferable that the drain port catches foreign matters such as dust and hairs in the drain water and discards the waste water separately from the drain water. For this reason, various drain port filters to be attached to the drain port have been proposed.
[0003]
For example, Japanese Patent Application Laid-Open No. 8-49274 (Patent Document 1) discloses a sheet-shaped drain port filter in which countless needles are projected from the surface of a base material by pile weaving of synthetic fibers. The drain port filter is adhered to a perforated plate of the drain port by an adhesive material layer on the back surface, so that hairs and the like contained in the drain water are entangled with the needle-shaped body on the surface to be captured. Similarly, sheet-shaped drainage filters having needle-like bodies (bristles) are described in Utility Model No. 30422516 (Patent Document 2) and Japanese Utility Model Application Laid-Open No. 60-189305 (Patent Document 3). Have been.
[0004]
Further, Japanese Utility Model Laid-Open No. 6-30270 (Patent Document 4) discloses a sheet-shaped drain port filter that can be incorporated along the lower surface of the drain hole and a bag-shaped drain hole that wraps the hole. The filter is shown. As described above, Japanese Patent Application Laid-Open No. 6-285309 (Patent Document 5), Japanese Utility Model Application Laid-Open No. 7-15872 (Patent Document 6) And JP-A-10-252115 (Patent Document 7).
[0005]
Japanese Utility Model Application Laid-Open No. 61-173401 (Patent Document 8) and Japanese Utility Model Application Laid-Open No. 62-94164 (Patent Document 9) disclose a net-shaped drain port filter that is suspended from the peripheral edge of a perforated plate downward. Is described.
[0006]
Japanese Utility Model Laid-Open No. 63-173305 (Patent Document 10) describes a drainage filter provided with an adhesive surface so as to surround an outer peripheral portion of a dome-shaped raised filter. Japanese Unexamined Patent Application Publication No. 8-296265 (Patent Document 11) discloses a drain filter having a plurality of dust removing members radially spreading from above the center of the perforated plate to cover the perforated plate.
[0007]
Further, Japanese Patent Application Laid-Open No. 9-225214 (Patent Document 12) describes a substantially cylindrical drain port filter having a three-dimensional mesh structure used by being inserted into a drain pipe immediately below a drain port.
[0008]
[Patent Document 1]
JP-A-8-49274 (page 3)
[0009]
[Patent Document 2]
Utility Model No. 3042516 (page 3)
[0010]
[Patent Document 3]
Japanese Utility Model Publication No. 60-189305 (page 3)
[0011]
[Patent Document 4]
Japanese Utility Model Application Laid-Open No. 6-30270 (page 3)
[0012]
[Patent Document 5]
JP-A-6-285309 (page 4)
[0013]
[Patent Document 6]
Japanese Utility Model Laid-Open Publication No. 7-15872 (page 4)
[0014]
[Patent Document 7]
JP-A-10-252115 (page 4)
[0015]
[Patent Document 8]
Published Japanese Utility Model Application No. 61-173401 (page 4)
[0016]
[Patent Document 9]
Japanese Utility Model Publication No. Sho 62-94164 (page 4)
[0017]
[Patent Document 10]
JP-A-63-173305 (page 4)
[0018]
[Patent Document 11]
JP-A-8-296265 (page 4)
[0019]
[Patent Document 12]
JP-A-9-225214 (page 4)
[0020]
[Problems to be solved by the invention]
However, in the drainage filters described in Patent Documents 1 to 7 and 12, the shape of the filter portion for receiving drainage is a flat plate installed in the opening of the drainage or in the drainage pipe, and the area thereof is drainage. It is about the same as the diameter of the mouth and drain. Therefore, there is a drawback that the drainage passes through this limited area and the filter portion is immediately clogged.
[0021]
Also, in the case of a net portion hanging down below the perforated plate, as in the drain outlet filters described in Patent Literatures 8 and 9, the net portion for catching foreign matter containing water has a mesh surface that is difficult to flow air. Since it is installed below, there is a problem that germs easily propagate and are unsanitary.
[0022]
In addition, the filter for a drain port described in Patent Document 10 has a drawback that foreign matter is easily released because the mesh of the filter is a single layer. For this reason, a form in which a plurality of the same filters are stacked is also shown, but also in this case, the ability to capture foreign matter, particularly the ability to capture foreign matter such as small dust, is determined by each single-layer filter, so that a significant improvement is achieved. I can't expect it. Further, problems such as increased cost and more troublesome cleaning of the filter are caused by stacking a plurality of sheets.
[0023]
The drainage port filter described in Patent Document 11 also has a problem that the ability to capture foreign matter is similarly low. In this case, since the filter has a comb-like shape instead of a mesh, the ability to capture foreign matter is further reduced.
[0024]
As described above, the conventional drainage filter cannot maintain the drainage capability for a long period of time while maintaining a high foreign matter trapping capability.
[0025]
The inventor has an annular installation portion, a shell-like wall having a rising portion upward from the installation portion and a closed top surface, and the shell-like wall has a portion formed of a three-dimensional network structure. It has been found that the drainage filter characterized in that the drainage capability can be maintained for a long period of time while maintaining a high foreign matter trapping capability.
[0026]
Another object of the present invention is to provide a method and an apparatus for manufacturing a filter for a drain port for manufacturing the filter for a drain port having the above configuration.
[0027]
[Means for Solving the Problems]
The method for manufacturing a drainage filter according to the present invention includes an annular installation portion, a shell-like wall having a rising portion upward from the installation portion and a closed top surface, and the shell-like wall is three-dimensional. It is provided with a portion having a mesh structure, wherein the installation portion is a method for manufacturing a drain port filter that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port, Using a convex mold having a convex portion corresponding to the inner shape of the shell-like wall and an annular mold having an inner diameter corresponding to the outer periphery of the lower end of the shell-like wall, while maintaining the convex mold at a molding temperature, a three-dimensional mesh The annular mold is applied to one surface of a sheet made of thermoplastic foamed resin having a structure, and the convex is applied to the other surface, and the sheet and the convex are passed through the opening of the annular mold. The sheet body is formed into a shell shape along the convex shape.
[0028]
According to the above manufacturing method, the shell shape of the shell-like wall is formed by a simple device such as a convex shape having a convex portion corresponding to the inner surface shape of the shell-like wall and an annular type having an inner diameter corresponding to the outer periphery of the lower end of the shell-like wall. Can be obtained, and the drainage filter can be manufactured.
[0029]
In addition, the sheet body having a three-dimensional network structure is deformed such that the mesh on the inside of the sheet body has a smaller opening than the mesh on the outside by making the sheet body have a convex shape. The mesh can be fixed by applying molding heat. This makes it possible to easily manufacture a drain filter in which the mesh inside the portion having the three-dimensional mesh structure has a smaller opening than the mesh outside.
[0030]
Further, another method of manufacturing a filter for a drain port according to the present invention includes an annular installation portion, a shell-like wall having a rising portion upward from the installation portion and a closed top surface, and A method for manufacturing a filter for a drain port that can be in contact with the drain port or in the vicinity thereof, such that the wall has a portion having a three-dimensional mesh structure, and the installation portion takes a position where the shell-shaped wall covers the drain port. A male mold having a convex portion corresponding to the inner surface shape of the shell-like wall, and a female mold having a concave portion corresponding to the shape of the outer surface of the shell-like wall, and the male mold is heated to a molding temperature. While maintaining the female mold at a temperature lower than the molding temperature, a sheet body made of a thermoplastic foamed resin having a three-dimensional network structure is formed into a shell by being sandwiched between the male mold and the female mold. .
[0031]
According to the above manufacturing method, the shell-like wall is formed by a simple device including a male mold having a convex portion corresponding to the inner shape of the shell-like wall and a female mold having a concave portion corresponding to the shape of the outer surface of the shell-like wall. Can be obtained, and the drainage filter can be manufactured.
[0032]
Further, as compared with the case where the convex mold and the annular mold are used, since the sheet body is molded by sandwiching the sheet body between the male mold and the female mold from both sides, molding accuracy is improved. Also in this case, the sheet body having the three-dimensional mesh structure is made to conform to the convex shape, thereby deforming the sheet body such that the mesh on the inner side of the sheet body has a smaller opening than the mesh on the outer side. The mesh can be fixed by applying molding heat to the body. This makes it possible to easily manufacture a drain filter in which the mesh inside the portion having the three-dimensional mesh structure has a smaller opening than the mesh outside.
[0033]
Further, still another method of manufacturing a filter for a drain port according to the present invention includes an annular installation portion, a shell-like wall having a rising portion upward from the installation portion and a closed top surface; Manufacturing a drain filter capable of contacting the drain or the vicinity thereof so that the shell-shaped wall takes a position covering the drain, wherein the installation wall has a portion having a three-dimensional network structure. A method, comprising: a molding surface comprising a convex portion corresponding to the inner surface shape of the shell-like wall or a concave portion corresponding to the outer surface shape of the shell-like wall; and a number of small holes for intake opening to the molding surface. The three-dimensional stitch structure member is heated to a molding temperature by using a forming die, and the three-dimensional stitch structure member and the low air permeable sheet are positioned by a pressing member so as to cover the forming surface, and the suction of the forming die is performed. The molding surface and the low air permeable sheet Characterized by forming the three-dimensional stitches structural member to thereby be shell-like along the molding surface by vacuum between.
[0034]
An apparatus for manufacturing a drainage filter according to the present invention includes an annular installation portion, and a shell-like wall having a rising portion upward from the installation portion and a closed top surface, and the shell-like wall is three-dimensional. It is provided with a portion having a mesh structure, wherein the installation portion is a drain port filter manufacturing apparatus that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port, A convex mold having a convex portion corresponding to the inner shape of the shell-like wall, and an annular mold having an inner diameter corresponding to the outer periphery of the lower end of the shell-like wall; The heating section for applying the heat of the above is provided on the convex shape.
[0035]
According to the manufacturing apparatus, the manufacturing method can be performed.
[0036]
Further, another apparatus for manufacturing a filter for a drain port according to the present invention includes an annular installation portion, a shell-like wall having a rising portion upward from the installation portion and a closed top surface, and The wall is provided with a portion having a three-dimensional network structure, and the installation unit is configured to be in a position where the shell-shaped wall covers the drain, so that the drain outlet or a device for manufacturing a filter for the drain can be in contact with the vicinity thereof. A male mold having a convex portion corresponding to the inner surface shape of the shell-like wall, and a female mold having a concave portion corresponding to the shape of the outer surface of the shell-like wall, the member having the three-dimensional mesh structure The male mold is provided with a heating unit for applying heat for forming a shell-like wall to the male mold.
[0037]
According to the manufacturing apparatus, the manufacturing method can be performed.
[0038]
Further, still another apparatus for manufacturing a filter for a drainage port according to the present invention includes an annular installation portion, a shell-like wall having a rising portion upward from the installation portion and a closed top surface, Manufacturing a drain filter capable of contacting the drain or the vicinity thereof so that the shell-shaped wall takes a position covering the drain, wherein the installation wall has a portion having a three-dimensional network structure. An apparatus, comprising: a molding surface comprising a convex portion corresponding to the inner surface shape of the shell-like wall or a concave portion corresponding to the outer surface shape of the shell-like wall; and a number of small intake holes opened in the molding surface. Forming die, a heating unit for setting the three-dimensional stitch structure member to a forming temperature, and a pressing member for positioning the three-dimensional stitch structure member and the low air permeable sheet so as to cover the forming part of the forming die, Connection for connecting the suction hole of the mold to a suction source Characterized by comprising a.
[0039]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0040]
FIG. 1A is a perspective view of a drain port filter manufactured by a method for manufacturing a drain port filter according to an embodiment of the present invention, and FIG. 1B is a region illustrated in FIG. 1A. 1A and FIG. 1C show cross sections of the drainage filter in the area B, respectively. FIG. 2A is a diagram illustrating a use state of the drain port filter, and FIG. 2B is a cross-sectional view of the drain port filter in a region C illustrated in FIG. 2A.
[0041]
As shown in the figure, the drain filter 10 according to the embodiment of the present invention includes a dome-shaped shell-like wall 10a having an annular installation portion 10b, a rising portion upward from the installation portion 10b, and a closed top surface. And a disposal lifting member 14 connected to the shell-shaped wall 10a near the top surface of the shell-shaped wall 10a.
[0042]
The shell-shaped wall 10a is entirely formed by a portion 10c having a three-dimensional network structure in this example. Such a three-dimensional network structure is made of polyurethane, polyethylene, polypropylene, polystyrene, polyvinyl chloride, or polyethylene terephthalate or a copolymer thereof (for example, foamed polyethylene / polystyrene copolymer resin), or a resin composed of a mixture thereof; Alternatively, it can be obtained by a foaming treatment of various resins such as a melanin resin and a biodegradable tree (aliphatic polyester resin), or a foaming treatment and a foam breaking treatment. Among these, from the viewpoint of obtaining a desired mesh (cell) size and stability (water resistance), it is desirable to form the polyurethane foam by foam breaking treatment, and to form the polyethylene foam and the like by foam breaking treatment. You can also. The polyurethane foam can be formed into either an ester type or an ether type depending on the type of the polyol. In the case of the ester type, the size of the voids is varied, which is advantageous in terms of stretchability, strength, abrasion resistance, heat resistance, oil resistance, and weather resistance. The ether type is excellent in elasticity, a variety of materials can be selected, and is usually less expensive than the ester type.
[0043]
In the embodiment of the present invention, as shown in FIG. 1 (b), the outside of a portion 10c having a three-dimensional network structure has a raised shape having a plurality of protruding fiber ends 10d. The mesh inside the portion 10c has a smaller opening than the mesh outside the portion 10c. The size (density) of meshes (cells) in the three-dimensional mesh structure is desirably manufactured so as to be 4 to 30 per 25 mm (set according to JIS K6400) in the densest part of the main part through which drainage passes. If the number is more than 30, the permeation of water is very poor and clogging is rapid. If the number is less than 4, the ability to catch foreign substances is reduced. From this point of view, it is more preferable to manufacture so as to have 8 to 25 pieces, more preferably 10 to 20 pieces.
[0044]
In the present embodiment, as shown in FIG. 1C, the installation part 10b is formed in a planar shape. Such a shape is formed, for example, by thermally melting the bottom of the shell-shaped wall 10a and solidifying it into a planar shape. Due to this planar shape, the installation portion 10 comes into contact with the peripheral portion 20a of the drain port 20 as shown in FIG.
[0045]
The disposal lifting member 14 may be connected to the shell-shaped wall 10a, and may be provided on the side surface, the installation portion 10b, or the like instead of near the top surface of the shell-shaped wall 10a, or may be omitted. Further, the disposal lifting member 14 may be provided with a knob and a connecting part to the shell-shaped wall 10a, and may be provided with a detent part widening in the width direction at an end inserted into the shell-shaped wall. Various forms are possible.
[0046]
The drain port filter 10 according to the embodiment of the present invention configured as described above is used by being installed on the peripheral portion 20a of the drain port 20 by the installation section 10b as shown in FIG. Drainage flowing to the drainage port 20 passes through the shell-shaped wall 10a, and the three-dimensional network structure portion 10c captures foreign matter X such as dust and hair contained in the drainage. In addition, since it is installed above the drain outlet, drainage is good and sanitary.
[0047]
According to the drain port filter 10 according to the embodiment of the present invention, the foreign matter X in the waste water can be three-dimensionally dispersed and captured in the structure by the three-dimensional network structure portion 10c. Even if trapped, voids serving as drainage paths are likely to remain in the structure. Therefore, it is possible to maintain the drainage capacity for a long period of time while maintaining a high foreign matter capturing ability.
[0048]
In addition, since the three-dimensional shell-like wall 10a having the rising portion from the installation portion and the closed top surface is provided with the three-dimensional network structure portion 10c, the portion that comes in most contact with the drainage is clogged or the like to reduce drainage capacity. Even if lowered, drainage from other portions of the shell-shaped wall 10a is ensured. Therefore, also from this point, a high drainage capacity can be maintained for a long time.
[0049]
Further, in the present embodiment, since the outside of the three-dimensional network structure portion 10c is in a raised state in which the continuation of the network in the network structure is cut, the foreign matter X in the drainage can be entangled with the raised part. Thus, a higher foreign matter trapping ability can be obtained. Further, as shown in FIG. 2 (b), based on the dome shape of the shell-like wall 10a, the mesh inside the three-dimensional mesh structure 10c has a smaller opening than the mesh outside, The capturing positions of the foreign matter X can be more three-dimensionally dispersed, such as capturing the large foreign matter X1 outside the three-dimensional network structure and capturing the small foreign matter X2 inside. Therefore, the drainage capacity can be maintained for a longer period.
[0050]
The drainage filter 10 as described above may be provided with an adhesive layer on the installation portion 10b. Thereby, the drainage port or the vicinity thereof can be fitted with adhesion.
[0051]
The adhesive layer can be made of various resins such as rubber, acrylic, urea resin, melanin resin, phenol, epoxy resin, urethane resin, and silicone. These may be any of a solvent type and an aqueous type, and may be a pressure-sensitive adhesive type. The one that maintains the close contact state by the intermolecular force between the installation part and the target surface may be used. Further, the adhesive layer may be omitted as in the above embodiment.
[0052]
In addition, the adhesive layer can be provided annularly along the installation portion 10b, or can be provided discretely at a plurality of locations of the installation portion 10b or at only one location. When a material having high adhesiveness is used, the adhesive layer is preferably covered with a release paper or the like in order to protect the adhesiveness until use.
[0053]
Further, a medicine mounting recess may be provided near the top surface of the shell-shaped wall 10a. Thereby, the medicine can be set in the medicine mounting recess. As the chemical, a detergent, a fragrance, a deodorant, a deodorant, a bactericide, a disinfectant, an antibacterial, and the like can be used. Obtainable.
[0054]
3 (a) and 3 (b) are cross-sectional views schematically showing a state in which the drain filter according to another embodiment that can be manufactured according to the present invention is installed in a drain.
[0055]
As shown in FIG. 3A, the drainage filter 10A includes an annular installation portion 10Ab, and a shell-like wall 10Aa having a rising portion upward from the installation portion 10Ab and a closed top surface. I have. The installation part 10Ab has a shape in which the shell-shaped lower end of the shell-shaped wall 10Aa is bent inward in the radial direction, and the tip is bent downward again. As shown, the drain filter 10A can be adapted by inserting the distal end of the installation portion 10Ab into the drain 20.
[0056]
As shown in FIG. 3B, a drain filter 10B according to still another embodiment has a shell-like shape having an annular installation portion 10Bb, a rising portion upward from the installation portion 10Bb, and a closed top surface. The installation portion 10Bb has a flange portion projecting radially outward from a lower portion of the shell-shaped wall 10Ba.
[0057]
As shown in the drawing, the drain port filter B is adapted so that the installation portion 10Bb is placed on the peripheral edge portion 20Ea of the drain port 20E. According to the drain port filter 10B, the flange area of the installation portion 10Bb increases the contact area of the drain port 20E with the peripheral edge portion 20Ea, so that the drain port filter 10B can be stably installed.
[0058]
The mounting portion can be formed in various annular shapes such as a triangle or other polygonal shapes, or a circle or a star.
[0059]
The shell-like wall can be formed in various shapes having a rising portion upward from the installation portion and a closed top surface, and can be formed in, for example, a dome shape, a covered cylindrical shape, a weight shape, or the like. The dome shape includes not only a shape formed in a perfect circle but also a shell shape that is round as a whole, such as an oval shape, an elliptical shape, or a combination thereof.
[0060]
Next, an example of a method and an apparatus for manufacturing a drainage filter according to the present invention will be described.
[0061]
FIG. 4A is a side view schematically showing a method of manufacturing a block as a basis of a sheet having a three-dimensional network structure, and FIG. 4B is a diagram illustrating a sheet body cut from the block. FIG. 4 is a perspective view schematically showing the state of the operation.
[0062]
First, as shown in FIG. 4A, in order to form a foam m1 of a polyurethane foam, a polyol, an isocyanate, and the like are derived from a raw material tank 50, and water, a catalyst (an amine catalyst, a metal catalyst), a surfactant, and the like are used. Are added, and these are mixed in the reaction device 60 and reacted by stirring with a propeller in the device. The foam m1 is discharged from the discharge port at the tip of the reaction device 60, and is loaded on the transport paper drawn out from the roller 70 and expanded. The reaction temperature in this case is desirably 70 ° C or higher, more desirably 150 to 200 ° C, and further desirably 170 to 180 ° C. The heating time is preferably 1.5 to 5 minutes, more preferably 2 to 4 minutes.
[0063]
In this reaction, a polyol and an isocyanate combine to form a urethane bond, and a foaming reaction occurs in which the isocyanate and water react to generate carbon dioxide. The reaction continues on the transport paper, and the foam m1 is transported on the conveyor while expanding on the transport paper.
[0064]
When the expansion has stopped, the foam m1 is broken by foam breaking means (not shown). For this foam breaking treatment, various foam breaking means, such as a vibrating device for giving vibration to the foam m1, a gas injector for blowing gusts to the foam m1, and a press for applying pressure to the foam m1, can be used. The foam m1 that has been subjected to the foam breaking treatment forms a three-dimensional network structure by the framework of the foamed structure that has been broken and remains. As described above, the size of the mesh (cell) in the three-dimensional network structure is 4 to 30, more preferably 8 to 25, and still more preferably 25 to 25 mm (in accordance with JIS K6400) in the densest part of the main part. It is desirable to manufacture so as to have 10 to 20 pieces. The size of the cell can be adjusted by changing the reaction conditions such as the type of the material and the surfactant to be added and the stirring speed in the reaction device 60 which affects the amount of carbon dioxide generated.
[0065]
The foam m1 conveyed by the conveyor is formed into a substantially rectangular parallelepiped by passing through a conveying path before the cutter 80 or a forming slit (not shown) provided in the cutter 80. Thereafter, the foam m1 is cut into a plurality of blocks m2 by the cutting machine 80, and further, as shown in FIG. 4B, is cut from the block m2 into a plurality of sheets m3. At the time of this cutting, the cut surface of the sheet m3 is in a raised state. The above-mentioned bubble breaking treatment can also be performed after these cutting treatments.
[0066]
5 (a) to 5 (e) are cross-sectional views schematically showing a process for manufacturing a drainage filter according to an embodiment of the present invention. As described above, the drainage port filter according to the embodiment of the present invention has an annular installation portion 10b in contact with the drainage hole or the vicinity thereof, a shell having a rising portion upward from the installation portion 10b and a closed top surface. And a wall 10a.
[0067]
First, as shown in FIG. 5A, a convex mold 95 having a convex portion 95a corresponding to the inner shape of the shell-like wall and an annular mold 90 having a ring portion 90a having an inner diameter corresponding to the outer periphery of the lower end of the shell-like wall 10a. Then, the sheet m3 is transported between the convex die 95 and the annular die 90 by a suitable transport means (not shown). In this embodiment, the convex part 95 is provided with a tube part 95x, and the tube part 95x is inserted with a heating wire and filled with oil for heat transfer. As a result, heat from the heating wire can be conducted to the convex (male) 95A, and power supply to the heating wire is shut off during cooling. Alternatively, if necessary, a fluid such as water heated or cooled by a temperature controller or the like can be passed through the pipe 95x to control the temperature. It is preferable that the tube portion 95x is provided along a convex shape so that the shape is not damaged.
[0068]
Next, while the convex mold 95 is maintained at the molding temperature, as shown in FIG. The mold 95 is applied, and the sheet m3 and the convex 95 are passed through the opening of the ring portion 90a of the annular mold 90, so that the sheet m3 is formed into a shell shape along the convex 95. At this time, the annular mold 90 presses the sheet body m3 with the ring portion 90a, so that the outside of the portion having the three-dimensional network structure is prevented from being softened or melted by heat, and the outside is maintained in a raised state at the time of the above cutting. be able to. Further, by aligning the sheet having the three-dimensional mesh structure with the convex 95, the sheet m3 is deformed such that the mesh on the inside of the sheet m3 has a smaller opening than the mesh on the outside. The mesh can be fixed by applying molding heat to the sheet body m3, whereby a drain filter in which the mesh inside the portion having the three-dimensional mesh structure has a smaller opening than the mesh outside can be easily formed. Can be manufactured.
[0069]
At the portion of the annular mold 90 that is sandwiched between the bottom surface of the ring portion 90a and the plane surrounding the convex portion 95a of the convex shape 95, the sheet m3 is heated and compressed to form the flat plate portion 100b.
[0070]
When a polyurethane foam is used as in the present embodiment, the molding temperature is preferably 160 ° C. or more as a softening point, 250 ° C. or less as a melting point, more preferably 150 to 240 ° C., and still more preferably 180 to 220 ° C. is there.
[0071]
As shown in FIG. 5C, when the annular mold 90 is removed by the heat molding, a shell m4 having a shell-like wall 100a and a flat plate portion 100b compressed by a press remains on the convex mold 95. .
[0072]
Next, as shown in FIG. 5D, the convex mold 95 on which the shell m4 is placed is transported immediately below the cutting mold 92. The cutting die 92 includes a ring-shaped blade 92a that hits the periphery of the projection 95a when combined with the projection 95. Next, as shown in FIG. 5E, a shell-shaped drain filter 10 is cut out from the shell m4. This cutting may be performed along the outer peripheral edge of the shell-shaped wall, but the flat plate portion 100b is cut so that the flange portion of the installation portion 10b of the drainage filter 10 slightly projects from the outer peripheral surface of the shell-shaped wall 10a. You can also. As a result, the flat portion of the installation portion 10b increases, and the installation portion 10b easily conforms to a substantially horizontal surface of the periphery of the drain port. When the above-described adhesive layer 12 is used, the adhesive layer 12 is attached to the installation portion 10b. It becomes easy to provide. In addition, the above-mentioned disposal lifting member 14 can be attached to the shell-shaped wall 10a as needed. Further, it is preferable to dispose the convex below, because the heating efficiency at the time of molding increases and the shape retention of the drainage filter as a molded product is also improved.
[0073]
In order to provide a reduced diameter portion with a step portion as shown in FIG. 3 (a) in the installation portion, the convex shape including the installation portion is formed along the inner surface shape of the drain filter, and the annular shape is used. What is necessary is just to make it the structure which can expand and contract a diameter, and to make the said annular type | mold contract after passing through the largest diameter part of a convex type. The annular mold whose diameter can be expanded or contracted can be formed of an elastic body such as a heat-resistant rubber. Alternatively, the annular mold can be divided into a plurality in the circumferential direction, and the diameter can be reduced by increasing or decreasing the distance between the annular molds. After molding, the filter is cut in the middle of the reduced diameter portion to obtain a drainage filter.
[0074]
As described above, according to the above-described manufacturing method, the simple shape of the convex mold 95 having the convex portion 95a corresponding to the inner surface shape of the shell-shaped wall 10a and the annular mold 90 having the inner diameter corresponding to the outer periphery of the lower end of the shell-shaped wall 10a are provided. With the device, the shell shape of the shell-like wall 10a can be obtained.
[0075]
FIGS. 6A to 6E are cross-sectional views schematically showing a part of a manufacturing process of a drainage filter according to another embodiment of the present invention.
[0076]
As shown in FIG. 6A, a female mold 91 having a concave portion 91a corresponding to the shape of the outer surface of the shell-like wall 10a is used instead of the annular mold 90 having the ring portion 90a in the embodiment shown in FIG. Used. In this case, the female mold 91 is kept lower than the molding temperature. In the present embodiment, the female mold 91 is provided with a pipe portion 95y for flowing a fluid having an antifreezing agent such as water or a cooling chiller, so that the temperature of the female mold 91 can be lowered. ing. Alternatively, if necessary, a fluid such as water heated or cooled by a temperature controller or the like can be passed through the pipe 95y to control the temperature. This prevents the outside of the portion having the three-dimensional network structure from being softened or melted by heat, and the outside can be maintained in a raised state during the cutting. It is desirable that the tube portion 95y is provided along the concave shape so that the shape is not damaged.
[0077]
The process shown in FIG. 6 is performed in the same manner as in the process of FIG. 5 except that the convex mold 95 and the annular mold 90 are replaced with a male mold 95 and a female mold 91, respectively, and thus the description is omitted.
[0078]
FIGS. 7A to 7C are cross-sectional views schematically showing a part of a manufacturing process of a drainage filter according to still another embodiment of the present invention.
[0079]
As shown in FIG. 7 (a), instead of the annular mold 90 having the ring portion 90a and the cutting mold 92 having the ring-shaped blade 92a in the embodiment shown in FIG. It is also possible to use a cut female mold 93 provided with a concave portion 93a forming a shell-shaped gap between the convex portion 95a of the mold 95 and a ring-shaped blade 93b corresponding to the peripheral edge of the convex portion 95a of the male mold 95. Thereby, the heat compression molding and the cutting out of the drainage filter 10 can be performed simultaneously. This can be applied to the method using the ring portion 90a shown in FIG.
[0080]
Further, raw materials such as polyol, isocyanate, water, catalyst (amine catalyst, metal catalyst) and surfactant are directly used between the male mold 95 and the female mold 91 as shown in FIG. And a drain filter can be formed through a hot blast stove.
[0081]
In the above embodiment, the case where a polyurethane foam is used has been described. However, when a polyethylene foam is used instead of the polyurethane foam, a main material (such as low-density polyethylene) and an additive such as an organic foaming auxiliary are used. A sheet m3 is formed by a method as shown in FIG. 4, and heat molding is performed in the same manner as in the above embodiment.
[0082]
However, in the case of polyethylene foam, since the heat resistance temperature is 1/2 to 1/3 of that of polyurethane, thermoforming cannot be performed by the above method. Therefore, it is preferable to heat the sheet m3 to about 40 ° C. to 50 ° C. in a container such as a heat retaining container and press-mold the sheet m3 using the male mold 95 and the female mold 91 as shown in FIG.
[0083]
Alternatively, the shell-like wall can be formed by vacuum forming. In this case, a small hole for intake is provided in one of the convex type (male type) 95 and the female type 91, and a convex portion corresponding to the inner surface shape of the shell-like wall or a concave portion corresponding to the outer surface shape of the shell-like wall. And a mold having a plurality of small intake holes opened in the molding surface. Then, the sheet body m3 is heated to a molding temperature to be softened, and placed on one of the convex (male) 95 and the female mold 91 having the small hole for intake. A deformable low air-permeability sheet, which is substantially difficult to transmit air, is placed on the surface of the opposite side of the sheet body m3. After positioning the sheet body m3 and the low-permeability sheet so as to cover the molding portion of the molding die with the pressing member, the convex portion of the molding die is connected by the connection portion for connecting the small hole for suction of the molding die to the suction source. The space between the portion or the concave portion and the sheet member m3 is rapidly reduced in pressure to form and cool.
[0084]
It is desirable that the low-breathable sheet is a substantially non-breathable non-breathable sheet, but is permeable to such an extent that the three-dimensional knitted structural member is deformed along the forming surface by suction from the small holes for intake. May be low.
[0085]
The holding member is an annular member that presses the three-dimensional stitch structure member and the low-permeability sheet around the molding surface, or is formed so that the three-dimensional stitch structure member and the low-permeability sheet can be sandwiched between the pressing member and the molding surface. It may be provided with a concave portion or a convex portion along the surface.
[0086]
FIG. 8A is a sectional view of a convex type (male type) provided with a tube according to another embodiment, and FIGS. 8B and 8C are provided with a tube according to another embodiment. It is sectional drawing of the convex type (male type).
[0087]
In the convex (male) 95A shown in FIG. 8A, the convex (male) 95A has a base 97A at its lower part, and the tube 95Ax is provided on the base 97A. The base 97A is formed in a flat plate shape, and a heating wire is inserted into the tube 95Ax and filled with oil for heat transfer. Thus, heat from the heating wire can be conducted to the convex (male) 95A. At the time of cooling, power supply to the heating wire may be shut off. Further, the temperature can be controlled by passing a liquid such as water heated or cooled by a temperature controller or the like through the pipe portion 95Ax.
[0088]
In the convex (male) 95B shown in FIGS. 8B and 8C, the convex (male) 95B includes a first member 95BA and a second member 95BB, and the tube portion 95Bx has a It is formed by combining a groove 95BAx provided in one member 95BA and a groove 95BBx provided in the second member 95BB.
[0089]
【The invention's effect】
According to the present invention, a convex shape having a convex portion corresponding to the inner surface shape of the shell-shaped wall, an annular shape having an inner diameter corresponding to the outer periphery of the lower end of the shell-shaped wall, or a convex shape corresponding to the inner surface shape of the shell-shaped wall. The above-mentioned drain filter having a shell shape can be manufactured by a simple device including a male type having a portion and a female type having a concave portion corresponding to the shape of the outer surface of the shell-shaped wall.
[Brief description of the drawings]
1A is a perspective view of a drainage filter manufactured by a manufacturing method and a manufacturing apparatus of the present invention, FIG. 1B is a region A shown in FIG. 1A, and FIG. 2 shows a cross section of the drainage filter in FIG.
2A is a diagram illustrating a use state of the drain port filter illustrated in FIG. 1, and FIG. 2B is a cross-sectional view of the drain port filter in a region C illustrated in FIG. .
FIGS. 3 (a) and 3 (b) are cut end views schematically showing a state in which a drain filter which can be manufactured by the method or apparatus of the present invention is installed in the drain.
FIG. 4 (a) is a side view schematically showing a method of manufacturing a block as a base of a sheet having a three-dimensional network structure, and FIG. 4 (b) is a sheet cut from the block. FIG. 4 is a perspective view schematically showing the state of the operation.
FIGS. 5A to 5E are cross-sectional end views schematically showing an example of a manufacturing process of the drainage filter according to the present invention.
FIGS. 6 (a) to 6 (e) are cut end views schematically showing another example of the production process of the drainage filter according to the present invention.
FIGS. 7A to 7C are cut end views schematically showing still another example of the manufacturing process of the drainage filter according to the present invention.
8A is a cut end view of a convex (male) provided with a tube according to another embodiment, and FIGS. 8B and 8C show a tube according to still another embodiment. FIG. 4 is a cut end view of a convex type (male type) provided.
[Explanation of symbols]
10 Drain outlet filter
10a shell-like wall
10b Installation part
10c Part consisting of a three-dimensional network structure
10d protruding fiber end
14 Lifting members for disposal

Claims

An annular installation portion, a shell-like wall having a rising portion rising upward from the installation portion and a closed top surface, wherein the shell-like wall has a portion having a three-dimensional mesh structure; A method for manufacturing a drain port filter that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port,
Using a convex type having a convex portion corresponding to the inner surface shape of the shell-like wall, and an annular type having an inner diameter corresponding to the outer periphery of the lower end of the shell-like wall,
While maintaining the convex mold at the molding temperature, the annular mold is applied to one surface of the sheet made of thermoplastic foamed resin having a three-dimensional network structure, and the convex mold is applied to the other surface, and the sheet and the convex are applied. A method for producing a filter for drainage, characterized in that the sheet is formed into a shell shape along the projection by passing a mold through the opening of the annular mold.

An annular installation portion, a shell-like wall having a rising portion rising upward from the installation portion and a closed top surface, wherein the shell-like wall has a portion having a three-dimensional mesh structure; A method for manufacturing a drain port filter that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port,
Using a male mold having a convex portion corresponding to the inner surface shape of the shell-like wall and a female mold having a concave portion corresponding to the shape of the outer surface of the shell-like wall,
While maintaining the male mold at the molding temperature, while lowering the female mold below the molding temperature, a sheet made of thermoplastic foamed resin having a three-dimensional network structure is sandwiched between the male mold and the female mold to form a shell. A method for producing a filter for a drain port, which is formed by molding.

An annular installation portion, a shell-like wall having a rising portion rising upward from the installation portion and a closed top surface, wherein the shell-like wall has a portion having a three-dimensional mesh structure; A method for manufacturing a drain port filter that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port,
Using a mold having a molding surface comprising a convex portion corresponding to the inner surface shape of the shell-like wall or a concave portion corresponding to the outer surface shape of the shell-like wall, and a number of small holes for intake opening to the molding surface. ,
Heating the three-dimensional stitch structural member to a molding temperature, positioning the three-dimensional stitch structural member and the low air permeable sheet by a pressing member so as to cover the molding surface,
Forming the three-dimensional stitch structural member into a shell along the forming surface by reducing the pressure between the forming surface and the low air permeability sheet by suction from the suction holes of the forming die. A method for producing a drainage filter, which is characterized by the following.

An annular installation portion, a shell-like wall having a rising portion rising upward from the installation portion and a closed top surface, wherein the shell-like wall has a portion having a three-dimensional mesh structure; Is a drain port filter manufacturing apparatus that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port,
A convex mold having a convex portion corresponding to the inner surface shape of the shell-like wall, and an annular mold having an inner diameter corresponding to the outer periphery of the lower end of the shell-like wall,
An apparatus for manufacturing a filter for a drain port, wherein a heating unit for applying heat for forming a shell-like wall to the member having the three-dimensional network structure is provided in the convex shape.

An annular installation portion, a shell-like wall having a rising portion rising upward from the installation portion and a closed top surface, wherein the shell-like wall has a portion having a three-dimensional mesh structure; Is a drain port filter manufacturing apparatus that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port,
A male mold having a convex portion corresponding to the inner shape of the shell-like wall, and a female mold having a concave portion corresponding to the shape of the outer surface of the shell-like wall,
An apparatus for manufacturing a drainage filter, wherein a heating unit for applying heat for forming a shell-like wall to the member having the three-dimensional network structure is provided in the male mold.

An annular installation portion, a shell-like wall having a rising portion rising upward from the installation portion and a closed top surface, wherein the shell-like wall has a portion having a three-dimensional mesh structure; Is a drain port filter manufacturing apparatus that can be in contact with the drain port or its vicinity so that the shell-shaped wall takes a position covering the drain port,
A molding surface comprising a convex portion corresponding to the inner surface shape of the shell-like wall or a concave portion corresponding to the outer surface shape of the shell-like wall, and a mold having a large number of small holes for intake opening to the molding surface;
A heating unit for setting the three-dimensional stitch structural member to a molding temperature,
A pressing member that positions the three-dimensional stitch structure member and the low air permeable sheet so as to cover a molding portion of the molding die,
And a connecting portion for connecting the suction hole of the mold to a suction source.