JP2004321937A - Folding-in type air filter and production method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a folding-in type filter maintaining a flatness of respective flat surfaces of a filter medium even when a filtration speed is fast and capable of keeping low shape resistance. <P>SOLUTION: The folding-in type air filter comprises a filter medium sheet 12 having a pleat formed by folding-in to a zig-zag shape along a folding line; and resin beads 57a formed at at least a secondary side of the opposed surfaces of the respective pleats of the filter medium sheet 12 and provided at a plurality of rows at predetermined gaps along the folding line. The gap between the opposed surfaces constituting the pleat by adhering or contacting the apex parts of the resin beads 57a to each other by folding the filter medium sheet 12 is maintained to a taper shape. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to, for example, a folding air filter for air conditioning and a method of manufacturing the same.
[0002]
[Prior art]
A pleated filter is generally used as a filter element such as a folding air filter that does not use a separator. Pleated filters include embossed filters and mini-pleated filters that are not embossed.
[0003]
In a conventional embossed filter, embossing is performed at predetermined intervals in the length direction of a filter medium sheet made of a nonwoven fabric having a binder of a thermoplastic resin, and a fold line is formed in the width direction of the filter medium sheet (scoring). What is folded in a zigzag shape along this fold line is known (for example, see Patent Documents 1 and 2).
[0004]
Patent Document 1 discloses that after a filter medium sheet is folded along a fold line in order to maintain each plane forming pleats at a constant interval, the filter medium sheet is connected to a fold on a primary side and a fold on a secondary side by a resin bead. ing.
[0005]
In Patent Document 2, after a filter medium sheet is embossed by an embossing roll, a resin bead is applied to the top and folded.
[0006]
[Patent Document 1]
Japanese Utility Model Application Laid-Open No. 61-75819 (claims for registering utility models, FIG. 1)
[0007]
[Patent Document 2]
JP-A-9-220427 (Claims, FIG. 1)
[0008]
[Problems to be solved by the invention]
However, the one disclosed in Patent Document 1 is used only for light loads with low wind speed because the plane from the peak line to the valley line is bent and the shape resistance increases rapidly when the filtering speed of the air flow is high at high wind speed. .
[0009]
In the case of Patent Document 2, embossing cannot be performed unless a special filter medium capable of embossing is used. Further, the embossing rolls are expensive, and it is necessary to prepare a plurality of embossing rolls each time the embossing interval is different or the folding height is different, which causes an increase in cost.
[0010]
The present invention has been made in view of the above circumstances, and aims at maintaining high flatness of each plane of the filter medium and maintaining low shape resistance even at a high flow rate and a high filtration rate. A foldable air filter and a method for manufacturing the foldable air filter, which can achieve a significant cost reduction because a general filter medium having no embossing property can be used without requiring an expensive embossing roll required for each fold height. To provide.
[0011]
[Means for Solving the Problems]
In order to achieve the above-mentioned object, the present invention is directed to a filter medium sheet folded in a zigzag shape along a fold line to form a fold, and at least two opposing surfaces of the folds of the filter medium sheet. A bead formed on the next side and formed in a plurality of rows provided at equal intervals along the fold line, and the top of the bead is bonded or contacted to each other by folding the filter medium sheet to form the fold. The foldable air filter is characterized in that an interval between surfaces to be formed is maintained.
[0012]
A second aspect of the present invention is characterized in that the bead of the first aspect is a gradient bead formed such that a distance between opposing surfaces of each fold of the filter medium sheet is substantially proportional to a distance from a fold line.
[0013]
A third aspect of the present invention is characterized in that the bead of the first aspect is a bead obtained by stacking a plurality of beads such that a distance between opposing surfaces of each fold of the filter medium sheet is substantially proportional to a distance from a fold line. .
[0014]
A fourth aspect of the present invention is characterized in that the bead of the first aspect is an intermittent bead whose height is different in size so that the interval between the opposing surfaces of each fold of the filter medium sheet is substantially proportional to the distance from the fold line. .
[0015]
According to a fifth aspect of the present invention, the beads of the first to fourth aspects are formed on a primary side and a secondary side of opposing surfaces of each fold of the filter medium sheet, and the primary side and the secondary side bead are formed by folding the filter medium sheet. It is characterized in that they are arranged at positions shifted from each other in the line direction.
[0016]
Claim 6 is a first step of forming a fold line on the filter medium sheet, and a second step of forming a plurality of rows of beads at predetermined intervals along the fold line on at least a secondary side of both surfaces of the filter medium sheet. And a third step of folding the filter medium sheet and bonding or contacting the tops of the beads with each other so as to maintain the distance between the opposing surfaces constituting the folds. In a method of manufacturing a filter.
[0017]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0018]
1 to 4 show a first embodiment, and FIG. 1 (a) is an overall configuration diagram of a folding filter manufacturing apparatus. Reference numeral 10 denotes a filter material sheet supply unit. A belt-shaped filter material sheet 12 is wound around a filter material stand 11 and supported rotatably. The filter medium sheet 12 is fed out from the filter medium sheet supply unit 10 and is conveyed through the conveyance path 13. Reference numeral 12a denotes a spare filter medium sheet. When all of the front filter medium sheets 12 are fed out, the leading end of the spare filter medium sheet 12a is connected to the end of the filter medium sheet 12 and fed out in the same manner.
[0019]
A cutting mechanism 20 that cuts the filter medium sheet 12 into a predetermined width is provided on the transport path 13 adjacent to the filter medium sheet supply unit 10. The cutting mechanism 20 is provided with a pair of feed rollers 21 for transporting the filter medium sheet 12 while nipping the filter medium sheet 12. A cutter 23 is provided on the entrance side of the feed roller 21 with respect to the receiving roller 22. The cutter 23 is cut into a predetermined width while conveying the filter medium sheet 12 by pressing the filter medium sheet 12 against the receiving roller 22 by a cylinder 23a. Here, the scraps (scrap) 12b of the filter medium sheet 12 are discharged, and when two filter medium sheets 12 are taken, they are conveyed in parallel and simultaneously.
[0020]
On the transport path 13 adjacent to the cutting mechanism 20, a reciprocating creasing mechanism 30 for forming streaks 30a (see FIG. 1B) at regular intervals in the width direction of the filter medium sheet 12 cut to a predetermined width. Is provided. The creasing mechanism 30 is provided with a pair of feed rollers 31 for transporting the filter medium sheet 12 while sandwiching the same. At the inlet side of the feed roller 31, a tapping member 32 for applying a tapping force to the filter medium sheet 12 from above and below is provided.
[0021]
When the filter medium is a synthetic nonwoven fabric, a first crease with a heater for zigzag forming a zigzag shape along the streak 30a of the filter medium sheet 12 on the conveyance path 13 adjacent to the creasing mechanism 30 and for forming a crease habit. A mechanism 40 is provided. A tension roller 41 is provided on the entrance side of the first creasing mechanism 40. The tension roller 41 is configured such that a plurality of rollers 42 are arranged in an overlapping manner, and a certain tension is applied by passing the filter medium sheet 12 therebetween.
[0022]
At the outlet side of the tension roller 41, a pair of folding blades 43 are provided which press the filter medium sheet 12 in a zigzag manner along the streaks by pressing the filter medium sheet 12 from above and below toward the fold habit. Further, a guide member 44 for guiding the zigzag filter medium sheet 12 is provided behind the pair of folding blades 43, and a heater 45 is provided on the guide member 44. Then, the zigzag filter medium sheet 12 is heated by the heater 45 to impart a bending habit to the bent portion.
[0023]
A bead applying mechanism 50 for applying a resin bead to both surfaces of the bent filter medium sheet 12 in a state where it is stretched flat once is provided on the transport path 13 adjacent to the first creasing mechanism 40. Has been. When the filter medium is other than the synthetic nonwoven fabric, a bead application mechanism 50 is provided on the transport path 13 adjacent to the creasing mechanism 30.
[0024]
A tension mechanism 51 is provided on the entrance side of the bead application mechanism 50, and a feed roll 52 is provided on the exit side. This bead application mechanism 50 is configured as shown in FIG. That is, inside the main body 53 of the bead application mechanism 50, a pair of upper and lower first guide rollers 54 which are installed to be biased to one side, and are biased to the upper side and the opposite side above the first guide roller 54. It is composed of a pair of upper and lower second guide rollers 55 installed, and a pair of upper and lower third guide rollers 56 installed at the same height as the second guide roller 55 and offset to the left. .
[0025]
Then, the filter medium sheet 12 carried out from the tension mechanism 51 is wrapped around the first guide roller 54, then turned back at the first direction changing unit and wrapped around the second guide roller 55. Further, it is folded back from the second guide roller 55 by the second direction changing unit and is wrapped around the third guide roller 56. Therefore, the filter medium sheet 12 is horizontal between the first and second guide rollers 54 and 55, and the back surface is facing upward, and the filter medium sheet 12 is horizontal between the second and third guide rollers 55 and 56, and the front surface is Is upward.
[0026]
A plurality of first resin discharge nozzles 57 are provided between the first and second guide rollers 54 and 55 in the width direction of the filter medium sheet 12 so as to face the back surface of the filter medium sheet 12. A plurality of second resin discharge nozzles 58 are provided between the three guide rollers 55 and 56 toward the surface of the filter medium sheet 12 in the width direction of the filter medium sheet 12.
[0027]
The first and second resin discharge nozzles 57 and 58 are connected to a resin supply source (not shown) via a resin pipe 59 so that the resin in a heated and molten state is supplied. An electromagnetic valve 60 is provided in the middle of the resin pipe 59. When the electromagnetic valve 60 is opened, the molten resin is discharged from the first and second resin discharge nozzles 57 and 58. The first and second resin discharge nozzles 57 and 58 apply resin beads at predetermined intervals in the length direction of the filter medium sheet 12 and at predetermined intervals in the width direction, and are carried out by the feed roll 52.
[0028]
The first to third guide rollers 54 to 56 and the feed roll 52 are grooved rollers so that the resin beads 57a and 58a do not contact the first to third guide rollers 54 to 56 and the feed roll 52. Is formed.
[0029]
When the resin beads 57a, 58a are adhered on the transport path 13 on the side adjacent to the bead applying mechanism 50, the resin beads 57a, 58a applied to the filter medium sheet 12 are not adhered before the resin beads 12 are solidified. In the case of (2), a second creasing mechanism 70 is provided which forms a zigzag fold along the folding line after being sufficiently dried. A tension roller 71 is provided on the entrance side of the second creasing mechanism 70. The tension roller 71 is configured such that a plurality of rollers 72 are arranged in an overlapping manner, and a certain tension is applied by passing the filter medium sheet 12 between them.
[0030]
At the outlet side of the tension roller 71, a pair of folding blades 73 are provided which press the filter medium sheet 12 in a zigzag manner along the streaks by pressing the filter medium sheet 12 from above and below toward the crease habit. Therefore, the filter medium sheets 12 folded in a zigzag shape are joined by the resin beads 57a and 58a when they are adhered to each other, but when both are dried, an interval is formed by contact. . Further, an unloading conveyor 74 is provided behind the pair of folding blades 73. The unloading conveyor 74 includes a pitching conveyor for unloading the zigzag filter medium sheet 12.
[0031]
Next, the operation of the first embodiment will be described.
[0032]
When the feed roller 21 of the cutting mechanism 20 rotates, the filter medium sheet 12 of the filter medium sheet supply unit 11 is fed out and carried into the cutting mechanism 20. Since the cutter 23 of the cutting mechanism 20 presses the filter medium sheet 12 against the roller 22 by the cylinder 23a, the filter medium sheet 12 is cut into a predetermined width while being conveyed. Here, the scraps (scrap) 12b of the filter medium sheet 12 are discharged, and when two filter medium sheets 12 are taken, they are conveyed in parallel and simultaneously.
[0033]
Next, the filter medium sheet 12 cut to a predetermined width is conveyed by the feed roller 31 of the creasing mechanism 30, and during the conveyance, the striking member 32 applies a striking force to the filter medium sheet 12 from above and below. Streaks 30a are provided at regular intervals in the longitudinal direction of the filter medium sheet 12 and in the width direction.
[0034]
After a certain tension is applied to the filter medium sheet 12 with the streaks 30 a by a tension roller 41 provided on the entrance side of the first crease mechanism 40, the pair of folding blades 43 operate up and down to filter medium. The filter medium sheet 12 is pressed toward the streak 30a of the sheet 12 to make a zigzag fold along the streak 30a.
[0035]
The zigzag filter medium sheet 12 is heated by the heater 45 while passing through the guide member 44, and has a fold in a fold, thereby preventing restoration. However, the first creasing mechanism 40 is used for a material in which heating is effective, such as a synthetic fiber nonwoven fabric, and is not used for a glass nonwoven fabric.
[0036]
The bent filter medium sheet 12 is conveyed to the bead application mechanism 50. Here, the sheet is once transported in a state of being stretched flat, and resin beads are applied to both sides thereof. Since the tension mechanism 51 is provided on the entrance side of the bead application mechanism 50, a certain tension is applied by the feed roll 52.
[0037]
The filter medium sheet 12 to which the tension has been applied is wrapped around the first guide roller 54, then folded and wrapped around the second guide roller 55. Further, it is folded back from the second guide roller 55 and wrapped around the third guide roller 56. Therefore, the resin bead 57a is applied to the back surface of the filter medium sheet 12 between the first and second guide rollers 54 and 55 at a predetermined interval in the length direction and at a predetermined interval in the width direction by the first resin discharge nozzle 57. You. Further, between the second and third guide rollers 65 and 66, a resin bead 58a is applied to the surface of the filter medium sheet 12 by a second resin discharge nozzle 58 at a predetermined interval in the length direction and at a predetermined interval in the width direction. Is done.
[0038]
Here, the method of applying the resin beads 57a and 58a will be described. A normal resin bead has a constant pressure discharged from the resin discharge nozzle, is discharged continuously or intermittently, and passes at a constant speed. Applied on top. However, it has been confirmed that the height (thickness) of the resin bead changes when the feeding speed of the filter medium sheet is changed while the resin is being discharged from the resin discharge nozzle. The relationship between the height of the resin beads 57a and 58a and the height of the resin beads 57a and 58a are grasped in advance, and the rotation speed of the feed roll 52 on the outlet side of the bead applicator 50 is periodically controlled to form a gradient bead (taper bead) on the filter medium sheet 12. The resin beads 57a and 58a can be formed. A similar gradient bead can be formed by keeping the speed of the filter medium sheet 12 constant and moving the first and second resin discharge nozzles 57 and 58 with a speed difference in the direction of transport of the filter medium sheet 12. .
[0039]
After the resin beads 57a, 58a applied to both sides of the filter medium sheet 12 are applied by the bead applying mechanism 50, when the resin beads 57a, 58a are bonded, the resin beads 57a, 58a are not solidified before the resin beads 57a, 58a The paper is conveyed to a second crease mechanism 70 that forms a zigzag fold along the fold. Then, a certain tension is applied to the filter medium sheet 12 by the tension roller 71. In the case where the resin beads 57a and 58a are brought into contact with each other without being adhered, an interval is formed by drying and then contacting the two.
[0040]
The filter medium sheet 12 to which the tension has been applied is pressed by a pair of folding blades 73 from above and below toward a fold habit and folded in a zigzag shape. The filter medium sheets 12 folded in a zigzag shape are joined by resin beads 57a and 58a applied to the front and back surfaces thereof, and are carried out by a carry-out conveyor 74 composed of a pitching conveyor.
[0041]
3A and 3B show the manufactured folding filter 75, wherein FIG. 3A is a side view, and FIG. 3B is a view as seen from the direction of the arrow XX. In the filter medium sheet 12, the peaks 75a and the valleys 75b are folded in a zigzag manner at regular intervals, and between the peaks 75a and the valleys 75b, the tops of the resin beads 57a and 58a applied to the front and back surfaces of the filter medium sheet 12 are arranged. Are adhered or contacted. The manufactured folding filter 75 has a primary side and a secondary side adhered or contacted by resin beads 57a, 58a applied to the front and back surfaces of the filter medium sheet 12, respectively.
[0042]
When the relative speed between the first and second resin discharge nozzles 57, 58 and the filter medium sheet 12 is high, the height of the resin beads 57a, 58a is low, and when the relative speed is low, the height is high. In the course of progress, it is crushed by its own weight, the width is expanded, and the height is reduced. Therefore, as shown in FIG. 3 (b), the thicker ones of the resin beads 57a and 58a have a rounded trapezoidal shape, the thinner ones are almost circular, and the middle part is as shown in FIG. 3 (a). An intermediate cross-sectional shape is obtained as shown by hatching.
[0043]
As shown in FIG. 4, the foldable filter has a sharp fold of the filter medium sheet 12 and a plane where the inclination of the surface from the mountain fold line to the valley fold line maintains a constant angle θ with respect to the airflow. However, in the present invention, since the primary side and the secondary side are bonded or contacted by the gradient beads of the resin beads 57a, 58a, the filter medium sheet 12 is rigid, has a high flow rate, and has a high filtration speed. The flatness of each plane can be maintained, and a low shape resistance can be maintained.
[0044]
5 and 6 show a second embodiment, FIG. 5 is a longitudinal sectional side view of a bead applicator, FIG. 6 shows a folding filter, (a) is a side view, and (b) is an arrow YY line. FIG. 3 is a view seen from the direction of the arrow, and the same components as those in the first embodiment are denoted by the same reference numerals and description thereof is omitted.
[0045]
This embodiment differs from the first embodiment only in the bead applicator. That is, the first-stage resin discharge nozzle 76 and the second-stage resin are disposed between the first and second guide rollers 54 and 55 so as to face the back surface of the filter medium sheet 12 from the upstream side to the downstream side of the conveyance of the filter medium sheet 12. The discharge nozzle 77 and the third-stage resin discharge nozzle 78 are arranged at predetermined intervals. A plurality of first, second, and third-stage resin discharge nozzles 76, 77, 78 are arranged in the width direction of the filter medium sheet 12.
[0046]
Further, between the second and third guide rollers 55 and 56, the first-stage resin discharge nozzle 76 a and the second-stage resin discharge nozzle 76 a face the surface of the filter medium sheet 12 from the upstream side to the downstream side of the conveyance of the filter medium sheet 12. The discharge nozzle 77b and the third-stage resin discharge nozzle 78c are arranged at predetermined intervals. A plurality of first, second, and third-stage resin discharge nozzles 76a, 77a, 78a are arranged in the width direction of the filter medium sheet 12.
[0047]
By controlling the timing of application by the solenoid valve 60, the first-stage resin discharge nozzles 76, 76a are the longest in the transport direction of the filter medium sheet 12 and extend over the entire length between the stripes 30a and 30a. A resin bead 79a is applied. The second-stage resin discharge nozzles 77, 77a move the middle-stage resin bead 79b over the lower-stage resin bead 79a over substantially half the length of the lower-stage resin bead 79a applied by the first-stage resin discharge nozzles 76, 76a. And apply it again. The third-stage resin discharge nozzles 78, 78a move the upper-stage resin bead 79c over the middle-stage resin bead 79b over substantially half the length of the middle-stage resin bead 79b applied by the second-stage resin discharge nozzles 77, 77a. And apply it again.
[0048]
When the middle resin bead 79b is overlaid on the lower resin bead 79a and when the upper resin bead 79c is overlaid and applied on the middle resin bead 79b, it is desirable that the resin bead is somewhat hardened and three-stage ejection is performed. By appropriately arranging the nozzles or cooling the resin bead with a fan or the like, it is possible to suppress the resin bead from being crushed by its own weight.
[0049]
FIG. 6 shows that the middle resin bead 79b is applied on the lower resin bead 79a on one of the surfaces facing each other, the middle resin bead 79b is overlaid on the lower resin bead 79a, and the middle resin bead is applied on the other. This shows a state in which an upper resin bead 79c is applied on top of 79b.
[0050]
According to this embodiment, since the lower resin bead 79a, the middle resin bead 79b, and the upper resin bead 79c having different lengths are applied on the filter sheet 12 in an overlapping manner, the gradient bead is formed by the resin beads 79a, 79b, 79c. It is formed. Since the primary side and the secondary side are adhered or adhered by this gradient bead, the rigidity is high, the flow rate is high, and even when the filtration speed is high, the flatness of each plane of the filter medium sheet 12 is maintained and the low shape is maintained. You can keep the resistance.
[0051]
7 to 9 show a third embodiment, FIG. 7 is a longitudinal side view of a bead applicator, FIG. 8 is a side view of a state where a filter medium sheet is stretched flat, and FIG. 9 is a side view of a foldable filter. The same components as those of the first and second embodiments are denoted by the same reference numerals, and description thereof is omitted.
[0052]
This embodiment differs from the first and second embodiments only in the bead applicator. That is, a first resin discharge nozzle 80a, a second resin discharge nozzle 80b, and a third resin discharge nozzle 80c are provided between the first and second guide rollers 54 and 55 so as to face the back surface of the filter medium sheet 12. It is arranged at intervals. A plurality of the first to third resin discharge nozzles 80a, 80b, 80c are arranged in the width direction of the filter medium sheet 12.
[0053]
A first resin discharge nozzle 80a ', a second resin discharge nozzle 80b', and a third resin discharge nozzle 80c are provided between the second and third guide rollers 55 and 56 so as to face the surface of the filter medium sheet 12. 'Are arranged at predetermined intervals. A plurality of the first to third resin discharge nozzles 80a ', 80b', 80c 'are arranged in the width direction of the filter medium sheet 12. The first to third resin discharge nozzles 80a, 80b, 80c and 80a ', 80b', 80c 'have different nozzle diameters, the first resin discharge nozzles 80a, 80a' have a large diameter, and the first resin discharge nozzle 80b and 80b 'have a medium diameter, and the third resin discharge nozzles 80c and 80c' have a small diameter.
[0054]
By controlling the opening and closing by a discharge pump (not shown) for discharging the resin and the electromagnetic valve 60, the resin is applied between the streaks 30a and 30a of the filter medium sheet 12, and the intermittent beads, for example, the resin large dots 81a, Medium dots 81b and small resin dots 81c can be formed.
[0055]
FIG. 8 shows a case where large resin dots 81a, medium resin dots 81b, and small resin dots 81c are formed on the surface of the filter medium sheet 12 by the first resin discharge nozzle 76. A case in which a large resin dot 81a, a medium resin dot 81b, and a small resin dot 81c are sequentially formed from a line to a mountain fold line will be described. First, large resin dots 81a are formed on the filter medium sheet 12 by the first resin discharge nozzle 80a, medium resin dots 81b are formed by the second resin discharge nozzle 80b, and small resin dots 81c are formed by the third resin discharge nozzle 80c. . Next, small resin dots 81c, medium resin dots 81b, and large resin dots 81a are formed intermittently from the valley fold line to the mountain fold line. Next, large resin dots 81a, medium resin dots 81b, and small resin dots 81c are formed intermittently from the mountain fold line to the valley fold line. By repeating this operation, resin can be applied onto the filter medium sheet 12 by periodically changing resin dots of different sizes.
[0056]
According to the present embodiment, by folding the filter medium sheet 12 in a zigzag shape, the large resin dots 81a, the medium resin dots 81b, and the small resin dots 81c adhere or contact with each other to form a gradient bead. And since the primary side and the secondary side are adhered or contacted by this gradient bead, they are rigid, have a high flow rate, and maintain the flatness of each plane of the filter medium sheet 12 even when the filtration speed is high, and maintain a low profile. You can keep the resistance.
[0057]
FIGS. 10 (a) and 10 (b) show a fourth embodiment of a folding filter manufacturing apparatus. The same components as those of the first embodiment are denoted by the same reference numerals and description thereof is omitted.
[0058]
In this embodiment, a tension adjuster 90 and a meandering correction mechanism 91 are provided between the filter medium sheet supply unit 10 and the cutting mechanism 20. The tension adjuster 90 causes the tension rollers 92 to overlap with each other to apply a constant tension to the filter medium sheet 12 and convey the same to the meandering correction mechanism 91. The meandering correction mechanism 91 includes a plurality of guide rollers 93, and corrects the filter medium sheet 12 so as not to be shifted in the width direction during the conveyance, and conveys the filter medium sheet 12 to the cutting mechanism 20.
[0059]
The creasing mechanism 30 is composed of a pair of rolls 94a and 94b arranged vertically, and is configured to pinch and transport the filter medium sheet 12. The rolls 94a and 94b are provided with ridges 95 and concave ridges 96 alternately at regular intervals on the circumference, and the upper roll 94a and the lower roll 94b are arranged such that the ridges 95 and the concave ridges 96 are engaged. It is designed to rotate synchronously. Therefore, when the filter medium sheet 12 is nipped and conveyed by the pair of rolls 94a and 94b, it bites between the convex ridges 95 and the concave ridges 96, and is streaked at regular intervals in the longitudinal direction of the filter medium sheet 12 and in the width direction. It has become. Note that an elastic body such as rubber may be embedded inside the concave streak 96.
[0060]
The first creasing mechanism 40 includes a folding roller 40a, and folds the filter medium sheet 12 provided with the streaks 30a into the guide member 44 by the folding roller 40a to cause the filter medium sheet 12 to buckle. It has become.
[0061]
In the bead application mechanism 50, a tension roller 98 is provided at a lower part of a main body 97, and a feed roller 99 is provided at an upper part. Between the tension roller 98 and the feed roller 99, a direction changing roller 100 for changing the direction of the filter medium sheet 12 conveyed from the tension roller 98 by approximately 90 ° is provided.
[0062]
Further, resin discharge nozzles 101 and 102 are provided between the tension roller 98 and the direction changing roller 100 toward the front and back surfaces of the filter medium sheet 12. A plurality of resin discharge nozzles 101 and 102 are arranged at regular intervals in the width direction of the filter medium sheet 12, and resin beads are formed by the resin discharge nozzles 101 and 102 at predetermined intervals in the length direction of the filter medium sheet 12 and at predetermined intervals in the width direction. It is to be applied.
[0063]
The second creasing mechanism 70 includes a folding roller 70a, and folds the filter medium sheet 12 with the streaks 30a by causing the folding roller 70a to buckle.
[0064]
According to the fourth embodiment, when applying the resin bead to the front and back surfaces of the filter medium sheet 12, there is no need to detour the filter medium sheet 12 in an S-shape by a large number of guide rollers, and the direction of approximately 90 ° Conversion is enough.
[0065]
Note that the present invention is not limited to the above-described embodiment as it is, and can be embodied by modifying constituent elements in an implementation stage without departing from the scope of the invention. In addition, various inventions can be formed by appropriately combining a plurality of constituent elements disclosed in the embodiments. For example, some components may be deleted from all the components shown in the embodiment. Further, components of different embodiments may be appropriately combined.
[0066]
【The invention's effect】
As described above, according to the present invention, a plurality of rows of beads provided at predetermined intervals along a fold line are formed on at least the secondary side of the opposing surface of each fold of the filter medium sheet, and the filter medium sheet is folded. By bonding or contacting the tops of the beads with each other to maintain the interval between the opposing surfaces constituting the fold in a tapered shape, even at a high flow rate and a high filtration speed, the flatness of each plane of the filter medium It is possible to maintain a low profile resistance, and it does not require expensive embossing rolls required for each folding fold height. it can.
[Brief description of the drawings]
FIGS. 1A and 1B show a filter element manufacturing apparatus according to a first embodiment of the present invention, wherein FIG. 1A is a configuration diagram of the entire apparatus, and FIG. 1B is a plan view of a filter medium sheet with creasing.
FIG. 2 shows the same embodiment, and is a perspective view of a bead applying mechanism.
FIGS. 3A and 3B show the same embodiment and show a folding filter, in which FIG. 3A is a side view, and FIG.
FIG. 4 shows the same embodiment, and is an explanatory diagram of a folding filter.
FIG. 5 shows a second embodiment of the present invention and is a longitudinal sectional side view of a bead applicator.
FIGS. 6A and 6B show the same embodiment and show a folding filter, in which FIG. 6A is a side view, and FIG.
FIG. 7 shows a third embodiment of the present invention and is a longitudinal side view of a bead applicator.
FIG. 8 shows the same embodiment, and is a side view of a state where the filter medium sheet is stretched flat.
FIG. 9 shows the same embodiment, and is a side view of a folding filter.
FIGS. 10A and 10B show a third embodiment of the present invention, in which FIG. 10A is a configuration diagram of a folding filter manufacturing apparatus, and FIG.
[Explanation of symbols]
12: filter medium sheet, 57a, 58a: resin bead, 81a: large resin dot, 81b: medium resin dot, 81c: small resin dot

Claims (6)

A filter medium sheet folded in a zigzag shape along a fold line and formed on at least a secondary side of an opposing surface of each fold of the filter medium sheet, and a plurality of rows are provided at predetermined intervals along the fold line Bead
A folding type air filter, wherein a top portion of the bead is adhered or contacted with each other by folding the filter medium sheet to maintain an interval between opposing surfaces constituting the fold. The foldable air filter according to claim 1, wherein the bead is a gradient bead formed such that an interval between opposing surfaces of each fold of the filter medium sheet is substantially proportional to a distance from a fold line. The foldable air filter according to claim 1, wherein the bead is a bead formed by stacking a plurality of beads such that an interval between opposing surfaces of each fold of the filter medium sheet is substantially proportional to a distance from a fold line. . 2. The folding air filter according to claim 1, wherein the beads are intermittent beads having different heights such that a distance between opposing surfaces of each fold of the filter medium sheet is substantially proportional to a distance from a fold line. . The beads are formed on the primary and secondary sides of the opposing surfaces of each fold of the filter medium sheet, and the primary and secondary beads are arranged at positions shifted from each other in the direction of the fold line of the filter medium sheet. The foldable air filter according to any one of claims 1 to 4, wherein: A first step of forming a fold line in the filter medium sheet;
A second step of forming a plurality of rows of beads at regular intervals along the fold line on at least the secondary side of both surfaces of the filter medium sheet,
A third step of folding the filter medium sheet and bonding or contacting the tops of the beads with each other so as to maintain a space between opposing surfaces constituting the folds;
A method for manufacturing a foldable air filter, comprising:

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