JP2005125179A - Molded filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To efficiently and stably provide a molded filter having a high dust collection capacity, reduced in filter medium resistance and having good form stability. <P>SOLUTION: This molded filter is constituted so that the bottom part thereof is composed of a molded frame body, and the bottom part and body part thereof are fixed by bonding filter parts comprising a nonwoven fabric. Both of the molded frame body and the filter parts are constituted of a polypropylene resin. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention cuts so-called house dust such as pollen, earth and sand, carbon, indoor yarn, cotton, and ticks that flow in from outside air, mainly in the outside air intake section for indoor ventilation systems and air conditioning filters for indoor air supply. In addition, the present invention relates to an air conditioning filter for maintaining a comfortable environment.

  Technological development to maintain a comfortable environment is being promoted, such as the ventilation rate of living rooms being set based on building materials as a countermeasure against sick houses in the revision of the Building Standard Law.

  For this reason, houses with built-in type filters, a 24-hour planned ventilation system for cooling and heating of the entire building, and a sensible heat exchange type 24-hour planned ventilation system will be built in the outside air intake holes of buildings and apartments. It was.

  As these filter media, a sheet-like material in which card cotton, which is generally used for coarse dust, is bonded with resin, and heat-adhesive fibers instead of resin are blended into a sheet by thermal bonding. Filters made by sewing these are used.

  However, the installation location of equipment using these is limited space, and the amount of filter media used is limited. On the other hand, it is necessary to select a material with low pressure loss due to the restriction of the ventilation rate. Although it is collected, the present condition is that the filter has poor ability to efficiently remove dust such as pollen, earth and sand, and carbon.

  In order to efficiently remove dust such as pollen, earth and sand, and carbon, it is preferable to use filter media with high dust collection ability of the filter media themselves, but these are generally filter media with high pressure loss and increase ventilation efficiency. It was not economical because it was necessary to increase the power.

  In any case, a known example regarding a molded filter has not been found.

  In view of the background of such prior art, the present invention intends to provide a molded filter having high dust collection ability, low filter medium resistance, and good shape stability efficiently and stably.

  The present invention employs the following means in order to solve such problems. That is, the molded filter of the present invention is a molded filter in which the bottom part is configured by a molded frame body, and the bottom part and the body part are configured by adhering and fixing filter parts made of a nonwoven fabric. The filter parts are both made of polypropylene resin.

  According to the present invention, cut out so-called house dust such as pollen, earth and sand, carbon, yarn generated in the room, cotton, mites, etc. flowing in from the outside air by an outside air intake for a home ventilation system or an air supply filter for indoor air supply. In addition, an air conditioning filter for maintaining a comfortable environment can be provided.

  The present invention has been intensively studied on the above-mentioned problems, that is, a molded filter having a high dust collecting ability, low filter medium resistance, and good form stability, and is composed of a specific resin, a specific molded frame, and a nonwoven fabric. When I made a bucket-type filter using filter parts, I found out that I could solve the above problems all at once.

  In the molded filter of the present invention, it is important that the bottom part is formed of a molded frame. By using such a molding frame, it is possible to form the entire filter in a stable shape, and to form a filter having good shape stability and excellent filter function efficiently and stably. it can.

  It is important that the molded frame is made of the same resin as the filter parts, particularly a resin mainly composed of polypropylene. By adopting such a configuration, it is a durable filter with excellent adhesion to each member, and it can also meet the demand for flame retardant materials as building materials. It is possible to provide a molded filter that does not occur and is good for the environment.

  Such a molded frame is a frame having a groove for adhering / fixing the filter parts constituting the body of the molded filter, and the filter parts constituting the bottom of the molded filter are bonded to the inside of the frame. It is a molding frame which has an edge part fixed. Such a molded frame may have any other shape, but a circular shape is preferable in terms of form stability and filter function. Among such circular shapes, an elliptical shape is more preferable, and a vertical elliptical shape that is preferably about 1.5 times the circular radius may be excellent in shape stability. That is, by attaching the vertically long elliptical shaped frame body to the vertically long shape, there is an effect of stably holding the shape of the body portion of the molded filter.

  Such a molding frame is formed by injection molding using, for example, a resin mainly composed of polypropylene, in accordance with the size of the molding filter. By adopting such injection molding means, it is possible to efficiently, stably and inexpensively provide a molded filter with good form stability.

  In other words, the molding frame has an edge part for setting the bottom filter part and pouring the olefin-based adhesive, and a groove part for setting the body filter part and pouring the olefin-based adhesive. Since it is a simple shape, it is preferable to produce an injection mold once because it can be supplied in a stable shape at a low cost and in large quantities.

  The molded filter of the present invention is a bucket-shaped molded filter, that is, a bottom peripheral portion of the molded filter is formed of a molded frame, and the molded frame is made of a nonwoven fabric that constitutes the body and the bottom of the molded filter. The parts are bonded and fixed.

  It is important that the filter part is composed of a nonwoven fabric. That is, this nonwoven fabric affects the filter function of the molded filter of the present invention. As such a non-woven fabric, a laminate with a net is preferable in terms of form stability and strength reinforcement.

  The material constituting the nonwoven fabric and the net is preferably composed of a nonwoven fabric mainly composed of polypropylene and a net mainly composed of polypropylene for the same reason as in the molded frame. That is, it is preferably employed in view of adhesiveness with each member, flame retardancy, and environmental hygiene.

  As such a nonwoven fabric, any nonwoven fabric is within this range, but a secant nonwoven fabric and a melt blown nonwoven fabric mainly composed of polypropylene satisfy this condition and are particularly preferable.

  The spun pond non-woven fabric has thick fibers and has a large variation in sheet performance at this point in the range of the air flow rate due to the manufacturing method.

  Moreover, if the spunlace ensures the form stability of the nonwoven fabric, the inter-fiber gap becomes too small, and the card cotton increases the inter-fiber gap.

  The reason why the nonwoven fabric mainly composed of polypropylene is selected is a material that is very suitable for imparting electric charges to the fibers, and in particular, the electret-processed filter medium is most suitable for the filter medium of the present invention. This method can be performed by a conventional method such as the method described in US Pat. No. 5,057,710.

As a filter part composed of either such a nonwoven fabric or a laminate of the nonwoven fabric and the net, the interfiber gap is relatively small and uniform, and the air permeability by the Frazier method is 100 to 600 cc / cm ^2. . Those having sec are preferably used.

100 cc / cm ² . When the air flow rate is less than sec, it is necessary to increase the filter medium area excessively in order to hear the pressure loss resistance of the molded filter, which is not suitable for a place where facilities are limited. Also, 600 cc / cm ² . If the air flow rate exceeds sec, the gap between the fibers becomes large and the leakage rate of dust from the filter medium increases, which is not preferable for the filter.

  As such filter parts, those subjected to pleating are preferably employed because of their high dust collecting ability and low filter medium resistance.

Such pleating should have a pleated peak height of 5 to 20 mm and a pitch of about 2 to 10 mm. Also, the net that gives the waist and strength is not less than 3 × 3 mm and not more than 10 × 10 mm. And the basis weight is preferably about 15 to 50 g / m ² .

  That is, if the height of the pleat is higher than 20 mm, the amount of the filter medium increases as the height increases, the passing air speed of the filter medium decreases, the dust collecting property improves, but the stability of the form decreases, so this Absent. On the other hand, if the thickness is less than 5 mm, it is necessary to increase the size of the molded filter, which is not suitable for a place where there is a restriction on equipment. In addition, when the pitch of the pleats is less than 2 mm, although depending on the thickness of the filter medium, the distance between the filter mediums is narrow and structural pressure loss is not preferable. In addition, if it exceeds 10 mm, it is necessary to increase the size of the molding filter as in the case of a low mountain height, and it is not suitable for a place where there is a restriction on facilities. A more preferable range of the pleat height is a pitch of 4 to 8 mm.

Next, in the net, if the mesh is as small as 3 × 3 mm or less, it causes an increase in the resistance of the filter medium. The basis weight of such a net is preferably 15 to 50 g / m ² , since the thickness of the fibers constituting the net is controlled and, as a result, the stability of the pleat shape is led. A more preferable range of the basis weight of such a net is 18 to 40 g / m ² .

  Thus, the obtained filter parts are used for the body and bottom of the molded filter, but there are various methods for punching and edging according to a predetermined molded filter size, and any method can be used, but preferably Thomson A die punching machine and an ultrasonic punching machine are preferably used.

  In the case of pleated type filter parts, the shape is not only stabilized when set by a predetermined pitch and fixed with tape made of non-woven fabric, woven fabric, paper, etc. or resin used for bead material, and then punched. , The role of the reinforcing body against the wind pressure during use, when fixing the body filter parts to the molded frame with an adhesive, it also has the effect of improving workability and adhesive strength, which is preferable from the viewpoint of durability during production . Such a pleat reinforcing tape preferably has a width of 5 to 12 mm.

  Such a pleat reinforcing tape has a great effect particularly when the body filter part is bonded to the forming frame. In other words, if the end of the body filter parts on the side to be inserted and adhered to the frame is stabilized by affixing the pleated reinforcement tape in advance, not only the workability but also the subsequent adhesion will be greatly improved. There is an advantage to up.

  When the pitch of the pleat peaks is fixed with the pleated reinforcing tape, the interval is preferably 3 to 15 cm from the viewpoint of form stability. At this time, it is preferable for the net to be installed outside the filter parts in terms of form stability during use.

  What constitutes the body of the obtained filter part is formed in a cylindrical shape before the molding step. In this case, the end faces are overlapped by about 0.5 to 2 cm and melted by a method of heat and ultrasonic waves. It can be formed into a cylindrical shape by a method of attaching, a glue material, or a method of adhering with an olefin-based adhesive. A non-woven fabric or a net is particularly preferable because sufficient adhesive strength can be obtained.

  The molded filter of the present invention is made of a material mainly composed of a polypropylene resin, that is, the main body here means a polypropylene homopolymer, a copolymer of polypropylene and other olefins, and 1-methylpentene. And other olefin blend resins.

  In the present invention, a molded filter can also be formed using a molded frame body and a filter part made of polylactic acid resin obtained from corn, although the price is high and not generally used in the present invention. This resin also has biodegradable properties, is an optimal material for environmental protection, and is desired to be versatile quickly.

  Next, the molded filter of the present invention will be described with reference to the drawings. FIG. 1 is a schematic view showing an example of a bottom filter part viewed from the opening of the molded filter of the present invention. Molded frames 1, 1 ′, 1 ″ are F-shaped, that is, a frame in the form of lying F. The outer wall 1 is higher than the inner wall 1 ′, and further inside the inner wall 1 ′. It is a frame having a form provided with an edge 1 ″.

  A body filter part 2 is inserted and bonded in a groove between the outer wall 1 and the inner wall 1 'of the molding frame. An edge 1 ″ is provided on the inner side of the inner wall 1 ′ of the molded frame, and the bottom filter part 3 is attached to the edge 1 ″ to complete the molded filter of the present invention.

  The body filter part 2 of this molded filter has pleated reinforcement tapes 4 affixed at two locations. Further, the end on the side to be inserted and adhered to the molded frame body of the body filter part 2 is preliminarily provided. Adhering and stabilizing the pleat reinforcing tape 4 has the advantage of greatly improving workability and adhesion.

  EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples.

Example 1
Toraymicron CES02040 (flow rate by Frazier method is 500 cc / cm ² .sec) made by Toray Fine Chemical Co., Ltd., and a net made of polypropylene by Nisshin Plast Co., Ltd. (weight: 22 g / m ² , scale: 6 mm × 6 mm) was laminated and bonded to form a filter part. The filter parts were further pleated at a height of 9 mm to prepare pleated filter parts.

  On the other hand, a bottom frame filter is prepared by preparing a molding frame made of polypropylene as shown in FIG. 1, and adjusting the pleated mountain gap to the edge 1 "of the bottom by adjusting the pleated filter parts to 5 mm pitch. The parts were set and integrated with the molding frame with hot melt adhesive Hitachi Chemical Polymer Co., Ltd. Hot Melt Hibon (R) XH494-3.

  Next, after cutting the pleated filter parts according to the diameter of the bucket-shaped molded filter (full length including pleats: 473 mm), and further cutting according to the tube length of 230 mm when this is formed into a cylindrical shape The filter part after this cutting is adjusted to the 5 mm pitch by adjusting the gap between the pleats to form a body filter part. The body part of the filter part of the body part is 10 mm wide in two places corresponding to the outside of the molded filter. As a pleated reinforcing tape, a cotton bias tape was applied at almost equal intervals using a hot melt adhesive (Hitachi Chemical Polymer Co., Ltd. Hot Melt Hibon (R) XH494-3). Next, the cotton bias tape was affixed in the same manner to the end portion that is the insertion portion of the body filter part into the molding frame.

  Next, the cylindrical body part of the planar filter is formed into a cylindrical shape, and both ends thereof are polymerized and bonded using the adhesive, together with the cotton bias tape slightly longer than the body filter diameter, Finally, three cotton bias tapes with stabilized barrel filter parts were formed. The pleat interval of the filter parts was fixed and the form was stabilized by the cotton bias tape.

  A hot melt adhesive (Hitachi Chemical Polymer Co., Ltd. Hot Melt Hibon (R) XH494-3) is poured into the groove between the outer wall 1 and the inner wall 1 'of the molding frame, The end side to which the cotton bias tape was bonded was inserted and fitted, and was integrated with the molding frame.

  As shown in Table 1, the performance of the bucket-type molded filter thus obtained was suitable as an outside air intake filter in the planned ventilation system air conditioning.

  In this performance evaluation, atmospheric dust was evaluated using a MET ONE equipment number 3315 with a passing air volume of 200 cubic meters / hour.

Comparative Example 1
A polyester resin cotton (ML-300RF made by Dynic) having a basis weight of 300 g / m ² and a thickness of 14 mm was sewed with the same diameter and the same length as the molded filter of Example 1 to form a sock filter. . The sock-like filter was evaluated in the same manner as in Example 1.

表１から明らかなように、実施例１のものは、比較例１のものに比して、除去目的とする花粉、土砂、カーボン類等のいずれのものに対しても優れたカット性能を示したが、比較例のものは１０〜２５ミクロン以上の粒子に対してもカット性能に劣るもので実用性に乏しいものであった。

As is clear from Table 1, the sample of Example 1 shows superior cutting performance for any of pollen, earth and sand, carbons and the like intended for removal, compared to the sample of Comparative Example 1. However, the comparative example was inferior in cutting performance even for particles having a particle size of 10 to 25 microns or more, and was impractical.

This figure is a schematic view showing an example of a bottom filter part viewed from the opening of the molded filter of the present invention. This figure shows a view of the side of the molded filter of FIG. 1 with a partial cut.

Explanation of symbols

1, 1 ', 1 ": Molded frame 2: Body filter part 3: Bottom filter part 4: Pleated reinforcement tape

Claims (13)

A molded filter having a bottom part formed of a molded frame body and a bottom part and a body part formed by adhering and fixing filter parts made of nonwoven fabric, both of the molded frame body and the filter parts being polypropylene-based Molded filter characterized by being made of resin. The molded frame is a frame having a groove to which a filter part constituting the body is bonded and fixed, and a circular shape having an edge portion to which the filter part constituting the bottom is bonded and fixed. The molded filter according to claim 1, which is a frame. The molded filter according to claim 1 or 2, wherein the nonwoven fabric constituting the filter part is a laminate with a net. The filter part has an air flow rate by the Frazier method of 100 to 600 cc / cm ² . The molded filter according to any one of claims 1 to 3, wherein the molded filter has air permeability of sec. The molded filter according to any one of claims 1 to 4, wherein the nonwoven fabric is subjected to at least one of electret processing and antibacterial processing. The molded filter according to claim 1, wherein the filter part is pleated. The molded filter according to claim 6, wherein a peak height of the pleats of the filter parts is 5 to 20 mm and a pitch is 2 to 10 mm. The net has a 10 × 10 mm or less eyes focus at 3 × 3 mm or more and molded filter according to claim 1, basis weight is characterized by a 15 to 50 g / m ² . The molded filter according to any one of claims 1 to 8, wherein a net layer of the filter part is disposed on the downstream side, and a pleat mountain is disposed on the upstream side. The molding according to any one of claims 1 to 9, wherein a stiffener is installed at the top of the mountain at intervals of 3 to 15 cm on the pleat mountain of the filter part constituting the trunk portion. filter. The molded filter according to any one of claims 1 to 10, wherein the polypropylene resin is composed of the same kind of resin mainly composed of polypropylene. The molded filter according to claim 1, wherein the adhesive is an olefin-based adhesive. The molded filter according to any one of claims 1 to 12, wherein the molded filter is used for at least one selected from outside air intake and indoor air supply in planned ventilation system air conditioning.

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