JP2006092876A - Ion generator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an ion generator capable preventing molding resin from flowing out to the front surface of an ion-generating element, even when the size of an opening of a casing is designed to be relatively large, and capable of preventing contamination of the ion-generating element surface. <P>SOLUTION: The plate-like ion generating element 1 is so formed as to close an opening 10a of a lid part 2 of a casing 10. The opening 10a is designed large enough to cope with thermal contraction and electrode size dispersion. A film member 3 having elasticity is sandwiched between the ion generation element 1 and the opening 10a in a form completely covering the ion generating element 1; and a space between the ion-generating element 1 and the opening 10a is filled with the film member 3 to fix the ion-generating element 1 in the opening 10a. The molding resin 4 enclosed in the casing 10 is prevented from flowing out to the front surface side of the ion-generating element 1 through the space. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a discharge type ion generator using a flat plate electrode, which is attached to a device such as an air purifier.

  In recent years, development of a technique for realizing a clean and comfortable living space, particularly a technique for purifying air in the living space has been desired. For such air purification, an air purifier configured to generate a circulating air flow that sucks the target air, passes it through a filter, and discharges it, and traps floating substances present in the circulating air flow with the filter. Is widely used.

  On the other hand, an air purifier has been proposed that purifies the air in the living space by releasing ions into the living space (see, for example, Patent Document 1). In this air cleaner, an ion generator that generates positive ions and / or negative ions is disposed in the middle of an air passage that discharges air current into a target space, and the ions are discharged together with air. The ions released into the air inactivate suspended particles and kill suspended bacteria, so that the entire space can be cleaned.

  6 and 7 are a top view and a cross-sectional view showing a configuration of a conventional ion generator. In the figure, reference numeral 10 denotes a housing having a structure that is divided into a main body portion 7 and a lid portion 2. A plate-like ion generating element 1 is provided so as to close the opening of the lid portion 2 of the housing 10. The ion generating element 1 is made of ceramic, and generates positive ions and / or negative ions by applying an alternating driving voltage. In the main body 7, a circuit component 6, a circuit board 8 on which the circuit component 6 is mounted, and a wiring 9 that connects the circuit board 8 and the ion generating element 1 are accommodated. Further, the inside of the housing 10 is filled with a mold resin 4 such as urethane resin injected from the resin injection port 5.

Since the individual differences in the external dimensions of the ion generating element 1 are large, and in order to improve the thermal and thermal shock resistance of the product after the assembly is completed, the hollow portion of the fixed position of the ion generating element 1, that is, the lid 2 The size of the opening must be designed to be large. Therefore, conventionally, even when the ion generating element 1 is fitted into the opening of the lid part 2, the ion generating element 1 is temporarily fixed to the lid part 2 using the adhesive 33.
JP 2003-45611 A

  Since it is necessary to design the size of the opening of the lid portion 2 where the ion generating element 1 is installed to be large, it must be fixed with an adhesive 33 for temporary fixing. Further, when the body portion 7 of the housing 10 and the lid body portion 2 are combined to make the mold resin 4 liquid and fill the space inside the housing 10, the ion generating element 1 and the opening of the lid body portion 2 When the mold resin 4 overflows or oozes out from the gap from the gap, the black mold resin 4 adheres to the surface of the white ion generating element 1 and not only the appearance becomes dirty, but also on the surface of the ion generating element 1. When the mold resin 4 spreads to the extent, there arises a problem that the discharge is hindered. For this reason, it is necessary to carefully fill the mold resin 4 so that the mold resin 4 does not flow out onto the surface of the ion generating element 1, and there is a problem that workability is poor.

  Further, even when the filling of the mold resin 4 can be performed without any trouble, the surface of the ion generating element 1 is exposed in the subsequent steps, so that dirt easily adheres to the ion generating element 1 in the subsequent process. Has a problem that the surface of the ion generating element 1 must be cleaned.

  By the way, as a countermeasure against the problem that the mold resin 4 easily overflows from the gap between the ion generating element 1 and the opening of the lid body 2 as described above, the variation in the size of the ceramic ion generating element 1 is reduced. A method of increasing the dimensional accuracy and reducing the gap between the ion generating element 1 and the opening of the lid 2 is conceivable. However, in this method, even if this gap is filled, if the temperature difference in the thermal shock test is larger than the difference in the thermal expansion coefficient between the casing 10 and the ion generating element 1 generated in the thermal shock test, the ion generating element A problem arises in that stress is applied between the casing 1 and the casing 10, and one of them breaks.

  The present invention has been made in view of such circumstances, and even when the size of the opening of the lid portion is designed to be large, it prevents outflow (overflow or exudation) of the mold resin to the surface of the ion generating element. Thus, it is an object of the present invention to provide an ion generating apparatus capable of preventing the occurrence of contamination on the surface of an ion generating element and the occurrence of discharge inhibition.

  Another object of the present invention is to provide an ion generator capable of improving workability.

  An ion generating apparatus according to the present invention includes a plate-like ion generating element attached to an opening of a housing, and the ion generating apparatus generates ions by applying a voltage to the ion generating element. And an ion generating element, an elastic film member is provided.

  In the ion generator of the present invention, an elastic film member is provided in the gap between the ion generating element and the opening of the housing (lid body). The size of the opening of the casing (lid body) where the ion generating element is installed is designed to be large as before, and when the ion generating element is fixed, it has a thickness more than the design gap and is elastic. After a certain film member is incorporated so as to cover the outside of the ion generating element and sandwiched between the openings, a liquid mold resin is filled into the casing. By doing so, the film member closes the gap between the ion generating element and the opening of the casing (lid part), so that the mold resin does not flow out to the surface of the ion generating element when filling with the mold resin. The surface of the ion generating element is not soiled and the discharge is not hindered by the mold resin. In addition, it is possible to fill the mold resin with the ion generating element surface side down, and workability is improved. Furthermore, since the surface of the ion generating element is covered with a film member in the next process, there is no need for cleaning because there is no adhesion of dirt.

  The ion generator according to the present invention is characterized in that a perforated cut is formed in the film member.

  In the ion generator of the present invention, perforated cuts are formed in the film member. In actual use, the film member on the surface is in the way, so it is necessary to delete it with a cutter or the like. Since the film member is cut in advance, it can be easily cut by hand, and the workability is excellent.

  In the ion generator according to the present invention, the film member has a multilayer structure.

  In the ion generator of the present invention, the film member has a multilayer structure. Therefore, each layer of the film member can be peeled off or pasted as necessary.

  In the ion generating apparatus according to the present invention, the film member includes a first film member having a notch corresponding to the ion generating element, and a second film covering the first film member including a surface of the ion generating element. And a member.

  In the ion generator of the present invention, the film member has a configuration in which the first film member having a notch corresponding to the ion generating element is laminated with the second film member covering the entire surface including the surface of the ion generating element. There is. Therefore, for example, the surface of the ion generating element can be maintained in a clean state until the final process by peeling off the second film member at the time of operation inspection and reattaching the second film member after the inspection is completed. It becomes unnecessary.

  In the ion generator of the present invention, an elastic film member is sandwiched between the ion generating element and the opening of the housing (lid portion) so as to fill the gap. When filled, the mold resin does not flow out to the surface of the ion generating element from the gap between the ion generating element and the opening of the housing (lid portion), and the surface of the ion generating element can be prevented from being contaminated. Further, since the surface of the ion generating element is covered with the film member, it is possible to prevent the surface of the ion generating element from being soiled even in the work after the mold resin filling step.

  In the ion generator of the present invention, since the perforated cut is formed in the film member, the film member can be easily cut out by hand.

  In the ion generator of this invention, since the film member is made into the multilayer structure, each layer of a film member can be peeled off or reapplied as needed.

  In the ion generating apparatus of the present invention, the film member has a two-layer structure of the first film member of the first layer that is cut out while avoiding the ion generating element and the second film member that covers the entire film member. In some cases (such as during operation inspection), only the second film member can be turned, so that the surface of the ion generating element can be kept clean until the work process to be incorporated into the final product. This eliminates the need for cleaning work, can contribute to work reduction, and can improve workability.

Hereinafter, the present invention will be described in detail with reference to the drawings showing embodiments thereof.
(Embodiment 1)
1 and 2 are a top view and a cross-sectional view showing the configuration of the ion generator according to Embodiment 1 of the present invention. In the figure, reference numeral 10 denotes a housing having a structure that is divided into a main body portion 7 and a lid portion 2. In the main body 7, a circuit component 6, a circuit board 8 on which the circuit component 6 is mounted, and wiring 9 that connects the circuit board 8 and the ion generating element 1 are provided.

  A part of the lid part 2 of the housing 10 is opened to form an opening 10a, and the plate-like ion generating element 1 is provided so as to close the opening 10a. The ion generating element 1 is made of ceramic such as alumina, and generates positive ions and / or negative ions by applying an alternating driving voltage, and discharges the generated ions from the grid-shaped discharge electrode pattern 1a. The size of the opening 10a is designed to be sufficiently large in order to cope with individual differences in the external dimensions of the ion generating element 1 and to improve the thermal shock resistance of the product after assembly.

  An elastic film member 3 is sandwiched between the ion generating element 1 and the opening 10a so as to completely cover the ion generating element 1, and the ion generating element 1 and the opening 10a The gap is filled with the film member 3 to fix the ion generating element 1 in the opening 10a. The inside of the housing 10 is filled with a mold resin 4 such as urethane resin injected from the resin injection port 5. Since the film member 3 is provided in the gap between the ion generating element 1 and the opening 10a, the filled mold resin 4 does not flow out to the surface side of the ion generating element 1 through the gap.

  The film member 3 is formed with a perforated cut 3 a in accordance with the planar shape of the ion generating element 1. Therefore, when exposing the surface of the ion generating element 1 (discharge electrode pattern 1a), the film member 3 may be peeled off along the notch 3a, and a tool such as a cutter is not necessary, and the film is easily formed by hand. The member 3 can be removed.

  A manufacturing procedure of the ion generator having such a configuration will be described. The opening 10a of the housing 10 (lid body part 2) is designed to be sufficiently large so as to be able to cope with thermal shrinkage and electrode size variation, and when the ion generating element 1 is attached, the elastic film member 3 generates ions. By wrapping and fitting the discharge electrode pattern 1a (shown in FIG. 5) side of the element 1 with the film member 3, the ion generating element 1 is fixed (see FIG. 3). Thereafter, after combining the main body portion 7 and the lid portion 2, a liquid mold resin 4 is injected from the resin injection port 5, and the inside of the housing 10 is filled with the mold resin 4, thereby producing an ion generator. To do.

  At this time, since the gap between the ion generating element 1 and the opening 10a is sealed with the film member 3, the mold resin 4 overflows from the periphery of the ion generating element 1 even when the mold resin 4 is excessively injected. Thus, the surface of the ion generating element 1 is not soiled. Further, in the subsequent work process, since the surface of the ion generating element 1 is covered with the film member 3, foreign matter such as dust does not adhere to the surface of the ion generating element 1. In the inspection for confirming the discharge, the film member 3 needs to be peeled off. However, if the inspection process is performed in the last step, the surface of the ion generating element 1 is hardly contaminated. As a result, since the surface of the ion generating element 1 can be maintained in a clean state until the final step of incorporating the ion generating device into an apparatus such as an air purifier, the surface cleaning operation of the ion generating element 1 is not necessary.

(Embodiment 2)
4 and 5 are top views showing the configuration of the ion generator according to Embodiment 2 of the present invention. 4 and 5, the same parts as those in FIG. 1 are denoted by the same reference numerals. In the second embodiment, the film member 3 has a two-layer configuration in which a first film member 13 on the ion generating element 1 side and a second film member 23 on the outer side are laminated. In addition, in FIG. 5, the state which peeled the 2nd film member 23 is shown in figure.

  The first film member 13 has a notch 13a formed in accordance with the planar shape of the discharge electrode pattern 1a. That is, the first film member 13 has a shape in which a portion of a region in contact with the surface of the discharge electrode pattern 1a of the ion generating element 1 is cut out. (See FIG. 5). A second film member 23 is laminated on the first film member 13 so as to cover the first film member 13 including the surface of the discharge electrode pattern 1a (see FIG. 4).

  In Embodiment 2, when the film member 3 has such a two-layer structure, the film member 3 can be easily peeled off when being used. Only when the operation inspection is performed in the subsequent process, the discharge electrode pattern 1a is exposed by turning over the second film member 23 on the ion generating element 1, and is reattached after the inspection is completed. Can prevent dirt. With this method, the surface of the ion generating element 1 is covered with the film member 3 up to the final customer stage in which the ion generator is incorporated into an apparatus such as an air cleaner, so that cleaning work in the final customer process is unnecessary. Thus, convenience can be enhanced.

It is a top view which shows the structure of the ion generator which concerns on Embodiment 1 of this invention. It is sectional drawing which shows the structure of the ion generator which concerns on Embodiment 1 of this invention. It is sectional drawing which shows a part of manufacturing process of the ion generator which concerns on Embodiment 1 of this invention. It is a top view which shows the structure of the ion generator which concerns on Embodiment 2 of this invention. It is a top view which shows the structure of the ion generator which concerns on Embodiment 2 of this invention. It is a top view which shows the structure of the conventional ion generator. It is sectional drawing which shows the structure of the conventional ion generator.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Ion generating element 1a Discharge electrode pattern 2 Cover part 3 Film member 3a Notch 4 Mold resin 5 Resin injection port 7 Body part 10 Housing | casing 10a Opening part 13 1st film member 13a Notch 23 2nd film member

Claims (4)

  In an ion generator that includes a plate-like ion generating element attached to an opening of a housing and generates ions by applying a voltage to the ion generating element, the ion generating element is provided between the opening and the ion generating element. An ion generator comprising a film member having elasticity.   The ion generator according to claim 1, wherein the film member has a perforated cut.   The ion generator according to claim 1, wherein the film member has a multilayer structure.   The film member includes a first film member having a notch corresponding to the ion generating element, and a second film member including the surface of the ion generating element and covering the first film member. The ion generator according to claim 3.

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