JP2008049301A - Filter element and method for producing the same, and method for installing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a filter element that can replace a prior art planar filter present in an existing apparatus without a substantial design change of the apparatus to extend the filter life, can be installed in a limited space, enables design change of the apparatus at a low cost, and is usable in an apparatus required of down-sizing, a method for producing the same, and a method for installing the same. <P>SOLUTION: The filter element is constituted of a filter sack formed and comprised of a corrugated face and a plurality of side faces fabricated from a sheet of filter medium with the filter sack fixed to a planar frame member, which filter element can be pressed down to 70% or less of its original height and can restore 80% or more of its original height upon releasing the downward pressure. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a filter element that is used by being mounted on an air conditioner, OA equipment, household appliance, etc. in a living environment such as an automobile, a home air cleaner, a total heat exchanger, etc. It relates to the mounting method.

  In order to remove dust, air-conditioning equipment, office automation equipment, home appliances, etc. in the living environment such as automobiles, home air purifiers, total heat exchangers, etc., the sheet-like filter medium is folded into a corrugated shape. A filter element which is attached to the material and formed so as to maintain the overall rigidity is used for an air inlet / outlet. Such a filter element is used in a storage part provided in an air conditioner or the like, but the storage part is designed according to the specifications of the filter element and depends on the size of the filter element. It can be stored without deforming the filter element.

  As such a filter element, for example, there is a filter of Patent Document 1 shown in FIG. This filter element is a filter formed by surrounding the outer periphery of a filter base material pleated in a cross-sectional waveform with a frame-shaped frame body, and bonding and fixing the outer peripheral edge of the filter base material to the inner peripheral surface of the frame body Since the shape of the pleated filter base material is securely held by the frame body, it is easy to handle, and the outer peripheral edge of the filter base material is adhered to the frame body. The pitch at the time of manufacture is reliably maintained without changing the pitch, and the initial performance can be reliably exhibited.

  Further, as another example of the filter element, there is a filter element according to the air cleaner filter element manufacturing method of Patent Document 2 shown in FIG. This manufacturing method is a method of manufacturing a filter element of an air cleaner having a filter medium having a plurality of wavy bag portions and a filter medium frame disposed on the outer periphery of the filter medium. Either one of the side plates of one of the corrugated plates forming the respective corrugated portions and the side plate of the other of the corrugated plates that form the respective corrugated portions are formed in contact with each other. The filter element manufacturing is intended to contact the side plate of the corrugated plate and the end of the side opening of the other corrugated plate, and to form the side plate by joining the contacting parts with the ultrasonic wave. Is the method. In the filter element obtained by this manufacturing method, the side plates of the corrugated plates are in contact with each other without overlapping, or the side plates and the corrugated plate are in contact with each other without overlapping. Is shown in the figure. And this filter element is comprised so that the filter medium frame arrange | positioned at the outer periphery of the said filter medium may be shape | molded with a waste paper mixing thermoplastic resin material, and it may join integrally, and the rigidity of the said filter element whole can be ensured. Yes.

  However, after an air conditioner with a built-in filter is installed, the dust removal performance required for the air conditioner may be further enhanced according to the user's request. For example, in the past, a flat filter medium was used to remove coarse dust and inserted into a thin frame material. However, by extending the filter filter life, the cost for replacing the filter will be reduced. It may be. Therefore, in order to lengthen the filtration life, even if an attempt is made to use the filter element formed by bending the above-mentioned sheet-like filter medium, the height of the peak of the filter element is large, so long as no major design changes are made, There was a problem that it could not be attached to existing air conditioning equipment.

  For example, when a filter element formed into a corrugated shape by folding a sheet-like filter material is installed in an existing duct provided in an air conditioner or the like, a large frame for storing the filter element is installed in the duct. It is necessary to. However, there is a problem that the space required for installation cannot be secured, and even if it is secured, there is a problem that construction costs increase.

  In addition, a household air purifier, an OA device, a household appliance, and the like are required to be a compact device, and are desired to be a facility that does not require much maintenance. Therefore, when it is attempted to attach a filter element formed in a corrugated shape by folding the sheet-like filter medium, it is necessary to secure a large entrance for accommodating the filter element, which hinders downsizing. In addition, even if there is room in the internal space, there is a problem that a space for entrance cannot be secured outside, and a smart appearance may be required. That is, there has been a demand for downsizing such that the internal space of these devices is effectively used, the appearance is smart, and the mounting structure is simple.

JP 2002-58943 A Japanese Patent Laid-Open No. 11-22214

  The present invention solves the above problems and can extend the filter life by replacing with a conventional flat plate filter without a large design change, and requires a small space for installation, and requires a design change. It is an object of the present invention to provide a filter element that can be applied to an apparatus that is low in cost and that is required to be compact, a method for manufacturing the filter element, and a method for mounting the filter element.

  In order to solve the above-mentioned problems, in the inventions according to claims 1 to 3, the sheet-shaped filter medium is formed in a bag shape having a corrugated surface and a side surface, and the sheet-shaped filter medium is fixed to a flat frame material. It is a filter element, and the height of the filter element can be reduced to 70% or less with respect to the original height by pressing, and the height of the filter element is reduced to the original height by releasing the pressing. It is a filter element characterized in that it can recover 80% or more.

  In the invention according to claim 4, the height of the filter element can be reduced to 70% or less with respect to the original height by pressing, and the height of the filter element is reduced to the original height by releasing the pressing. A filter element manufacturing method capable of recovering 80% or more of the thickness, forming a sheet-like filter medium into a bag shape composed of corrugated surfaces and side surfaces, and fixing the sheet-like filter medium to a flat frame material In doing so, a step of preparing a sheet-like filter medium comprising a central portion, an end portion adjacent to the central portion, and a tip portion adjacent to the end portion, and the same shape consisting of a mountain and a valley by bending the central portion Forming the corrugated surface into a corrugation, forming the side surface by cutting an end and bending it between a central portion and the end, overlapping the sheet-like filter medium on the side surface, and A step of partially bonding, a step of forming a frame surface adjacent to the side surface by bending between an end portion and a tip portion, and arranging the frame surface on the same surface as the bottom of the valley And a step of fixing the frame surface to the frame member.

  In the invention which concerns on Claim 5, the sheet-like filter material is formed in the bag shape which consists of a corrugated surface and a side surface, And the filter element by which the said sheet-like filter material is fixed to the flat frame material is carried out by temporary pressing. The height of the filter element is set to 70% or less of the original height, and the filter element is inserted into the slit of the filter housing body provided with the slit in a direction parallel to the surface of the frame member. The filter element mounting method is characterized in that the height of the filter element is recovered by 80% or more of the original height by the release.

  The present invention can be replaced with a conventional flat filter without a large design change, requires a small space for installation, requires a low cost for design change, and is required to be compact. It is possible to provide a filter element applicable to the above, a method for manufacturing the same, and a method for mounting the filter element.

  Hereinafter, a filter element according to the present invention, a manufacturing method thereof, and a preferred embodiment of a filter element mounting method will be described in detail. In addition, the manufacturing method of the filter element of this invention and the mounting method of a filter element are demonstrated in description of a filter element.

  In the filter element of the present invention, as illustrated in FIG. 1, the sheet-shaped filter medium 20 is formed in a bag shape including a corrugated surface 30 and a side surface 40, and the sheet-shaped filter medium is fixed to a flat frame material 100. 2A and 2B, the height of the filter element is reduced to 70% or less of the original height A by pressing in the direction of arrow P. The filter element is characterized in that the height of the filter element can be recovered by 80% or more with respect to the original height A by releasing the pressure. In the filter element of FIG. 1, the angle of the mountain is 90 degrees.

  In the filter element of the present invention, since the sheet-like filter medium 20 is formed in a bag shape composed of the corrugated surface 30 and the side surface 40, the side surface also has a filtering function, so that only the corrugated surface has a filtering function and In comparison, there is an advantage that the filtration life is long. Moreover, since a sheet-like filter medium can be used effectively, there is an advantage that it is environmentally friendly by saving resources and waste.

  In the filter element of the present invention, the height of the filter element can be 70% or less of the original height A, and the height of the filter element can be reduced by releasing the pressure. It has a characteristic that it can recover 80% or more with respect to the height A. The change in height due to the pressing of the filter element can be confirmed as follows.

(Pressure test method for filter element)
(1) Measurement of the original height (h ₀ ) of the filter element As shown in the schematic diagram of FIG. 2A, the filter element 10 is mounted on the horizontal plate 300 with the frame member 100 facing down. Put. Next, as shown in FIG. 2B, a flat plate 310 is placed on the filter element 10. The mass of the horizontal plate is set to 0.7 kg / m ² with respect to the bottom area of the filter element (excluding the frame material 100 portion). The mass of the horizontal plate can be adjusted by placing a weight on demand. Next, after standing in this state for 1 minute, the distance between the horizontal plate and the flat plate is measured. At the time of measurement, measurement is performed at a total of eight points of the four corners of the flat plate and the central portion of each side of the flat plate, and the average value of the obtained values is defined as the original height (h ₀ ) of the filter element.
(2) Measurement of height (h _P ) when the filter element is pressed Next, as shown in FIG. 2B, a weight 320 is placed on the flat plate 310 so that the crest of the filter element 10 is crushed. The total mass of the horizontal plate 310 and the weight 320 is set to be 25 kg / m ² with respect to the bottom area of the filter element (excluding the frame material 100 portion). Next, after standing for 1 minute in this state, the distance between the horizontal plate and the flat plate is measured at eight places as described above, and the average value is defined as the height (h _P ) when the filter element is pressed.
(3) Measurement of Recovery Height (h _R ) of Filter Element Next, the horizontal plate 310 and the weight 320 are removed from the top of the filter element, and after 2 minutes, “the original height of the filter element described in (1)” Similarly to “Measurement of”, the distance between the horizontal plate and the flat plate is measured, and the obtained value is defined as the recovery height (h _R ) of the filter element.
(4) Calculation of height recovery rate of filter element The recovery rate (%) is obtained by calculating the calculation formula (h _R / h ₀ ) × 100.

  In addition, as a press in actually using the filter element of the present invention, a temporary press required when the filter element is mounted can be exemplified. For example, as illustrated in FIG. 6A, the filter housing 200 is provided with slits 210a and 210b, and is inserted in a direction parallel to the surface of the frame member 100 (in the direction of arrow I in FIG. 6). Then, as illustrated in FIG. 6C after the insertion, there is a pressure when the height of the filter element is restored to the original height by releasing the pressure.

  In the filter element of the present invention, the height of the filter element can be set to a height of B of 70% or less with respect to the original height A, and the height of the filter element is reduced to the original by releasing the pressure. 80% or more can be recovered with respect to the height A, but it is preferable that the height be 60% or less with respect to the original height, and it is possible to be 55% or less. More preferably, it is even more preferable that it can be 50% or less. Further, it is preferable that the filter element can be recovered by 85% or more with respect to the original height by releasing the pressure, more preferably 90% or more can be recovered, and more preferably 92% or more can be recovered. .

  Hereinafter, these preferred embodiments will be described in detail based on FIGS. 3A, 3B, and 3C illustrating the assembly of the filter element of FIG. FIG. 3A is a development view before the sheet-shaped filter medium 20 is bent. The sheet-shaped filter medium 20 has a central portion 30 ′, an end portion 40 ′ adjacent to the central portion, and a tip portion 50 adjacent to the end portion. A mountain fold line 31 and a valley fold line 32 are provided in the center, and a mountain fold line 43 is provided between the center 30 'and the end 40'. Further, a valley fold line 44 is provided between the end 40 'and the tip 50', and a cut 42 is formed in the end 40 '. A second end 60 ′ is provided via the valley fold line 32.

  Next, the sheet-shaped filter medium 20 shown in this development view is folded at each folding line so that the mountain fold line becomes a mountain and the valley fold line becomes a valley, and the end portion 40a of the sheet-like filter medium 20 is adjacent thereto. The other arranged end portions 40b are overlapped and partially joined. Furthermore, by making the front end portion 50 ′ of the sheet-like filter medium 20 on the same plane as the bottom of the valley, the central portion 30 ′ becomes the corrugated surface 30, the end portion 40 ′ becomes the side surface 40, and the front end portion 50 ′ It becomes the frame surface 50. Then, the second end portion 60 ′ and the tip portion 50 ′ are fixed to a plate-like frame member 100 formed in a band shape so as to surround the periphery of the corrugated surface 30, respectively (FIG. 3B). The filter element 10 shown in c) can be formed.

  That is, the step of forming the corrugated surface 30 into a corrugated shape having a peak and a valley by bending the central portion 30 ′ of the sheet-like filter medium 20, and cutting the end portion 40 ′ and the central portion 30 ′ Forming the side surface 40 by bending it between the end portions 40 ', and overlapping the end portion 40a of the sheet-like filter medium 20 with the other end portion 40b disposed adjacent thereto on the side surface 40, and A step of partially joining, a step of forming a frame surface 50 adjacent to the side surface 40 by bending between the end 40 'and the tip 50', and the frame surface 50 the same as the bottom of the valley The filter element 10 may be formed by a method of manufacturing the filter element 10 including a step of arranging the frame surface 50 on the surface and fixing the frame surface 50 to the frame material 100.

  In this way, the filter element 10 is formed such that the corrugated surface 30 is formed in a corrugated shape having a crest and a valley by bending the central portion 30 ', and the side surface 40 is cut into the end portion 40'. And is formed by being bent at a right angle between the central portion 30 ′ and the end portion 40 ′, and further, the sheet-like filter medium 20 is overlapped on the side surface 40, that is, the end piece 40a is disposed adjacent to the end piece 40a. The end piece 40b has the same shape and overlaps, and the end piece 40a and the end piece 40b are partially joined at the overlapped portion. Further, a frame surface 50 is formed adjacent to the side surface 40 by being bent at a right angle between the end portion 40 ′ and the tip portion 50 ′. In the frame surface 50, the tip portion piece 50 a and the tip portion piece 50 b are formed. And are overlapping. The frame surface 50 is on the same plane as the bottom of the valley, and the frame surface 50 and the second end portion 60 ′ are fixed to the frame member 100. In FIG. 3, the angle of the peak of the filter element is 90 degrees.

  In the case of the filter element shown in FIG. 3, since the end portions of the same shape overlap each other, there is an advantage that the side surfaces are reinforced and the shape retaining property of the entire filter element is excellent. Moreover, since the shape of a side surface is formed only by overlapping, there exists an advantage that it is easy to assemble.

  The form in which the above-described sheet-shaped filter medium 20 is partially joined at the overlapping portion is not particularly limited as long as the entire overlapping portion is not joined, and is formed by dots or lines by ultrasonic fusion or thermal fusion. The form joined to the shape can be mentioned. Of these, specific examples of joining in a spot form include a method of joining in a spot form by ultrasonic fusion using an ultrasonic stapler or the like, for example, when the sheet filter medium is thermoplastic. Further, for example, there is a method of joining in a dot shape using a paste adhesive. By partially joining, the texture of the side surface 40 after joining becomes flexible, and there is an advantage that it can be easily restored to its original height immediately even for temporary compression of the filter element. In addition, when joining partially with a dotted | punctate form, 0.1-20% of the area ratio of the junction part with respect to the area of the overlapping part is preferable, 0.5-10% is more preferable, 1-7% Is more preferable. Moreover, when joining partially in a linear form, 1-50% of the area ratio of the junction part with respect to the area of the overlapping part is preferable, 2-40% is more preferable, 5-30% is further more preferable.

  As a preferable aspect of the filter element of the present invention, as exemplified in FIG. 4B in addition to FIG. 3, the angle of the crest of the corrugated surface 30 is 120 degrees which is larger than 90 degrees in FIG. As illustrated in FIG. 5B, it is possible that the angle of the crest of the corrugated surface 30 is 60 degrees smaller than 90 degrees in FIG. From the viewpoint of practicality, the angle of the mountain is preferably 30 to 150 degrees, and more preferably 50 to 130 degrees. When the angle of the ridge is less than 30 degrees, the area of the tip 50 'is reduced, so that it is difficult to form the frame surface 50 and it may be difficult to fix it to the frame member 100. Further, if the angle of the mountain exceeds 150 degrees, the disadvantage that the cost is higher than the advantage of increasing the dust holding capacity by forming the corrugated surface 30 on the sheet-like filter medium 20 may be lost, and the utility may be lost. .

  FIG. 4 shows a case where the peak angle of the filter element is larger than 90 degrees, for example, 120 degrees. FIG. 4A is a development view before the sheet-shaped filter medium 20 is bent. Like FIG. 3A, the sheet-shaped filter medium 20 includes a central portion 30 ′ and an end portion 40 ′ adjacent to the central portion. , And a fold line 31 and a valley fold line 32 are provided in the central part, and a fold line 43 is formed between the central part 30 ′ and the end part 40 ′. Is provided. Further, a valley fold line 44 is provided between the end 40 'and the tip 50', and a cut 42 is formed in the end 40 'and the tip 50'. A second end 60 ′ is provided via the valley fold line 32.

  Next, the sheet-like filter medium 20 shown in this development view is folded at each folding line so that the mountain fold line becomes a mountain and the valley fold line becomes a valley, and the sheet-like filter medium 20 is overlapped on the side surface 40. And partially joining. Then, by fixing the second end portion 60 ′ and the tip portion 50 ′ to the flat frame member 100 formed in a band shape so as to surround the periphery of the corrugated surface 30, respectively, as in FIG. 4 (b) and 4 (c) can be formed. In FIG. 3C, the tip piece 50a and the tip piece 50b have the same shape and are completely overlapped. However, in FIG. 4C, the tip piece 50a and the tip piece 50b are overlapped. Are different in that they partially overlap.

  FIG. 5 shows a case where the peak angle of the filter element is smaller than 90 degrees, for example, 60 degrees. FIG. 5A is a development view before the sheet-shaped filter medium 20 is bent. At the upper end and the lower end of the sheet-shaped filter medium 20, a triangular cutout is made with respect to the original rectangular sheet-shaped filter medium. 3A, the sheet-like filter medium 20 includes a central portion 30 ′, an end portion 40 ′ adjacent to the central portion, and a distal end portion 50 ′ adjacent to the end portion. A mountain fold line 31 and a valley fold line 32 are provided in the central portion, and a mountain fold line 43 is provided between the central portion 30 ′ and the end portion 40 ′. Further, a valley fold line 44 is provided between the end 40 'and the tip 50', and a cut 42 is formed in the end 40 '. A second end 60 ′ is provided via the valley fold line 32. The above triangular cutout is for avoiding that the triangular cutout portion of the sheet-like filter medium 20 overlaps the end portion 40 ′ or the central portion 30 ′ and the filter element is not easily deformed.

  Next, the sheet-like filter medium 20 shown in this development view is folded at each folding line so that the mountain fold line becomes a mountain and the valley fold line becomes a valley, and the sheet-like filter medium 20 is overlapped on the side surface 40. And partially joining. Then, by fixing the second end portion 60 ′ and the tip portion 50 ′ to the flat frame member 100 formed in a band shape so as to surround the periphery of the corrugated surface 30, respectively, as in FIG. The filter element 10 shown to FIG.5 (b) (c) can be formed. 3C, the tip piece 50a and the tip piece 50b have the same shape and are completely overlapped. However, in FIG. 5C, the tip piece 50a and the tip piece 50b is partially different from that of 50b.

  In the present invention, the angle of the mountain can be other than the above-mentioned 90 degrees, 60 degrees, and 120 degrees, and the notches are formed at the upper end portion and the lower end portion of the sheet-like filter medium 20 according to the target angle. Preferably it is done.

The material of the frame member 100 is not particularly limited as long as it is a flat plate member having rigidity that can be formed in a band shape so as to surround the periphery of the corrugated surface 30 of the sheet-like filter medium 20. A synthetic resin plate, a metal plate, or a composite of these can be applied, but a cardboard plate is preferable in view of ease of disposal and cost. As the cardboard, for example, kraft paper having a basis weight of 80 g / m ² , 100 g / m ² or 120 g / m ² can be applied.

  Further, the form of fixing the tip portion 50 ′ to the flat frame member 100 is not particularly limited. For example, as the flat frame member 100, by cutting out the central portion of a rectangular cardboard plate into a square shape, Two sheets of cardboard plate are prepared so as to surround the corrugated surface 30 of the sheet-like filter medium 20, and then the tip 50 'is sandwiched between the two cardboard plates using a hot melt resin. , Can be fixed to this cardboard board. Further, for example, by combining L-shaped or U-shaped cardboard pieces, two upper and lower cardboard plates formed in a strip shape so as to surround the corrugated surface 30 of the sheet-like filter medium 20 are prepared. The tip 50 'can be sandwiched between the cardboard plates and can be fixed to the cardboard plate using a hot melt resin.

  Next, a preferable embodiment of the sheet-like filter medium 20 that can be applied as the filter element of the present invention will be described. The sheet-shaped filter medium is not particularly limited as long as it is a breathable material, and for example, a fiber substrate such as a woven fabric, a knitted fabric, a net, or a nonwoven fabric can be applied. Among these, a non-woven fabric is particularly preferable because it can efficiently use the total area of the fiber surface widely and has many small voids formed by the fibers. In addition, the nonwoven fabric can be a composite nonwoven fabric in which a nonwoven fabric is combined with a breathable material such as a net. In particular, a composite nonwoven fabric in which a nonwoven fabric is combined with a net is excellent in rebound resilience and can be said to be a more preferable form.

  The nonwoven fabric (hereinafter referred to as the nonwoven fabric substrate) as the fiber substrate is not particularly limited, and the structure of the nonwoven fabric substrate is typically a fiber length of 15 to 100 mm and a crimp number of 5 to 30 / inch. Generally called a dry method, in which a fiber called a staple fiber is formed on a fiber web using a card machine or an air array device, and then the constituent fibers are bonded together using an adhesive fiber or an adhesive. There is a nonwoven fabric obtained by a manufacturing method. Since the nonwoven fabric by the dry method has many fibers oriented in the thickness direction, there is an advantage that the thickness is large and the thickness is not easily crushed. In addition, the staple fiber is crimped so that it can be opened by a card machine or the like, so that it becomes a bulky nonwoven fabric base material and has an advantage of excellent repulsive force in the thickness direction against compression. is there.

  In the present invention, as described above, as a preferable form of the sheet-shaped filter medium, a sheet-shaped filter medium in which a nonwoven fabric is reinforced with a net-like support can be exemplified. For example, a composite nonwoven fabric obtained by combining a nonwoven fabric with a synthetic resin net can be used. Examples of such a composite nonwoven fabric include a composite nonwoven fabric in which a fiber web and a net are entangled and integrated and / or a composite nonwoven fabric in which constituent fibers are bonded.

  Examples of the web constituting fiber constituting the fiber web include polyclar fiber, polyvinylidene chloride fiber, polyvinyl chloride fiber, polyester fiber, polyamide fiber, acrylic fiber, modacrylic fiber, polyvinyl alcohol fiber, polypropylene fiber, polyethylene fiber, and polyurethane. Synthetic fibers such as fibers, regenerated fibers such as rayon and viscose, semi-synthetic fibers such as acetate, inorganic fibers such as carbon fibers and glass fibers, etc. Among these, polychlore with excellent flame resistance Fiber, polyvinylidene chloride fiber, modacrylic fiber, and polyvinyl chloride fiber can be preferably used.

  Moreover, it is also preferable that the web constituent fiber contains a heat-shrinkable fiber. When the heat-shrinkable fibers are heat-shrinked to develop crimps, the entanglement between the fiber web and the net becomes stronger, and the fiber web and the net are more difficult to peel off. Therefore, it is preferable that 40% by weight or more of heat-shrinkable fiber is contained, and more preferably 50% by weight or more. As this heat-shrinkable fiber, a fiber composed of a single component such as a polyvinyl chloride fiber can be applied, but the cross-sectional shape is a composite composed of a plurality of resin components such as a core-sheath type, an eccentric type, and a side-by-side type. If it is a fiber, it can be more suitably applied because it is more easily contracted and easily entangled with the net.

The heat-shrinkable fiber in the present invention is a fiber web having a length of 40 cm, a width of 25 cm, and a basis weight of 40 g / m ² formed from 100% of the same fiber by the card method, and heat-treated at the melting point temperature of the fiber for 30 seconds. This refers to a fiber having an area shrinkage of 20% or more. In addition, when a fiber is a composite fiber, it heat-processes with melting | fusing point temperature of the resin component which has the lowest melting | fusing point among resin exposed on the fiber surface. For example, in the case of the core-sheath type composite fiber, the treatment is performed at the melting point temperature of the sheath resin, and in the case of the side-by-side type composite fiber, the treatment is performed at the melting point temperature of the resin having the lower melting point. The area shrinkage rate is a value obtained by the following equation.

  Examples of combinations of resin components constituting the composite fiber include, for example, polypropylene / polyethylene, polyester / low melting point polyester, polypropylene / low melting point polypropylene, nylon 66 / nylon 6, nylon 6 / low melting point nylon, polyester / nylon 6, nylon 6 / Polyethylene, polyester / polypropylene, etc.

  In addition, when the low melting-point resin component of the said composite fiber has thermal adhesiveness, a web constituent fiber can be thermally bonded by this resin component. As described above, when the low melting point resin component of the composite fiber has thermal adhesiveness, the fiber shape can be maintained by the high melting point resin component, so that the strength is excellent and the fiber web can be used even if the height of the filter element is changed. There is an advantage that there is no fear of peeling off the net.

  The fineness of such a web-constituting fiber is preferably 3.3 to 33 dtex. If it is less than 3 deniers, the entanglement with the net tends to decrease, and if it exceeds 33 dtex, the gap of the fiber web tends to increase, and the collection efficiency tends to decrease. More preferably, it is 11-22 dtex suitable for removing coarse dust.

  After laminating the fiber web composed of the fibers as described above and the net, a sheet-like filter medium can be obtained by entanglement integration treatment and / or adhering the web constituent fibers. Examples of the adhesion of the web constituent fibers include adhesion with an adhesive fiber or an adhesive. The adhesive fiber is not necessarily a composite fiber, and may be a single component, for example, polyethylene fiber, polypropylene fiber, polyamide fiber, polyester fiber, polyvinyl chloride fiber, polyurethane fiber, or the like.

  The fiber web can be obtained, for example, by a card method, an air array method, a spun bond method, a melt blow method, a wet method, or the like. In addition, in order to improve the handleability, the fiber web can be lightly entangled by applying a needle or a water flow.

In the present invention, as the net constituting the composite nonwoven fabric, a net formed by thermoforming or filaments can be used. As the thermoformed net, for example, a net having a structure in which a crossing portion of a net yarn is fused by direct molding in a biaxially stretched net can be used. Further, the mesh size (interval between yarns) is not particularly limited, and is preferably 1 to 45 mm, more preferably 3 to 30 mm, and still more preferably 4 to 15 mm. The surface density is not particularly limited, is preferably from 5 to 200 g / ^{m 2,} more preferably from 10 to 100 g / ^{m 2,} and still more preferably from 15 to 50 g / ^{m 2.}

  As the net constituting the composite nonwoven fabric, in addition to the thermoformed net, a filament woven one can be used. If the net is a filament woven net, it is easy to make the mesh fine and pleated. There is an advantage that it is easy to do. Hereinafter, a net woven from this filament will be described.

  If the composite filament is included as the filament constituting the net, only one resin component of the composite filament can be fused, and the other resin component can be prevented from being fused. It can be maintained, and a net that does not deform or change the distance between filaments can be obtained even if washed.

  As the composite filament, those having a cross-sectional shape of a core-sheath type, an eccentric type, and a side-by-side type can be used. As combinations of constituent resin components, for example, 6 nylon / polyethylene, polyester / nylon 6, polypropylene / polyethylene, polypropylene / An ethylene-vinyl acetate copolymer, polyester / polypropylene, polyester / polyethylene, 6 nylon / 66 nylon, high-melting polyester / low-melting polyester, high-density polyethylene / low-density polyethylene, and the like can be used.

  In addition, as filaments other than composite filaments, for example, recycled fibers such as rayon, semi-synthetic fibers such as acetate, polyamide fibers, polyvinyl alcohol fibers, polyvinylidene chloride fibers, polyvinyl chloride fibers, polyester fibers, poly Synthetic fibers such as acrylonitrile fibers, polyethylene fibers, polypropylene fibers, polyurethane fibers, and polyclar fibers, and inorganic fibers such as carbon fibers can be used.

  In order to impart rigidity to the net, these filaments preferably have a fineness of 200 dtex or more, and if the fineness is 1000 dtex or less, they have excellent workability when pleating. A more preferable fineness is 250 to 650 dtex.

  Such a filament is preferably woven at a rate of 4 to 20 yarns / inch. If the number of driven wires is more than 20 / inch, the distance between the filaments is short, and the net rigidity is excellent, but it may be difficult to temporarily reduce the height of the filter element. Pressure loss may be high. Further, when the entanglement process described later is performed by a needle punch method, needle breakage may easily occur. On the other hand, if the number of driven wires is less than 4 / inch, the distance between the filaments becomes long, so that the rigidity of the entire net is lost and the rebound resilience is poor and the filter element may be easily deformed. A more preferable driving number is 5 to 17 / inch.

In the present invention, as the net constituting the composite nonwoven fabric, a thermoformed net or the like can be used in addition to the filament woven. As the thermoformed net, for example, a net having a structure in which a crossing portion of a net yarn is fused by direct molding in a biaxially stretched net can be used. Further, the mesh size (interval between yarns) is not particularly limited, and is preferably 1 to 45 mm, more preferably 3 to 30 mm, and still more preferably 4 to 15 mm. The surface density is not particularly limited, is preferably from 5 to 200 g / ^{m 2,} more preferably from 10 to 100 g / ^{m 2,} and still more preferably from 15 to 50 g / ^{m 2.}

  The fiber web and net as described above are laminated and entangled. Examples of the entanglement process include a fluid entanglement method such as a needle punch method and a water flow. Among these, the entanglement treatment by the needle punch method can be entangled and integrated with the net without crushing the thickness of the fiber web. Can be long. Thus, the integration of the fiber web and the net is performed by the entanglement process, so that the web constituent fibers after the integration are in a state of three-dimensional winding.

The entanglement process by the needle punch method is preferably performed at a needle density of 20 to 300 needles / cm ² . When the needle density is less than 20 / cm ² , the entanglement with the net is weak, and it is easy to peel off with respect to the change in the height of the filter element, and when it exceeds 300 / cm ² , the net is severely damaged by the needle. Because.

  After this entanglement treatment, the web constituent fibers are adhered to obtain a sheet-like filter medium. More preferably, the web constituent fibers can be bonded to the net so that the fiber web and the net are more difficult to peel off. In addition, it is preferable to perform adhesion | attachment of this web constituent fiber under no pressure. This is in order to maintain the three-dimensional winding and shrinkage of the web constituent fibers when they are intertwined and integrated so as not to reduce the dust holding capacity.

  This adhesion can be carried out by applying an emulsion type, suspension type, solvent type, or powder type adhesive, and the fibers having the thermal adhesive properties as described above are included in the web constituting fiber. In addition, it is also possible to adhere | attach with the fiber, and these can also be used together. Furthermore, when the filament constituting the net has adhesiveness, it is also possible to use filament adhesion together.

Examples of emulsion-type, suspension-type, solvent-type, or powder-type adhesives include vinyl chloride, acrylate ester, ethylene-vinyl acetate copolymer, polyvinyl acetate, synthetic rubber, polyurethane, and polyester. It is preferable to use 10 to 70 g / m ² in terms of solid content. If it is less than 10 g / m ^2, despite the use of an adhesive, and the fibrous web and the net is easily peeled off with respect to the change in the height of the filter element, if it exceeds 70 g / m ^2, the pressure This is because loss increases. More preferably, it is 20-60 g / m < ² >.

  The sheet-like filter medium obtained as described above has excellent rebound resilience because the fiber web and the net are intertwined and integrated, and the web constituent fibers are bonded in a state of three-dimensional winding. Even when the height of the element is changed, the fiber web and the net do not peel off, and it can be said to be a sheet-like filter medium having a large dust holding capacity.

As described above, various filter media can be used as filter elements depending on the purpose of use, but considering the formation of a bag, the thickness of the filter media of the present invention is 0. It is preferably 2 to 15 mm, more preferably 0.4 to 10 mm, and still more preferably 0.6 to 8 mm. If it is less than 0.2 mm, the dust removal efficiency may be insufficient, and if it exceeds 15 mm, it may be difficult to form a bag. In addition, this thickness says the value at the time of 1-g load per 1 cm < ² > unit area.

  In addition, the filtration performance of the sheet-like filter medium preferably functions as a filter for removing coarse dust. Specifically, in the test method defined in ASHRAE 52.1-1992, using ASHRAE TEST DUST, When evaluated by the mass method, when the test condition is a wind speed of 2.5 m / second, the mass method average efficiency is preferably 30 to 99%, the mass method average efficiency is preferably 30 to 95%, More preferably, the average efficiency is 40 to 90%. When the mass method average efficiency is less than 30%, coarse dust removal is insufficient, and when the mass method average efficiency exceeds 99%, the pore diameter of the sheet filter medium becomes too fine, so the sheet filter medium immediately. There is a possibility that the pressure loss before and after reaches the limit and the life is shortened, and it cannot be used as the sheet-like filter medium for the filter element of the present invention.

The initial pressure loss of the sheet-like filter medium is preferably 100 Pa or less, more preferably 50 Pa or less, and even more preferably 35 Pa or less when the test condition is a wind speed of 2.5 m / sec. In addition, when the final pressure drop 200 Pa, preferably dust supply amount is 130 g / ^{m 2} or more, 200 g / ^{m 2} or more, more preferably, 300 g / ^{m 2} or more is more preferable.

  The height of the filter element is preferably 5 to 150 mm, more preferably 8 to 100 mm, and still more preferably 15 to 50 mm. Moreover, 5-100 mm is preferable, and, as for a crest distance, 8-75 mm is more preferable, and 15-50 mm is still more preferable.

  The overall size of the filter element is such that the dimension of one side of the air inflow surface is 80 to 500 mm in the case of a filter element that is used by being mounted on an air conditioner in a living environment such as an automobile or a home air cleaner. Is preferable, 100 to 400 mm is more preferable, and 150 to 300 mm is still more preferable. Also, in the case of filter elements used as gas removal filters such as package filters, fan coil units, and central air conditioning filter units in air purifiers installed in buildings, factories, offices, etc., one side of the air inflow surface Is preferably 200 to 1500 mm, more preferably 300 to 1000 mm, and still more preferably 400 to 700 mm.

  The filtration performance of the filter element preferably functions as a filter for removing coarse dust. Specifically, in the test method defined in ASHRAE 52.1-1992, using ASHRAE TEST DUST, the mass method is used. When evaluated, when the wind speed is 2.5 m / sec, the mass method average efficiency is preferably 30 to 99%, the mass method average efficiency is preferably 30 to 95%, and the mass method average efficiency is More preferably, it is 40 to 90%. When the mass method average efficiency is less than 30%, coarse dust removal is insufficient, and when the mass method average efficiency exceeds 99%, the pore diameter of the sheet filter medium becomes too fine, so the sheet filter medium immediately. There is a possibility that the pressure loss before and after reaches the limit, shortens the service life, and cannot be used as a filter for removing coarse dust.

The initial pressure loss of the filter element is preferably 50 Pa or less, more preferably 20 Pa or less, and even more preferably 15 Pa or less when the test condition is a wind speed of 2.5 m / sec. In addition, when the final pressure drop 200 Pa, preferably dust supply amount 200 g / ^{m 2} or more, 300 g / ^{m 2} or more, more preferably, 450 g / ^{m 2} or more is more preferable.

  Next, a method for mounting the filter element of the present invention will be described. According to the filter element mounting method of the present invention, a filter element in which a sheet-like filter medium is formed in a bag shape having a corrugated surface and a side surface, and the sheet-like filter medium is fixed to a plate-like frame member is temporarily attached. By pressing, the height of the filter element is set to 70% or less of the original height, and the filter element is inserted into the slit of the filter housing body provided with the slit in a direction parallel to the surface of the frame member. It is characterized by recovering the height of the filter element by 80% or more with respect to the original height by releasing the pressure.

  In the filter element mounting method of the present invention, it is preferable to use the filter element of the present invention as the filter element. Hereinafter, the case where the filter element of the present invention is mounted will be described as an example.

  As described above, the filter element of the present invention has a height of B of 70% or less with respect to the original height A by pressing in the direction of arrow P as illustrated in FIG. 6 and has a characteristic that the height of the filter element is restored by 80% or more with respect to the original height A by releasing the pressure, for example, as illustrated in FIG. As described above, the height A of the filter element 10 is set to 70% or less of the original height by temporarily pressing the filter element 10, and then the height A of the filter element 10 is set to 70%. % Or less slits 210a and 210b are inserted into the slits of the filter housing body 200 in a direction parallel to the surface of the frame member 100 (in the direction of arrow I in FIG. 6). Example Wherein the releasing of the pressing (in this example may be recovered more than 80% the height of the filter element relative to the original height A by resilience having a filter element as.

  Here, the mode of temporary pressing is not particularly limited, and for example, a method of inserting into a slit while pressing with a hand, a method of inserting into a slit smaller than the height of the filter element, a stiff plate, etc. There is a method of pressing and then inserting into the slit. Further, “temporary” may be a time required for insertion or preparation thereof, and is not necessarily a time applied in a filter element thickness recovery test.

  Further, the filter housing body is not particularly limited as long as it has a space in which the filter element can be housed. For example, the filter housing body may be a filter unit frame made of a rigid frame, or may be provided in the middle of a duct. is there. Moreover, it is also possible to adopt a configuration in which the filter mechanism is provided in the middle of the air flow path of the device.

  In the filter element mounting method of the present invention, the height is 70% or less with respect to the original height, but the height is preferably 65% or less with respect to the original height, and 60% or less. More preferably, it is more preferably 55% or less. Further, by releasing the pressure, the filter element is rotated 80% or more with respect to the original height, but it is preferable to recover 85% or more, and more preferably 90% or more.

  As described above, according to the present invention, it is possible to extend the filter life by replacing with a conventional flat plate filter without a large design change, the space required for the installation can be reduced, and the cost required for the design change. Therefore, it is possible to provide a filter element that can be applied to a device that is low in size and that is required to be compact, a method for manufacturing the filter element, and a method for mounting the filter element.

  Examples of the present invention will be described below, but these are only suitable examples for facilitating the understanding of the present invention, and the present invention is not limited to the contents of these examples.

(Filtration performance test method for filter element or sheet filter medium-mass method)
In the test method specified in ASHRAE 52.1-1992, after supplying ASHRAE TEST DUST at a wind speed of 2.5 m / sec until the pressure loss reaches 200 Pa, the dust supply amount (g / m ² ) and the mass method Find the average efficiency (%). The dust supply amount (g / m ² ) is obtained by calculating the supply amount (g) of ASHRAE TEST DUST with respect to the area (m ² ) of the bottom surface of the filter element excluding the frame surface or frame member. The initial pressure loss (Pa) is a value measured at a wind speed of 2.5 m / sec.

(Example 1)
After blending 60% by weight of flame-retardant modacrylic fiber with a fineness of 15 dtex and a fiber length of 51 mm and 40% by mass of polyester fiber with a fineness of 20 dtex and a fiber length of 76 mm, carding and then fiber orientation direction by cross layer Were crossed to obtain a fiber web having a surface density of 45 g / m ² and a thickness of 15 mm.
Next, a biaxially stretched net having an areal density of 35 g / m ² , a net having a mesh of 6 × 6 mm with a crossover portion of the yarn fused directly by molding, and the fiber web, After laminating on this net, needle punching was performed at a needle density of 50 / cm ² and a needle depth of 16 mm, and the fiber web and net were entangled and integrated. Next, a vinyl chloride emulsion was sprayed from both sides as an adhesive and dried with a drier to obtain a sheet-like filter medium in which the constituent fibers were bonded to each other with an adhesive having a solid content of 40 g / m ² .

The surface density of this sheet-like filter medium was 120 g / m ² and the thickness was 5.0 mm. Moreover, according to the filtration performance test of this sheet-like filter medium, the dust supply amount was 116 g (429 g / m ² ), the mass method average efficiency was 56%, and the initial pressure loss was 23 Pa.

  Next, as shown in the development view of FIG. 3 (a), the sheet-like filter medium 20 has a central portion 30 ′ and an end portion 40 ′ (end piece 40a, which is adjacent to the central portion). An end piece 40b) and a tip 50 'adjacent to the end, and a mountain fold line 31 and a valley fold line 32 are provided in the center, and a mountain fold is formed between the center 30' and the end 40 '. Line 43 was provided. Further, a valley fold line 44 is provided between the end 40 'and the tip 50', and a cut 42 is made in the end 40 '. A second end 60 ′ is provided via the valley fold line 32.

  Next, the sheet-like filter medium 20 was bent at each fold line so that the mountain fold line was a mountain and the valley fold line was a valley, and the end piece 40a, which is an end 40 ', was arranged next to the end piece 40a. The end pieces 40b were overlapped and joined. Furthermore, by making the front end portion 50 ′ of the sheet-like filter medium 20 on the same plane as the bottom of the valley, the central portion 30 ′ is the corrugated surface 30, the end portion 40 ′ is the side surface 40, and the front end portion 50 ′ is The frame surface 50 was used. Then, the second end portion 60 ′ and the tip portion 50 ′ are fixed to a plate-like frame member 100 formed in a band shape so as to surround the periphery of the corrugated surface 30, respectively (FIG. 3B). The filter element 10 shown in c) was formed.

  In addition, in the part with which the sheet-like filter medium 20 overlaps, the sheet-like filter medium 20 was joined by ultrasonically fusing the spot-like three places using the ultrasonic stapler. The area ratio of the bonding portion to the area of the overlapping portion by this bonding was 3.3%. For fixing to the flat frame member 100, two L-shaped cardboard pieces are combined and bonded with an adhesive, and the center part of the square cardboard plate is cut out into a square shape. Two such cardboard plates were prepared, and the tip portion 50 ′ was sandwiched between the two cardboard plates, and the tip portion 50 ′ was fixed to the cardboard plate with hot melt resin.

  In this way, the filter element 10 is formed such that the corrugated surface 30 is formed in a corrugated shape having a crest and a valley by bending the central portion 30 ', and the side surface 40 is cut into the end portion 40'. And is formed by being bent at a right angle between the central portion 30 ′ and the end portion 40 ′, and further, the sheet-like filter medium 20 is overlapped on the side surface 40, that is, the end piece 40a is disposed adjacent to the end piece 40a. The end piece 40b has the same shape and overlaps, and the end piece 40a and the end piece 40b are partially joined at the overlapped portion. Further, a frame surface 50 is formed adjacent to the side surface 40 by being bent at a right angle between the end portion 40 ′ and the tip portion 50 ′. In the frame surface 50, the tip portion piece 50 a and the tip portion piece 50 b are formed. Overlapped. The frame surface 50 is on the same plane as the bottom of the valley, and the frame surface 50 and the second end portion 60 ′ are fixed to the frame material 100. The angle of the peak of the filter element was 90 degrees.

The height of the filter element was 26 mm, the distance between the peaks was 47 mm, the width of the frame member was 30 mm, and the overall size of the filter element was 510 mm long × 530 mm wide. Moreover, according to the filtration performance test of this filter element, the dust supply amount was 183 g (677 g / m ² ), the mass method average efficiency was 70%, and the initial pressure loss was 10 Pa. Further, according to the pressing test, this filter element has a height of 44% with respect to the original height, and the height of the filter element is restored by 95% with respect to the original height by releasing the pressure. I was able to.

It is a figure which shows an example of the filter element of this invention, (a) is a top view, (b) is a side view. It is a figure explaining the press test of the filter element of this invention. It is a figure which shows an example of the filter element of this invention, (a) is an expanded view, (b) is a side view, (c) is a top view. It is a figure which shows another example of the filter element of this invention, (a) is an expanded view, (b) is a side view, (c) is a top view. It is a figure which shows another example of the filter element of this invention, (a) is an expanded view, (b) is a side view, (c) is a top view. It is a figure explaining the mounting method of the filter element of this invention. It is a figure of the conventional filter element. It is a figure of the conventional filter element.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Filter element 20 Sheet-like filter medium 30 Corrugated surface 30 'Center part 31 Mountain fold line 32 Valley fold line 40 Side surface 40' End part 40a, 40b End part piece 42 Cut 43 Mountain fold line 44 Valley fold line 50 Frame surface 50 'Tip part 50a, 50b Tip piece 100 Frame member 200 Filter housing 210a, 210b Slit

Claims (5)

A filter element in which a sheet-like filter medium is formed into a bag shape composed of a corrugated surface and a side surface, and the sheet-like filter medium is fixed to a flat frame material,
By pressing, the height of the filter element can be made 70% or less of the original height, and by releasing the pressure, the height of the filter element is made 80% or more of the original height. A filter element characterized by being recoverable.   When the sheet-like filter medium is unfolded, it is composed of a central portion, an end portion adjacent to the central portion, and a tip portion adjacent to the end portion, and the corrugated surface is formed of a mountain and a valley when the central portion is bent. It is formed in a corrugated shape, and the side surface is formed by being cut at the end and bent between the center and the end, and the sheet-like filter material overlaps the side surface, In the overlapped portion, the sheet-like filter medium is partially joined, and further, a frame surface is formed adjacent to the side surface by being bent between an end portion and a tip portion, and the frame surface is The filter element according to claim 1, wherein the filter element is on the same plane as the bottom of the valley, and the frame surface is fixed to the frame member.   The filter element according to claim 1 or 2, wherein the sheet-like filter medium is formed by reinforcing a nonwoven fabric with a net-like support. By pressing, it is possible to reduce the height of the filter element to 70% or less of the original height, and by releasing the pressure, the height of the filter element is restored to 80% or more of the original height. A method of manufacturing a filter element that is possible,
In forming a sheet-like filter medium into a bag shape composed of a corrugated surface and a side surface, and fixing the sheet-like filter medium to a flat frame material, a central portion, an end portion adjacent to the central portion, and an adjacent end portion A step of preparing a sheet-like filter medium composed of a tip portion, a step of forming the corrugated surface into a corrugated shape having a peak and a valley by bending the central portion, and cutting the end portion into the central portion Forming the side surface by bending between the end portion and the end portion, overlapping the sheet-like filter medium on the side surface and partially joining the side surface, and bending the end portion and the tip portion to form the side surface. A step of forming a frame surface adjacent to and a step of disposing the frame surface on the same surface as the bottom of the valley and fixing the frame surface to the frame member. Production method. A filter element in which a sheet-like filter medium is formed in a bag shape composed of a corrugated surface and a side surface, and the sheet-like filter medium is fixed to a plate-like frame member, is temporarily pressed to increase the height of the filter element. 70% or less of the original height is inserted into the slit of the filter housing provided with the slit in the direction parallel to the surface of the frame member, and the height of the filter element is reduced by releasing the pressure after insertion. A filter element mounting method characterized by recovering 80% or more of the original height.

Images