JP2009136776A - Method of preparing honeycomb element, honeycomb element, and filtration device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of preparing a honeycomb element capable of reducing the number of its parts, a honeycomb element, and a filtration device. <P>SOLUTION: The honeycomb element 21 is prepared by continuously molding a sheet of a strip filter medium having a plurality of flat parts 21a and a plurality of corrugated parts 21b each alternately disposed thereon one after the other in the longitudinal direction thereof, and thereafter alternately laying each of the flat parts 21a over each of the corrugated parts 21b one after the other by bending the resulting strip filter medium at a position between each of the flat parts 21a and each of the corrugated parts 21b. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a honeycomb element for purifying, for example, air sucked into an internal combustion engine, a honeycomb element, and a filter device including the honeycomb element.

Conventionally, in this type of honeycomb element, for example, those shown in Patent Documents 1 to 3, a plurality of sheet materials obtained by laminating a corrugated filter medium and a flat filter medium are laminated (or spirally laminated). ), A honeycomb element having a block (or cylindrical) honeycomb structure is formed. Then, by placing and arranging the honeycomb element in a casing or the like, for example, a filter device for adsorbing moisture or dust of air sucked into the internal combustion engine and supplying the purified air to the internal combustion engine is provided. It is configured.
Japanese Patent Laid-Open No. 9-19619 Japanese Patent Publication No. 64-10245 No. 2-5851

  By the way, in the honeycomb element as described above, the wavy filter medium is formed by a pair of forming rollers having corrugated teeth on the outer periphery of the band-shaped filter medium (flat filter medium) supplied from the filter medium roll. Molded with. On the other hand, the flat filter medium is supplied from a filter medium roll different from the wavy filter medium roll described above, and a long sheet material is formed by bonding the flat filter medium and the wavy filter medium. It has come to be. In the case of forming a block-shaped honeycomb element from a sheet material formed in this way, the sheet material is cut into a plurality of pieces by sequentially cutting the sheet material with a predetermined dimension, and then they are laminated and formed. Yes. Further, in the case of forming a cylindrical honeycomb element, a sheet material cut in a predetermined dimension is wound and laminated in a spiral shape. In such a honeycomb element, there is a problem that the number of members increases due to the flat filter medium and the wavy filter medium formed from separate filter medium rolls. Further, in the case of forming a block-shaped honeycomb element, there is a problem that not only an apparatus for cutting a sheet material but also an apparatus for aligning the cut material, and the production line becomes complicated.

  The present invention has been made to solve the above problems, and an object of the present invention is to provide a honeycomb element manufacturing method, a honeycomb element, and a filter device that can reduce the number of members.

  In order to solve the above-mentioned problem, the invention according to claim 1 continuously forms a flat plate portion and a corrugated portion in the longitudinal direction of one strip-shaped filter medium, and between the flat plate portion and the corrugated portion. The gist is to fold and alternately laminate the flat plate portions and the corrugated portions.

  In this invention, a flat plate portion and a corrugated portion are continuously formed in the longitudinal direction of one strip-shaped filter medium, and the flat plate portion and the corrugated portion are alternately laminated by bending the flat plate portion and the corrugated portion. By doing so, the honeycomb element is formed. Therefore, since the flat plate portion and the corrugated portion constituting the honeycomb element are formed of one filter medium, the number of members can be reduced. Further, since only one filter medium roll for supplying the filter medium is required, the space for forming the honeycomb element can be reduced. Furthermore, since the flat plate portion and the undulating portion are continuously formed, the number of portions to be bonded between the respective layers composed of the flat plate portion and the undulating portion is reduced, the amount of the adhesive for the bonding, and bonding It is possible to reduce the number of processes. Furthermore, when a block-shaped honeycomb element is formed, a device for cutting the sheet material, a device for aligning the cut material, and the like are not required, which can contribute to simplification of the production line.

  According to a second aspect of the present invention, in the method for manufacturing a honeycomb element according to the first aspect, the flat plate is formed by a pair of forming rollers provided with corrugated teeth for forming the wavy portion on the circumferential half of the outer peripheral surface. The gist is that the part and the wavy part are continuously formed.

  In the present invention, the flat plate portion and the corrugated portion are continuously formed by the pair of forming rollers provided with corrugated teeth for forming the corrugated portion on the circumferential half of the outer peripheral surface. Therefore, the flat plate portion and the wave-like portion can be continuously formed by a forming roller having a simple configuration.

  Invention of Claim 3 performs the process which laminates | stacks this flat plate part and a corrugated part in the manufacturing method of the honeycomb element of Claim 1 or 2 following the process of shape | molding the said flat part and a corrugated part. This is the gist.

In the present invention, since the step of laminating the flat plate portion and the undulating portion is performed continuously with the step of forming the flat plate portion and the undulating portion, it is possible to contribute to shortening the forming time of the honeycomb element.
In the invention according to claim 4, the flat plate portion and the corrugated portion are continuously formed in the longitudinal direction of one strip-shaped filter medium, and the flat plate portion and the corrugated portion are bent between the flat plate portion and the corrugated portion. The gist is that the honeycomb element is formed by alternately laminating portions.

  In the present invention, the flat plate portion and the waved portion are continuously formed in the longitudinal direction of one strip-shaped filter medium, and the flat plate portion and the waved portion are alternately bent by being bent between the flat plate portion and the waved portion. Since it is laminated, the number of members of the honeycomb element can be reduced. Moreover, since only one filter medium roll for supplying the filter medium at the time of molding is required, the space for forming the honeycomb element can be reduced.

The gist of the invention according to claim 5 is a filter device in which the honeycomb element according to claim 4 is accommodated and held in a casing.
In this invention, the honeycomb element according to claim 4 is accommodated and held in the casing to constitute the filter device. Therefore, a filter device with a small number of members can be provided.

  Therefore, according to the above-described invention, it is possible to provide a honeycomb element, a filter device, and a method for manufacturing a honeycomb element that can reduce the number of members.

DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, an embodiment of the invention will be described with reference to the drawings.
As shown in FIGS. 1 and 2, the casing 11 of the filter device 10 of the present embodiment includes a case main body 12 having a rectangular cross section and one open end of the case main body 12 (the left end in FIG. 1). And a cover 13 that can be opened and closed via a clamp 14. One end (left end) of the casing 11 in the opening direction extends from the outer surface of the side wall of the cover 13 and communicates with the outside air, and the other end (right end) extends from the outer surface of the side wall of the case body 12. An air outlet 16 connected to the intake side of the internal combustion engine is formed. Note that an element holding cylinder 17 is formed to protrude at a position corresponding to the air outlet 16 on the inner surface of the side wall of the case body 12.

  A honeycomb element (hereinafter referred to as an element) 21 that is detachably attached to the inside of the casing 11 is held at the cover 13 via a rectangular annular seal 30 at the introduction side end, and at the lead end of the case body 12. Is held by the element holding cylinder 17. The seal 30 is attached to the outer surface of the end portion of the element 21 and is in close contact with the inner surface of the cover 13. The element 21 is for adsorbing the moisture, dust and the like of the intake air from the air inlet 15, and the air cleaned by the element 21 is sent out from the air outlet 16.

  As shown in FIG. 2, the element 21 is formed by alternately laminating flat plate portions 21 a and wavy portions 21 b that are alternately and continuously formed in the longitudinal direction of one strip-shaped filter medium at respective boundaries. The whole is formed so as to form a rectangular parallelepiped honeycomb structure. A plurality of peaks and valleys are formed continuously in the wavy portion 21b, and a plurality of air passages 22 are defined between the flat plate portions 21a by the wavy portion 21b.

  Among these air passages 22, every other first air passage 22 a is opened at the introduction side end corresponding to the air introduction port 15, as shown in FIG. The corresponding lead-out end is sealed with the sealing material 23. On the other hand, with respect to the remaining second air passage 22b, the introduction side end is sealed with the sealing material 24 and the lead-out side end is opened. For this reason, the first opening 21c is formed at the introduction side end of the element 21, and the second opening 21d is formed at the lead-out end.

The operation of the filter device 10 configured as described above will be described.
When the filter device 10 is connected to the intake side of an internal combustion engine such as a vehicle engine, when the internal combustion engine is operated, intake air is supplied from the air inlet 15 to the casing 11 as indicated by an arrow in FIG. Introduced in. Then, this air is introduced into each first air passage 22a from the first opening 21c of the element 21 and passes through the flat plate portion 21a or the corrugated portion 21b, so that moisture, dust or the like contained in the air is passed through the flat plate portion 21a or It is adsorbed by the corrugated part 21b. Thereafter, the air is led out from the second opening 21d through the second air passage 22b and is sent out of the casing 11 through the air outlet 16.

[Element manufacturing method]
A method for manufacturing the element 21 having the above-described configuration will be described with reference to FIGS.
First, as shown in FIG. 3, the band-shaped filter medium 32 supplied from one filter medium roll 31 is formed by a pair of forming rollers 33, so that the flat plate portions 21 a and the wave-shaped portions 21 b are alternately formed on the band-shaped filter medium 32. Formed continuously. More specifically, the band-shaped filter medium 32 is made of paper formed of heat-resistant organic fibers. As the heat-resistant organic fibers, for example, natural fibers or synthetic fibers are used. Each of the pair of forming rollers 33 has a flat plate portion forming surface 33a for forming the flat plate portion 21a in the circumferential half of the outer peripheral surface, and a corrugated tooth 33b for forming the corrugated portion 21b in the other half. . Then, the belt-like filter medium 32 is supplied between the rollers 33 that rotate reversely at the same speed, and rotates while sandwiching the belt-like filter medium 32 between the flat plate portion molding surface 33a or the corrugated teeth 33b of each roller 33. Thus, the belt-like filter medium 32 is pulled out from the filter medium roll 31 and the flat plate portions 21 a and the wave-like portions 21 b are alternately and continuously formed on the belt-like filter medium 32. The wavy portion 21 b is formed such that a plurality of peaks and valleys are continuous in the longitudinal direction of the band-shaped filter medium 32. Further, at the time of forming the flat plate portion 21a and the wave-like portion 21b, the belt-like filter material 32 may be heated while being heated so that the band-like filter material 32 can be easily bent and the wave-like portion 21b can be easily formed.

  Next, a lamination process for alternately laminating the flat plate portions 21a and the corrugated portions 21b will be described. In this step, the flat plate portion 21a and the corrugated portion 21b that are sequentially formed by the forming roller 33 are sequentially laminated by a laminating machine (not shown). That is, the laminating process is performed continuously with the process of forming the flat plate portion 21a and the corrugated portion 21b as described above.

  As shown in FIGS. 4A and 4B, in the laminating process, first, a flat plate portion 21a connected to the corrugated portion 21b only on one side is placed on a flat base surface 40, and on the upper surface of the flat plate portion 21a, An adhesive 42a such as hot melt discharged from the drive nozzle 41a is applied. As shown in FIG. 4B, the adhesive 42a includes an end portion (hereinafter referred to as an open end portion) 21x that is not connected to the corrugated portion 21b in the flat plate portion 21a, and a width orthogonal to the open end portion 21x. It is applied in an L shape along one end 21y in the direction.

  Next, as shown in FIGS. 5A and 5B, the boundary portion 21z of the flat plate portion 21a with the corrugated portion 21b is bent and placed on the flat plate portion 21a so that the corrugated portion 21b is folded. Placed. At this time, the flat plate portion 21a and the corrugated portion 21b are bonded by the adhesive 42a applied on the flat plate portion 21a, and the air passage 22 is formed from the upper surface of the flat plate portion 21a and the lower surface of the corrugated portion 21b. The air passage 22 has a width direction end 21y sealed with an adhesive 42a, and the adhesive 42a that is cured later becomes the sealing material 23 (or the sealing material 24). The adhesive 42a has an application amount to the open end portion 21x set to an amount necessary for bonding the flat plate portion 21a and the corrugated portion 21b, and the application amount to the width direction end portion 21y seals the air passage 22. It is set to a possible amount. Therefore, the application amount to the width direction end portion 21y is set larger than the application amount to the open end portion 21x.

  Next, an adhesive 42b such as hot melt discharged from the drive nozzle 41b is applied to the upper surface of the waved portion 21b. The adhesive material 42b extends along the bent end 21s of the waved portion 21b and the end 21t (hereinafter referred to as the width direction end 21t) orthogonal to the bent end 21s and opposite to the width direction end 21y. The adhesive 42b is applied in an L shape, that is, in a position symmetrical to the adhesive 42a. Thereafter, the boundary portion 21u between the bonded corrugated portion 21b and the flat plate portion 21a is bent, and the flat plate portion 21a is placed on the corrugated portion 21b as shown in FIG. At this time, the corrugated portion 21b and the flat plate portion 21a are bonded by the adhesive 42b applied on the corrugated portion 21b, and the air passage 22 is formed from the upper surface of the wavy portion 21b and the lower surface of the flat plate portion 21a. The air passage 22 has a width direction end 21t sealed with an adhesive 42b, and the adhesive 42b that is cured later becomes the sealing material 24 (or the sealing material 23). Note that the adhesive 42b is continuously applied to the bent end portion 21s on the apex 21v of the peak portion closest to the bent end portion 21s. Also, the adhesive 42b is set to have a larger application amount to the width direction end 21t than the application amount to the bent end 21s (vertex 21v), like the adhesive 42a applied to the flat plate portion 21a. Has been.

  After the above steps are repeated for the desired number of layers, as shown in FIG. 7, the uppermost flat plate portion 21a is cut to complete the element 21. Thereafter, the element 21 having the seal 30 wound around the introduction side end portion is accommodated and fixed in the casing 11, thereby configuring the filter device 10.

Next, characteristic effects of the present embodiment will be described.
(1) In the present embodiment, the flat plate portion 21a and the corrugated portion 21b are continuously formed in the longitudinal direction of one filter medium (band-shaped filter media 32), and the flat plate portion 21a and the corrugated portion 21b are bent to The element 21 is formed by alternately laminating the flat plate portions 21a and the corrugated portions 21b. Therefore, since the flat plate portion 21a and the wave-like portion 21b constituting the element 21 are constituted by one band-shaped filter medium 32, the number of parts of the element 21, and thus the filter device 10 as a whole can be reduced. Further, since the flat plate portion 21a and the corrugated portion 21b are continuously formed, the number of places to be bonded between the respective layers composed of the flat plate portion 21a and the corrugated portion 21b is reduced, and the adhesive 42a, The amount of 42b can be reduced and the bonding process can be simplified.

  (2) In this embodiment, since only one filter medium roll for supplying a filter medium around which the belt-shaped filter medium 32 is wound is provided, the space for forming the honeycomb element 21 can be reduced.

  (3) In this embodiment, the flat plate portion 21a and the corrugated portion 21b are continuously formed by the pair of forming rollers 33 provided with the corrugated teeth 33b for forming the corrugated portion 21b on the circumferential half of the outer peripheral surface. The Therefore, the flat plate portion 21a and the waved portion 21b can be continuously formed by the forming roller 33 having a simple configuration.

(4) In the present embodiment, the lamination process is performed continuously with the molding process of the flat plate portion 21a and the corrugated portion 21b, which can contribute to shortening the molding time of the honeycomb element 21.
(5) In the present embodiment, the pair of forming rollers 33 rotate while sandwiching the band-shaped filter medium 32 so that the band-shaped filter medium 32 is pulled out from the filter medium roll 31, so that the band-shaped filter medium 32 is pulled out. It is not necessary to provide a single drive mechanism, and this can contribute to simplification of the forming equipment for the honeycomb element 21.

  (6) In the present embodiment, adhesion (sealing) of the width direction end portions 21y and 21t in the element 21 and the end portions (open end portion 21x, bent end portion 21s) orthogonal to the end portions 21y and 21t. Since the adhesives 42a and 42b are continuously applied, the molding process can be simplified.

  (7) When the configuration in which the flat plate portion 21a and the wave-like portion 21b are continuously formed on one band-like filter medium 32 is applied to the block-like element 21 as in the present embodiment, the flat plate portion 21a and the wave-like portion 21b. Since the step of sequentially cutting the sheet material in which the flat plate-like filter medium and the wave-like filter medium are bonded together is not necessary when the structure is separated, the molding process can be simplified particularly effectively. In addition, a cutting device for cutting the sheet material, a device for aligning the cut material, and the like are not necessary, which can contribute to simplification of the production line.

In addition, you may change embodiment of this invention as follows.
In the above embodiment, the casing 11 and the element 21 are formed in a block shape. However, the present invention is not particularly limited to this. For example, the molding lengths of the flat plate portion 21a and the corrugated portion 21b are not constant but changed. The opening direction cross section may be formed in a T shape, an L shape, or the like. Moreover, you may form in a column shape as shown in FIG. In the honeycomb element 50 shown in FIG. 8, the flat plate portion 21a and the corrugated portion 21b are continuously formed one by one, and the flat plate portion 21a and the corrugated portion 21b are folded and bonded together, and then wound and laminated. It is formed by.

  In the above embodiment, although not particularly mentioned, the wave-like portion 21b and the corrugated tooth 33b for forming the wave-like portion 21b are formed in a triangular wave shape, but other than this, for example, a curved wave shape or a trapezoidal wave shape may be used.

In the above embodiment, the elements 21 are stacked so that the flat plate portions 21a are arranged at the lowermost and uppermost stages, but the waved portions 21b may be arranged.
In the above embodiment, the laminating step is performed continuously with the step of forming the flat plate portion 21a and the corrugated portion 21b. However, after the necessary number of flat plate portions 21a and corrugated portions 21b have been formed, the laminating step is performed. May be.

  In the above embodiment, the band-shaped filter medium 32 is pulled out from the filter medium roll 31 by the forming roller 33. However, for example, a drive mechanism for pulling out the band-shaped filter medium 32 may be provided separately from the forming roller 33. .

  In the above embodiment, each of the pair of forming rollers 33 is configured to have one flat portion molding surface 33a and one corrugated tooth 33b portion on the outer peripheral surface thereof, but the circumferential direction of the flat plate portion forming surface 33a and the corrugated teeth 33b. If the formation ratio in is equal, it is good also as a structure which has two or more each of the flat plate part molding surface 33a and the corrugated tooth 33b part. Further, the corrugated teeth 33b are provided on the entire outer surface of the forming roller 33, and in a normal state (when forming the flat plate portion 21a), the pair of forming rollers 33 are separated from each other, and only when forming the corrugated portion 21b, You may provide so that 33b may mesh | engage.

  In the above embodiment, the corrugated portion 21b is formed by the forming roller 33. In addition to this, for example, one or a plurality of crest portions of the corrugated portion 21b are formed by pressing in a direction orthogonal to the surface of the band-shaped filter medium 32. You may shape | mold by the possible press mechanism.

-In the said embodiment, although the hot-melt-adhesive material was used for adhesive material 42a, 42b, you may use other adhesive materials.
-Although the filter apparatus 10 of the said embodiment was used for the engine for vehicles, it is not limited to this in particular.

Sectional drawing which shows the filter apparatus in this embodiment. AA sectional drawing in FIG. The schematic diagram for demonstrating the manufacturing method of a honeycomb element. (A) (b) The schematic diagram for demonstrating a lamination process. (A) (b) The schematic diagram for demonstrating a lamination process. The schematic diagram for demonstrating a lamination process. The schematic diagram which shows a honeycomb element. The perspective view which shows the honeycomb element of another example.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Filter apparatus, 11 ... Casing, 21, 50 ... Honeycomb element, 21a ... Flat plate part, 21b ... Wave-like part, 31 ... Filter medium roll, 32 ... Band-shaped filter medium, 33 ... Forming roller, 33b ... Corrugated tooth.

Claims (5)

  A flat plate portion and a corrugated portion are continuously formed in the longitudinal direction of one strip-shaped filter medium, and the flat plate portion and the corrugated portion are alternately laminated by bending the flat plate portion and the corrugated portion. A method for manufacturing a honeycomb element. In the manufacturing method of the honeycomb element according to claim 1,
A method for manufacturing a honeycomb element, wherein the flat plate portion and the corrugated portion are continuously formed by a pair of forming rollers provided with corrugated teeth for forming the corrugated portion on the circumferential half of the outer peripheral surface. . In the manufacturing method of the honeycomb element according to claim 1 or 2,
A method for manufacturing a honeycomb element, comprising performing a step of laminating the flat plate portion and the corrugated portion continuously with the step of forming the flat plate portion and the corrugated portion.   A flat plate portion and a corrugated portion are continuously formed in the longitudinal direction of one strip-shaped filter medium, and the flat plate portion and the corrugated portion are alternately laminated by being bent between the flat plate portion and the corrugated portion. A honeycomb element characterized by that.   A filter device, wherein the honeycomb element according to claim 4 is accommodated and held in a casing.

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