JP2011125832A - Method and apparatus for manufacturing filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and apparatus for manufacturing a filter that attains high manufacturing efficiency by simplifying manufacturing processes and can apply an adhesive easily and precisely. <P>SOLUTION: The filter 10 is manufactured as follows. A filter medium sheet 11 is folded in the form of corrugation, and two or more pairs of convex spacers 17 are formed so as to face each other between inclined walls 16 of corrugation between an upward-projecting part 12 of corrugation and downward-projecting part 12 of corrugation. An adhesive 19 is applied to the gaps between top parts 18 of the spacers 17 located at the both ends in the direction to which projecting parts 12 of corrugation extend, and then cooled and made solid to form sealing parts 20. Formation of the spacers 17 and application of the adhesive 19 are performed simultaneously. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a filter disposed, for example, in an intake system of an engine or an air introduction path of an air conditioner, and a filter manufacturing apparatus used in the method.

  Conventionally, for example, a method described in Patent Document 1 has been proposed as a method for manufacturing this type of filter. That is, the filter is formed in a pleat shape, and adjacent inclined folding walls are partially coupled to each other by the spacer via the adhesive. In manufacturing the filter, a spacer is formed on the filter material, an adhesive is applied to the adjacent spacer, and then the filter material is folded. The folding step of the filter material is then carried out in two partial steps, folded in a first partial step so as to obtain a small folding distance, and then the folding lines are pulled apart from each other in a second step. The interval is widened.

JP-T 9-507157

  However, in the filter manufacturing method described in Patent Document 1, first, a spacer is formed using a plurality of rollers or the like, and then an adhesive is applied to the spacer by an adhesive application device. Two steps were required. In addition, the step of folding the spacer material is performed in two partial steps: a first partial step that forms a small crease spacing and a second partial step that widens the crease spacing. For this reason, there are many steps for manufacturing the filter, which is complicated and leads to a decrease in manufacturing efficiency. In addition, since the formation of the spacer and the application of the adhesive are performed in separate steps, there is a problem that the application accuracy of the adhesive to the spacer is poor and the adjustment of the application amount is difficult.

  Accordingly, an object of the present invention is to provide a filter manufacturing method and a manufacturing apparatus capable of simplifying the manufacturing process, increasing the manufacturing efficiency, and easily and accurately applying the adhesive.

  In order to achieve the above object, the filter manufacturing method according to the first aspect of the present invention folds the filter medium sheet into a bowl shape, and maintains the interval between adjacent folding wall sections in the folded wall section inclined by the bowl. A plurality of pairs of spacers to be opposed to each other, and a method of manufacturing a filter that seals between the tops of spacers positioned at least at both ends in the extending direction of the ridges of the ridges based on the application of an adhesive, The formation of the spacer and the application of the adhesive are performed simultaneously.

  According to a second aspect of the present invention, there is provided a filter manufacturing method according to the first aspect, wherein the first spacer forming roller having a spacer forming concave portion and a spacer forming convex portion on the outer peripheral surface, and a spacer on the outer peripheral surface. When the second spacer forming roller having the forming concave portion and the spacer forming convex portion are arranged to face each other and rotated in the opposite direction, the spacer forming concave portion and the spacer forming convex portion of both rollers are fitted to each other. When the spacer is formed by passing the filter medium sheet between the rotating rollers, the filter medium sheet is passed between the rollers in a state in which the adhesive is injected into the spacer forming recess, and the spacer is formed. It is characterized by performing application | coating of this simultaneously.

  According to a third aspect of the present invention, there is provided a method for producing a filter according to the first or second aspect, wherein the top of the spacer is formed in a circular arc shape and the top of the spacer is sealed with an adhesive. It is characterized by being.

  According to a fourth aspect of the present invention, there is provided a method for producing a filter according to the second or third aspect, wherein the adhesive is a hot melt adhesive and is injected into the spacer forming recess in a heated and melted state. It is characterized by being applied to.

  In the filter manufacturing apparatus according to the fifth aspect of the present invention, the filter medium sheet is bent into a bowl shape, and the spacers that hold the interval between the adjacent folding wall sections are opposed to the inclined folding wall section of the bowl. A device for manufacturing a filter, in which a plurality of pairs are formed, and between the tops of the spacers positioned at least at both ends in the extending direction of the ridges of the ridges is sealed based on the application of an adhesive, In the spacer forming part, an adhesive applying part for applying an adhesive to the spacer, a filter medium sheet supplying part for supplying a filter medium sheet to the spacer forming part, and a filter medium sheet in which an adhesive is applied to the spacer in the spacer forming part A bent portion that is bent and formed into a bowl shape, and the spacer forming portion includes a first spacer forming roller having a spacer forming concave portion and a spacer forming convex portion on the outer peripheral surface, and also on the outer peripheral surface. When the spacer forming concave portion and the second spacer forming roller having the spacer forming convex portion are arranged opposite to each other and rotated in the opposite direction, the spacer forming concave portion and the spacer forming convex portion of both rollers fit each other. When the spacer is formed by passing the filter medium sheet from the filter medium sheet supply section between the two rollers that are configured and rotating, the filter medium sheet is passed between the two rollers in a state where the adhesive is injected into the spacer forming recess. It is characterized in that the formation and the application of the adhesive are performed simultaneously.

  According to a sixth aspect of the present invention, there is provided the filter manufacturing apparatus according to the fifth aspect, wherein the adhesive application portion includes an adhesive injection passage from the inside of the first spacer forming roller or the second spacer forming roller. The adhesive is poured into the spacer forming recesses on the outer peripheral surface.

According to the present invention, the following effects can be exhibited.
In the filter of the present invention, the filter medium sheet is bent into a bowl shape, and a plurality of pairs of spacers that maintain the interval between adjacent folding wall sections are formed on the inclined folding wall section so as to face each other. It is manufactured by sealing between the tops of spacers located at least at both ends in the extending direction of the part based on application of an adhesive. In this case, the formation of the spacer and the application of the adhesive are performed simultaneously. Therefore, it is not necessary to separately perform the spacer forming step and the adhesive applying step as in the prior art. In addition, since the adhesive is applied to the spacer at the same time as the spacer is formed and the space between the tops of the spacer is sealed, the sealing operation is performed smoothly.

  Therefore, according to the filter manufacturing method of the present invention, the manufacturing process can be simplified, the manufacturing efficiency can be increased, and the adhesive can be applied easily and accurately.

The perspective view which shows the filter in embodiment of this invention. The top view which shows a filter. The front view which shows a filter. Schematic explanatory drawing which shows the manufacturing process of a filter. Sectional drawing which expands and shows the state which has arrange | positioned the 1st spacer formation roller and the 2nd spacer formation roller in the up-down position. The perspective view which shows the roller for 1st spacer formation, and the roller for 2nd spacer formation. Explanatory drawing which shows the bending apparatus in the manufacturing apparatus of a filter.

Hereinafter, an embodiment embodying the filter manufacturing method of the present invention will be described in detail with reference to FIGS.
As shown in FIG. 1 to FIG. 3, the filter 10 of the present embodiment is formed by folding a filter material sheet 11 formed of filter paper, nonwoven fabric or the like into a bowl shape (pleated shape), and forming a convex shape upward. The ridges 12 and the ridges 12 that are convex downward are alternately arranged. A fold line 14 is formed at the top of these peaks 12. As shown by a two-dot chain line in FIGS. 1 and 3, a polyurethane resin frame 15 is fixed to the upper position of the filter 10, and the filter 10 is supported in a filter case (not shown) by the frame 15. It has become so. Note that the gas to be filtered (air) passing through the filter 10 flows from the lower side to the upper side in FIGS. 1 and 3.

  On both front and back sides of the filter medium sheet 11, a plurality of pairs of alternating spacers 17 are formed on the inclined folding wall portion 16 between the ridges 12 of each ridge so as to face each other. That is, the spacers 17 that are formed wider toward the upper and lower peak portions 12 are arranged in the direction in which the peak portions 12 extend at regular intervals.

  The top portion 18 of the spacer 17 is formed in an arc shape in cross section, and the top portion 18 is configured to abut against the top portion 18 of the spacer 17 of another adjacent folding wall portion 16. Sealing portions 20 sealed with an adhesive 19 are formed between the top portions 18 of the spacers 17 located at both ends in the extending direction of the ridge portion 12, and airtightness at both ends of the filter 10 is maintained. . In addition, the spacer 17 and the sealing portion 20 prevent the close contact between the folded wall portions 16, and the saddle shape of the filter medium sheet 11 is maintained. As the adhesive 19 that forms the sealing portion 20, a hot melt adhesive 19 is suitable. The hot melt adhesive 19 is applied between the top portions 18 of the spacers 17 in a heated and melted state, cooled, solidified, and sealed. A stop 20 is formed. The hot melt adhesive 19 is made of a polyester resin, a polyurethane resin, a polyamide resin, or the like.

  The frame body 15 is formed so as to fill a recessed portion formed by the folded wall portion 16 and the spacer 17 on the outer periphery of the filter 10 so that air does not flow through the recessed portion. Moreover, in drawing of embodiment, in order to understand easily, the number of the peak parts 12 and the spacers 17 is drawn fewer than actual.

Next, an apparatus for manufacturing the filter 10 configured as described above will be described.
As shown in FIG. 4, the apparatus for manufacturing the filter 10 supplies the filter material sheet 11 to the formation portion 21 of the spacer 17, the adhesive application portion 22 that applies the adhesive 19 to the spacer 17, and the formation portion 21 of the spacer 17. The filter medium sheet supply part 23 to perform and the bending part 24 which bends the filter medium sheet 11 by which the adhesive agent 19 was apply | coated to the spacer 17 and forms in a bowl shape are provided.

  As shown in FIGS. 5 and 6, the formation portion 21 of the spacer 17 is configured such that the first spacer forming roller 27 and the second spacer forming roller 28 are arranged to face each other in the vertical position. The first spacer forming roller 27 and the second spacer forming roller 28 rotate in synchronization in the reverse direction.

  The first spacer forming roller 27 has a spacer forming concave portion 25 and a spacer forming convex portion 26 on the outer peripheral surface. The spacer forming concave portions 25 and the spacer forming convex portions 26 are alternately arranged along the axial direction of the first spacer forming roller 27. The spacer forming recess 25 is formed in a long hole shape, and one end side thereof is formed in a circular arc shape in cross section, and the other end side is formed in a square shape in cross section. The bottom 29 of the spacer-forming recess 25 gradually becomes deeper from the other end side having a quadrangular cross section toward one end side having an arc cross section. The spacer-forming convex portions 26 are disposed so as to be opposite to the spacer-forming concave portions 25, and the concavo-convex shape is reversed, and protrudes from the peripheral surface of the first spacer forming roller 27.

  As shown in FIG. 5, at both ends in the first spacer forming roller 27, a receiving hole 30 for storing the melted hot melt adhesive 19 formed at the center thereof, and a first spacer is formed from the receiving hole 30. An adhesive injection passage 31 extending radially so as to communicate with the spacer forming recesses 25 at both ends of the roller 27 is provided. The accommodation hole 30 and the adhesive injection passage 31 are communicated with each other through a communication hole 30a, and the hot melt adhesive 19 can be supplied only from the accommodation hole 30 to the adhesive injection passage 31 at the upper position. The adhesive application part 22 is constituted by the accommodation hole 30, the communication hole 30a, the adhesive injection passage 31, and the spacer forming recesses 25 at both ends. And the hot-melt-adhesive agent 19 of the molten state accommodated in the accommodation hole 30 is supplied with respect to the recessed part 25 for spacer formation of both ends. The first spacer forming roller 27 is heated to a temperature necessary to maintain the molten state of the hot melt adhesive 19. At this time, the melted hot melt adhesive 19 is set to a predetermined high viscosity so as not to flow out of the spacer forming recess 25.

  On the other hand, similarly to the first spacer forming roller 27, a spacer forming concave portion 25 and a spacer forming convex portion 26 are provided on the outer peripheral surface of the second spacer forming roller 28. However, the spacer forming concave portions 25 and the spacer forming convex portions 26 of the second spacer forming roller 28 are respectively fitted into the spacer forming convex portions 26 and the spacer forming concave portions 25 of the first spacer forming roller 27. The rotational phases of the rollers 27 and 28 are determined so that the two rollers 27 and 28 are formed.

  As shown in FIG. 4, the filter material sheet supply unit 23 is provided in a front position (left position in FIG. 4) from the formation unit 21 of the spacer 17, and the filter material sheet 11 wound in a roll shape is provided by a guide roller or the like (not shown). It is configured to be supplied between the first spacer forming roller 27 and the second spacer forming roller 28. The folding part 24 of the filter material sheet 11 is provided at a position behind the forming part 21 of the spacer 17, and a pair of bending tools 36 in which the filtering material sheet 11 obtained by the forming part 21 of the spacer 17 is arranged up and down are spacers. It is comprised so that it may bend by pressing the center part between 17 alternately. The filter medium sheet 11 is formed in a predetermined bowl shape at the bent portion 24 of the filter medium sheet 11.

  Then, the filter medium sheet is supplied to the forming portion 21 of the spacer 17 in a state where the molten hot melt adhesive 19 is injected from the adhesive injection passage 31 into the spacer forming recesses 25 positioned at both ends of the first spacer forming roller 27. The filter medium sheet 11 is supplied from the section 23. In the forming portion 21 of the spacer 17, the spacer 17 is formed by being sandwiched between the spacer forming concave portion 25 and the spacer forming convex portion 26 in which the filter medium sheet 11 is fitted, and the adhesive 19 is applied to the spacer 17. The filter medium sheet 11 is bent at the bent portion 24 of the filter medium sheet 11 to form a bowl shape.

Next, a method for manufacturing a filter using the filter manufacturing apparatus configured as described above will be described.
Now, as shown in FIG. 4, the filter medium sheet 11 is supplied from the filter medium sheet supply unit 23 between the first spacer forming roller 27 and the second spacer forming roller 28. As shown in FIG. 5, in the first spacer forming roller 27, the molten hot melt adhesive 19 accommodated in the accommodation hole 30 is injected into the spacer forming recesses 25 at both ends via the adhesive injection passage 31. The The filter medium sheet 11 that has reached between the first spacer forming roller 27 and the second spacer forming roller 28 is sandwiched between the spacer forming concave portion 25 and the spacer forming convex portion 26, and its shape is formed by the spacer forming convex portion 26. The spacer 17 is formed while being shaped. At this time, the hot melt adhesive 19 injected into the spacer forming recess 25 is attached to the outer surface (top 18) of the spacer 17. That is, the formation of the spacer 17 and the application of the hot melt adhesive 19 are performed simultaneously.

  In FIG. 5, the hot melt adhesive 19 attached to the spacer 17 is drawn with a large thickness, but actually the hot melt adhesive 19 is only attached to the top 18 of the spacer 17 very thinly.

  As shown in FIG. 4, the filter medium sheet 11 proceeds with the hot melt adhesive 19 attached to the spacer 17, and reaches the bent portion 24 of the filter medium sheet 11, where the center of the filter medium sheet 11 between the spacers 17. Mountain folds and valley folds are alternately repeated at the position to be bent into a bowl shape. At this time, the tops 18 of the spacers 17 are butted together, and the adhesive 19 between the tops 18 at both ends is cooled and solidified to form the sealing part 20. In this way, the filter medium sheet 11 is bent into a bowl shape at regular intervals, and the filter 10 is manufactured. Subsequently, as shown in FIGS. 1 and 3, the obtained filter 10 is placed in a molding die and molded by injecting heat-melted polyurethane resin, thereby forming the filter 10 on the outer periphery of the filter 10. The frame 15 shown by the two-dot chain line is formed. Thereafter, the filter 10 with the frame 15 is housed in a filter case (not shown), and the filter 10 is supported in the filter case by the frame 15 and is used.

The effects exhibited by the embodiment configured as described above will be collectively described below.
(1) In the manufacturing method of the filter 10 according to the present embodiment, a plurality of pairs of spacers 17 are formed so as to face each other at the formation portion 21 of the spacer 17, and the spacers 17 positioned at both ends in the extending direction of the ridges 12 The space between the tops 18 is sealed based on the application of the adhesive 19. In this case, the formation of the spacer 17 and the application of the adhesive 19 are performed simultaneously. Therefore, there is no need to separately perform the spacer 17 forming step and the adhesive 19 applying step as in the prior art.

  Therefore, according to the manufacturing method of the filter 10 in the embodiment, the manufacturing process can be simplified and the manufacturing efficiency can be increased. In addition, since the adhesive 19 is injected into the spacer forming recess 25 where the spacer 17 is formed, and the adhesive 19 is directly applied to the spacer 17 obtained there, the application of the adhesive 19 is easy and accurate. It can be carried out.

  (2) The filter medium sheet 11 is supplied between the rollers 27 and 28 rotating in a state where the adhesive 19 is injected into the spacer forming recess 25 of the first spacer forming roller 27, and the formation of the spacer 17 and the adhesive 19 coatings are performed simultaneously and continuously. In this case, since the adhesive 19 is applied to the spacer 17 when the spacer 17 is formed simply by supplying the adhesive 19 to the spacer forming recess 25 in advance, the formation of the spacer 17 and the application of the adhesive 19 are performed. This can be done more efficiently.

  (3) The top portion 18 of the spacer 17 is formed in an arc shape in cross section, and the space between the top portions 18 is sealed with an adhesive 19. In this case, the contact between the top portions 18 is almost a line contact, so that the contact area can be reduced, and the sealing portion 20 can be formed with a small amount of the adhesive 19.

  (4) Since the adhesive 19 is the hot melt adhesive 19, the hot melt adhesive 19 is poured into the spacer forming recess 25 in a heated and melted state, applied to the spacer 17, and then naturally cooled and solidified. The sealing part 20 can be easily and quickly formed.

  (5) The adhesive application part 22 can supply the adhesive 19 to the spacer forming recess 25 on the outer peripheral surface via the adhesive injection passage 31 extending radially from the accommodation hole 30 in the central part of the first spacer forming roller 27. It is configured as follows. For this reason, it is not necessary to intermittently supply the adhesive 19 to the spacer forming recess 25 on the rollers 27, 28 rotating from the outside of the first spacer forming roller 27, and thus the configuration of the adhesive applying unit 22 is simple. The hot melt adhesive 19 can be easily supplied to the spacer forming recess 25.

It should be noted that the above embodiment can be modified as follows.
-The bending part 24 of the filter material sheet 11 can also be comprised as shown in FIG. That is, the lower roller 33 and the upper roller 34 having a plurality of sharp portions 32 extending in a triangular cross section on the outer peripheral portion are arranged vertically opposite to each other, and the sharp portions 32 of the lower roller 33 and the upper roller 34 are displaced by a predetermined angle. The rollers 33 and 34 are configured to rotate in synchronization with each other in the reverse direction. The adhesive 19 is attached from the adhesive supply pipe 35 to the outer surface of the tip of the sharpened portion 32 of each of the rollers 33 and 34. Then, by supplying the filter medium sheet 11 between both the rollers 33 and 34, the filter medium sheet 11 is bent into a mountain fold and a valley fold at the sharpened portion 32 of both the rollers 33 and 34, and simultaneously formed into a bowl shape. The adhesive 19 is applied to the inside of the peak portion 12. When the adhesive 19 is cured, the angle of the folded wall portion 16 of the V-shaped ridge is maintained.

  The spacer hole 30 and the adhesive injection passage 31 inside the first spacer forming roller 27 are omitted, and the spacer forming roller located above the first spacer forming roller 27 as shown by a two-dot chain line in FIG. It is also possible to provide an adhesive supply pipe 35 so as to face the recess 25. Then, the adhesive 19 is injected from the adhesive supply pipe 35 into the spacer forming recesses 25 at both ends of the first spacer forming roller 27, and the adhesive 19 is injected by the rotation of the first spacer forming roller 27. The forming recess 25 can be moved to the uppermost position of the first spacer forming roller 27.

-The top part 18 of the spacer 17 can also be formed in cross-sectional triangle shape, cross-sectional square shape, etc.
As the adhesive 19, a reaction curable adhesive, a light curable adhesive, or the like can be used.

  In addition to the tops 18 of the spacers 17 located at both ends in the extending direction of the ridges 12, an adhesive 19 may be applied to the tops 18 of the spacers 17 located at the intermediate part to form the sealing part 20. Is possible.

  DESCRIPTION OF SYMBOLS 10 ... Filter, 11 ... Filter material sheet, 12 ... Mountain part, 16 ... Folding wall part, 17 ... Spacer, 18 ... Top part, 19 ... Adhesive, 20 ... Sealing part, 21 ... Spacer formation part, 22 ... Adhesive Application part, 23 ... Filter material sheet supply part, 24 ... Bending part, 25 ... Concave part for spacer formation, 26 ... Convex part for spacer formation, 27 ... Roller for 1st spacer formation, 28 ... Roller for 2nd spacer formation, 31 ... adhesive injection passage.

Claims (6)

The filter medium sheet is bent into a bowl shape, and a plurality of pairs of spacers that maintain the interval between adjacent folding wall sections are formed on the folded folding wall section of the bowl so as to face each other, and at least in the extending direction of the peak portion of the bowl. A method for manufacturing a filter that seals between the tops of spacers located at both ends based on the application of an adhesive,
A method for producing a filter, wherein the formation of the spacer and the application of an adhesive are performed simultaneously. A first spacer forming roller having a spacer forming concave portion and a spacer forming convex portion on the outer peripheral surface, and a second spacer forming roller having a spacer forming concave portion and a spacer forming convex portion on the outer peripheral surface are arranged opposite to each other. The spacer forming recesses and the spacer forming projections of both rollers are fitted to each other when rotated in the opposite direction, and the spacer is formed by passing a filter sheet between the rotating rollers. 2. The method for producing a filter according to claim 1, wherein the filter medium sheet is passed between both rollers in a state where the adhesive is injected into the forming recess, and the formation of the spacer and the application of the adhesive are simultaneously performed. The method for manufacturing a filter according to claim 1 or 2, wherein the top portion of the spacer is formed in an arc shape in cross section, and the space between the top portions of the spacer is sealed with an adhesive. The method for producing a filter according to claim 2 or 3, wherein the adhesive is a hot melt adhesive, and is poured into a recess for forming a spacer in a heated and melted state and applied to the spacer. The filter medium sheet is bent into a bowl shape, and a plurality of pairs of spacers that maintain the interval between adjacent folding wall sections are formed on the folded folding wall section of the bowl so as to face each other, and at least in the extending direction of the peak portion of the bowl. A filter manufacturing apparatus in which the space between the tops of the spacers located at both ends is sealed based on the application of an adhesive,
The spacer forming portion, the adhesive applying portion for applying an adhesive to the spacer in the spacer forming portion, the filter material sheet supplying portion for supplying the filter material sheet to the spacer forming portion, and the spacer forming portion for bonding to the spacer And a bent portion for bending the filter material sheet coated with the agent to form a bowl shape, the spacer forming portion having a spacer forming concave portion and a spacer forming convex portion on the outer peripheral surface. When a roller and a second spacer forming roller having a spacer forming concave portion and a spacer forming convex portion on the outer peripheral surface are arranged opposite to each other and rotated in the opposite direction, the spacer forming concave portion and the spacer forming convex of both rollers are rotated. When forming the spacer by passing the filter media sheet from the filter media sheet supply unit between both rotating rollers, the spacer forming recess is formed. In a state where the adhesive is injected through the filter medium sheet between the rollers, the manufacturing apparatus of the filter, characterized in that the formation of the spacer, and application of the adhesive is configured to be performed simultaneously. The adhesive application section is configured to inject adhesive from the inside of the first spacer forming roller or the second spacer forming roller into the spacer forming recess on the outer peripheral surface via the adhesive injection passage. The filter manufacturing apparatus according to claim 5.

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