JP2012232229A - Method of manufacturing disk shape filter bag, and manufacturing apparatus thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a disk shape filter bag in which the manufacturing is prompt, and the yield of the filter bag is high, and to provide a manufacturing apparatus thereof.SOLUTION: The manufacturing apparatus of a disk shape filter bag includes: a transport unit 10; a thermocompression bonding unit 20; and a punch unit 30. The transport unit 10 includes: two or more transmission wheels 11, 222; two or more fixed shafts 12; and a two-layer thin film base material 13 and a water conducting screen base material 14 disposed on the fixed shafts 12. The thermocompression bonding unit 20 includes: an air pressure cylinder 21; a transmission set; a heating set 23; and a thermocompression bonding roller 24 driven by the air pressure cylinder 21 and the transmission set. A disk shape convex emboss is provided to the surface of the thermocompression bonding roller 24. The two-layer thin film base materials 13 are disposed to the top surface and the bottom face of the water conducting screen base material 14 respectively, and are transported under the thermocompression bonding roller 24 of the thermocompression bonding unit 20 by the driving transmission wheels 11.

Description

  The present invention relates to a filter bag used for separating a solid and a liquid, and more particularly, to a method for manufacturing a disk-shaped filter bag that is quick to manufacture, has a high filter bag yield, and is difficult to break, and a manufacturing apparatus therefor.

  As disclosed in Patent Document 1, a portable water purification device previously developed by the present inventor has a disk-shaped filter bag. In this disk-shaped filter bag, a mesh-like support net is disposed between two circular thin films having micropores. This support net has an outer edge overlapped with the above-described thin film by a waterproof adhesive, and a concentric shaft hole is provided in the central part of the thin film and the support net. In this way, a flat bag-like three-layer filter bag structure is formed. The shaft hole of the filter bag is provided in a pipe having a large number of through holes on the surface, and is fixed by pressing with a water guide set on both sides. Since the filter bag is disk-shaped and the shaft hole is provided at the center of the disk surface, the pressure of the filtrate generated against the thin film is the same when performing the backwashing process, which is good. The number of filter bags that can obtain a backwash effect and that the filter bag does not need to be attached to a thick frame at the side or outer edge, so that the overall weight is lighter and thinner and can be stacked in the same size space And the area for removing filth can be increased.

  However, the conventional manufacturing method of the filter bag is such that the support net and the thin film are first cut and formed into a predetermined size, and then a waterproof adhesive is applied to the peripheral portion, and then put into a mold and stacked. After the adhesive is cured, it is cut to form a shaft hole. However, this method is not suitable for mass production because it takes too much time for the adhesive to cure.

  As another manufacturing method, there is an ultrasonic welding method. In this ultrasonic welding method, mainly, an ultrasonic wave is used to adhere to the edge of the film, and then the film is cut using a cutter head, and a shaft hole is provided in the center. This manufacturing method can reduce the manufacturing time, but because the outer diameter of the filter bag is large, it is impossible to complete ultrasonic welding to the edge of the filter membrane at one time, while rotating in stages It is necessary to perform ultrasonic welding (generally, the outer edge is processed into three fan blocks each having 120 degrees). However, due to the high demand for water tightness at the edge, the filter membrane must be partly bonded repeatedly at the outer edge of the filter membrane, which takes longer time to weld and burns out on the surface of the filter bag. Alternatively, deformation may occur, damage or gaps that cannot be found with the naked eye, and the defect rate of the product may increase.

US Pat. No. 7,575,678

  An object of the present invention is to provide a method for manufacturing a disk-shaped filter bag and a manufacturing apparatus therefor, which are quick to manufacture and have a high yield of filter bags.

  In order to solve the above-described problem, Step A for preparing two thin film base materials and a water network base material having air permeability, and pasting the thin film base material on the top surface and the bottom surface of the water network base material, Step B constituting a three-layer laminated material, and the laminate material is continuously conveyed while maintaining tension by an apparatus, and the laminated material is thermocompression-bonded by a thermocompression unit on the conveyance path, and the thermocompression-bonding unit. Is positioned on the transport path of the laminated material, and is subjected to thermocompression bonding by a point contact method, a circular weld edge is formed on the laminated material, and a semi-finished disc-shaped and hollow filter bag is Step C for forming on the laminated material, Step D for punching the crimped filter bag semi-finished product, forming a shaft hole in the center of the filter bag semi-finished product, and completing the disc-shaped filter bag product And including Method for producing a disc-shaped filter bag is provided.

  It is preferable that the thermocompression bonding unit of the step C is formed on both sides of the semi-finished product of the filter bag, and two tensile positioning portions are continuously thermocompression bonded.

  When thermocompression bonding is performed in the step C, it is preferable to cut a semi-finished product of the filter bag.

  The thermocompression bonding in the step C is preferably performed by ultrasonic welding.

  In order to solve the above-described problem, a disk-shaped filter bag manufacturing apparatus including a transport unit, a thermocompression bonding unit, and a punch unit, wherein the transport unit includes a plurality of transmission wheels, a plurality of fixed shafts, and the fixed shaft. The thermocompression bonding unit is driven by a pneumatic cylinder, a transmission set, a heating set, and the pneumatic cylinder and the transmission set. A thermo-compression roller, and a disc-like convex emboss is provided on the surface of the thermo-compression roller, and the two-layer thin film bases are respectively provided on the top surface and the bottom surface of the water guide network base material. Arranged and transported below the thermocompression-bonding roller of the thermocompression-bonding unit by driving each of the transmission wheels to activate the pneumatic cylinder, the transmission set, and the heating set, and By using the convex embossing provided on the thermocompression roller by driving the solder, cutting is performed while thermocompression is applied to the two-layer thin film base material and the water conduit network base material, so that it is disc-shaped and hollow. A disk-shaped filter bag manufacturing apparatus is provided, in which a filter bag is molded, and a punching process is performed on a central portion of the filter bag by a punch unit.

  It is preferable that the thermocompression-bonding roller of the thermocompression-bonding unit has two side embossments provided on both sides of a disk-shaped convex embossment.

  The side embossing provided on the thermocompression roller is preferably a sawtooth shape.

The disc filter bag manufacturing method and the manufacturing apparatus thereof according to the present invention have the following effects (1) to (3).
(1) A disk-shaped filter bag can be formed by using a point contact heat welding method and simply welding a thermocompression-bonding roller once. Therefore, it can be quickly manufactured by mechanization. In this way, the manufacturing cost can be reduced, and the manufacturing cost can be reduced.
(2) Unlike the prior art where the filter bag is partially ultrasonically welded by surface contact, the laminated material of the present invention uses point contact welding within a unit time, so it consumes less power and is used Saving material.
(3) Since the continuous point contact welding method does not require overlapping welded parts, the filter bag is difficult to break and a gap is prevented from being generated at the welded parts. Therefore, quality and yield can be improved, and the amount of waste materials generated can be greatly reduced.

It is a flowchart which shows the manufacturing method of the disk shaped filter bag by one Embodiment of this invention. It is a schematic diagram which shows the manufacturing apparatus of the disk shaped filter bag by one Embodiment of this invention. It is a perspective view which shows the manufacturing apparatus of the disk shaped filter bag by one Embodiment of this invention. It is a top view which shows the completed product of the disk shaped filter bag of the three-layer structure by one Embodiment of this invention. It is sectional drawing which shows the finished product of the disk shaped filter bag by one Embodiment of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited thereby.

  Please refer to FIG. As shown in FIG. 1, the manufacturing method of the disk shaped filter bag by one Embodiment of this invention includes the following processes (A)-(D).

  In the step (A), two thin film base materials 13 and a water conveyance network base material 14 having air permeability are prepared.

  In the step (B), the thin film base material 13 is attached to the top surface and the bottom surface of the water conveyance network base material 14 to form a three-layer laminated material.

  In the step (C), the laminated material is continuously conveyed while maintaining the tension by the apparatus, and the laminated material is thermocompression bonded by the thermocompression bonding unit 20 on the conveyance path. The thermocompression bonding unit 20 is located on the laminated material conveyance path, and performs thermocompression bonding by a point contact method to form a circular weld edge 110 (see FIG. 3) in close contact with the above-described material on the laminated material. Then, a semi-finished product of the filter bag 100 having a disk shape and a hollow inside is formed on the laminated material. Further, when thermocompression bonding is performed on the laminated material, the semi-finished product of the filter bag 100 is separated and collected from the laminated material by the thermocompression bonding unit 20, and the semi-finished product of the filter bag 100 is stored.

  In step (D), a plurality of semifinished filter bags 100 that have been crimped and cut are horizontally stacked and punched, and a shaft hole 120 (see FIG. 4) is formed in the center of the semifinished filter bag 100. Form and complete the disc-shaped filter bag product.

  The thermocompression bonding in the step (C) of this embodiment is performed by ultrasonic welding, but high frequency welding may be used.

  Please refer to FIG. 2 and FIG. As shown in FIGS. 2 and 3, the disk-shaped filter bag manufacturing apparatus according to an embodiment of the present invention includes at least a transport unit 10, a thermocompression unit 20, and a punch unit 30. The transport unit 10, the thermocompression bonding unit 20, and the punch unit 30 of the present embodiment are disposed in the apparatus 40.

  The transport unit 10 includes a plurality of transmission wheels 11, a plurality of fixed shafts 12, and two thin film base materials 13 and a water conduit network base material 14 attached to the fixed shaft 12. The thin film base material 13 and the water conduit base material 14 of the present embodiment are respectively wound around a rotating shaft pivotally attached to the fixed shaft 12.

  The thermocompression unit 20 includes a pneumatic cylinder 21, a transmission set 22, a heating set 23, and a thermocompression roller 24 driven by the pneumatic cylinder 21 and the transmission set 22. The heating set 23 of this embodiment is an ultrasonic oscillation plate. A convex emboss 241 is provided on the outer peripheral surface of the thermocompression roller 24. The convex emboss 241 has a circular shape when unfolded.

  The transmission set 22 includes a chain 221 used for driving the thermocompression-bonding roller 24 and a plurality of transmission wheels 222 used for conveying the filter bag 100.

  When actually operating, the three-layered laminated material arranged so as to sandwich the water network base material 14 between the top surface and the bottom surface of the water network base material 14 is heated by the transmission wheel 11 by the thermocompression bonding unit 20. It is conveyed below the pressure roller 24. Subsequently, the pneumatic cylinder 21, the transmission set 22, and the heating set 23 are started, and the thermocompression roller 24 is moved downward by the driving of the pneumatic cylinder 21 to come into contact with the laminated material. Is pulled by the power transmission set 22 and the thermocompression-bonding roller 24, and the thermocompression-bonding roller 24 rotates synchronously when high-frequency oscillation is performed on the laminated material by the heating set 23. Thus, the ultrasonic embossing process is performed on the two thin film base materials 13 and the water guide network base material 14 using the convex embossing 241 provided on the thermocompression bonding roller 24, and the disc-shaped and hollow filter bag. 100 semi-finished products are molded. When performing the ultrasonic welding process, since the outer edge portion of the convex emboss 241 of the thermocompression roller 24 is provided with a fine sawtooth-shaped cut edge (not shown), the thermocompression roller 24 allows the laminated material to be formed. When crimped, the outermost side of the welded edge 110 is cut, and the semi-finished product of the filter bag 100 can be separated from the laminated material. As shown in FIGS. 4 and 5, the punch unit 30 is finally subjected to punching processing at the center of the semi-finished product of the filter bag 100, and a shaft hole 120 (see FIG. 4) is formed at the center of the filter bag 100. It is formed.

Unlike the prior art, the disc filter bag manufacturing method and the manufacturing apparatus according to the present invention have the following advantages (1) to (3).
(1) A disk-shaped filter bag can be formed by using a point contact heat welding method and simply welding a thermocompression-bonding roller once. Therefore, it can be quickly manufactured by mechanization. In this way, the manufacturing cost can be reduced, and the manufacturing cost can be reduced.
(2) Unlike the prior art where the filter bag is partially ultrasonically welded by surface contact, the laminated material of the present invention uses point contact welding within a unit time, so it consumes less power and is used Saving material.
(3) Since the continuous point contact welding method does not require overlapping welded parts, the filter bag is difficult to break and a gap is prevented from being generated at the welded parts. Therefore, quality and yield can be improved, and the amount of waste materials generated can be greatly reduced.

  In the disk-shaped filter bag of the present invention, the side embossing of the thermocompression-bonding roller is pressure-bonded synchronously, and appropriate tension is maintained on the surface of the laminated material, so that the laminated material is stably and continuously conveyed by the apparatus. Therefore, the quality of the disc-shaped filter bag can be improved and the manufacturing operation can be performed quickly.

  While the preferred embodiments of the present invention have been disclosed above, as may be appreciated by those skilled in the art, they are not intended to limit the invention in any way. Various changes and modifications can be made without departing from the spirit and scope of the present invention. Accordingly, the scope of the claims of the present invention should be construed broadly including such changes and modifications.

DESCRIPTION OF SYMBOLS 10 Conveyance unit 11 Transmission wheel 12 Fixed shaft 13 Thin film base material 14 Water conveyance network base material 20 Thermocompression bonding unit 21 Pressure cylinder 22 Transmission set 23 Heating set 24 Thermocompression roller 30 Punch unit 40 Device 100 Filter bag 110 Welding edge 120 Shaft hole 130 Tensile positioning portion 221 Chain 222 Transmission wheel 241 Convex emboss 242 Side emboss

Claims (7)

Step A for preparing two thin film base materials and a water conduit base material having air permeability;
Step B for pasting the thin film substrate on the top surface and bottom surface of the water conduit substrate, respectively, to constitute a three-layer laminated material,
The laminate material is continuously conveyed while maintaining tension by an apparatus, and the laminate material is thermocompression bonded by a thermocompression unit on the conveyance path, and the thermocompression unit is positioned on the conveyance path of the laminate material. And a step C of thermocompression bonding by a point contact method, a circular weld edge is formed on the laminated material, and a disk-like and hollow filter bag semi-finished product is formed on the laminated material;
A process D for punching the crimped filter bag semi-finished product, forming a shaft hole at the center of the filter bag semi-finished product, and completing the disc-shaped filter bag product. Of manufacturing a filter bag.   The thermocompression bonding unit in the step C is located on both sides of the semi-finished product of the filter bag, and is formed by continuously thermocompression-bonding two tensile positioning portions. A method for producing a disk-shaped filter bag.   The method for manufacturing a disk-shaped filter bag according to claim 1, wherein when the thermocompression bonding is performed in the step C, the semi-finished product of the filter bag is cut.   The method for manufacturing a disk-shaped filter bag according to claim 1, wherein the thermocompression bonding in the step C is performed by ultrasonic welding. A disk-shaped filter bag manufacturing apparatus including a transport unit, a thermocompression bonding unit, and a punch unit,
The transport unit includes a plurality of transmission wheels, a plurality of fixed shafts, and a two-layer thin film base material and a water network base material attached on the fixed shaft,
The thermocompression bonding unit includes a pneumatic cylinder, a transmission set, a heating set, and a thermocompression roller driven by the pneumatic cylinder and the transmission set, and a surface of the thermocompression roller has a disk shape. Convex embossing is provided,
The two-layer thin film base material is disposed on the top surface and the bottom surface of the water conveyance network base material, and is conveyed below the thermocompression-bonding roller of the thermocompression-bonding unit by driving the transmission wheels. The transmission set and the heating set are activated, and the embossed embossing provided on the thermocompression roller is used by driving the atmospheric pressure cylinder, to the two-layer thin film substrate and the water guide network substrate. An apparatus for producing a disk-shaped filter bag, wherein the apparatus is cut while performing thermocompression bonding, a disk-shaped and hollow filter bag is molded, and a punching process is performed on a central portion of the filter bag by a punch unit.   6. The disk-shaped filter bag manufacturing apparatus according to claim 5, wherein the thermocompression-bonding roller of the thermocompression-bonding unit has two side embossments provided on both sides of a disk-shaped convex embossment.   The disk side filter bag manufacturing apparatus according to claim 6, wherein the side embossing provided on the thermocompression roller has a sawtooth shape.

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