JP2013010092A - Air filter and manufacturing method thereof, and air cleaner equipped with the air filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an air filter capable of controlling the increase in a ventilation resistance.SOLUTION: The air filter is provided with a pleated filter medium part 10 and a shape holding part 11 for retaining the filter medium part 10 in a pleated shape, wherein the filter medium part 10 is formed with a base material portion 14 and a fine fiber layer 15 provided on an upstream side of an air flow ventilated to the base material portion 14, and the thickness of fine fiber layer 15 of an edge 16 in a mountain part of the upstream side of the air flow of the base material portion 14 is larger than the thickness of fine fiber layer 15 in a bilateral part of the mountain part.

Description

  The present invention relates to an air filter incorporated in an air conditioner and the like, a method for manufacturing the air filter, and an air purifier equipped with the air filter.

  A conventional air filter has a configuration in which a filter medium part is formed of a base material part and a fine fiber layer provided on an upstream side surface of an air flow blown to the base material part (see, for example, Patent Document 1). ).

JP 2010-274144 A

  The problem in the conventional example is that the ventilation resistance increases.

  That is, since the filter medium part has a structure formed from the base material part and the fine fiber layer provided on the upstream side surface of the air flow blown to the base material part, the size of the eyes is reduced by the fine fiber layer. Is reduced and the collection efficiency is improved, but the ventilation resistance is increased. On the other hand, if the size of the eyes is increased in order to suppress an increase in ventilation resistance, the collection efficiency is lowered.

  Therefore, the present invention aims to improve the collection efficiency and suppress an increase in ventilation resistance.

  In order to achieve this object, the present invention provides a pleated filter medium part and a shape holding part for holding the filter medium part in a pleated shape, and the filter medium part is connected to the base material part and the base material part. A thin fiber layer provided on the upstream side surface of the air flow to be blown, and the thickness dimension of the thin fiber layer at the tip of the base portion on the upstream side of the air flow is It is characterized by being larger than the thickness dimension of the fine fiber layer on both side portions, thereby achieving the initial purpose.

  As described above, the present invention can improve the collection efficiency and suppress an increase in ventilation resistance.

  That is, a pleat-shaped filter medium part and a shape holding part for holding the filter medium part in a pleated shape are provided, and the filter medium part is provided on the upstream surface of the base material part and the air flow blown to the base material part. Since the fine fiber layer reduces the size of the eyes and improves the collection efficiency, and the filter medium part is pleated, the surface area of the fine fiber layer is increased, so that the ventilation resistance is reduced. The increase can be suppressed.

  However, when the filter medium part is bent into a pleat shape, the fine fiber layer at the tip of the peak part on the upstream side of the air flow of the base part may be pulled, and the fine fiber layer may be cut. Thereby, the collection efficiency in the front-end | tip part in the peak part of a base material part falls.

  Therefore, the thickness dimension of the fine fiber layer at the tip of the peak part on the upstream side of the air flow of the base part is made larger than the thickness dimension of the fine fiber layer on both side parts of the peak part. Thereby, even if the fine fiber layer of the tip part in the peak part on the upstream side of the air flow of the base part is pulled by bending the filter medium part into a pleat shape, the peak part on the upstream side of the air flow of the base part It can suppress that all the thin fiber layers of the front-end | tip part are pulled and cut completely.

  As a result, the collection efficiency can be improved and an increase in ventilation resistance can be suppressed.

Sectional drawing which shows Embodiment 1 of this invention Perspective view of the air filter Cross section of the air filter Schematic showing the manufacturing method of the same air filter Sectional drawing of the air filter of Embodiment 2 of this invention Schematic showing the manufacturing method of the same air filter Schematic showing the manufacturing method of Embodiment 3 of the present invention

(Embodiment 1)
Embodiment 1 of the present invention will be described below with reference to the accompanying drawings.

  As shown in FIG. 1, the air purifier equipped with the air filter of this embodiment includes a blower 2 and an air filter 3 in a main body case 1.

  The main body case 1 has a substantially vertically long box shape. The main body case 1 is provided with a substantially square-shaped intake port 4 on the front side surface portion thereof, and the main body case 1 is provided with a substantially square-shaped exhaust port 5. Yes. The exhaust port 5 is provided with a wind direction louver 6.

  The air blowing means 2 is provided in an air passage between the air inlet 4 and the air outlet 5 of the main body case 1, and has a scroll-shaped casing 7 and a blade 8 which is a centrifugal air fan provided in the casing 7. And the electric motor 9 that rotates the blade 8. The air filter 3 is located at the air inlet 4 of the main body case 1. Air blown into the body case 1 from the air inlet 4 by the air blowing means 2 is sent to the air outlet 5 via the air filter 3. That is, the indoor air is cleaned by the air filter 3 and blown into the room.

  As shown in FIGS. 2 and 3, the air filter 3 is formed of a pleated filter medium part 10 and a shape holding part 11 for holding the filter medium part 10 in a pleat shape.

  The filter medium part 10 is obtained by bending a flat plate-shaped filter medium part 10 into a pleated shape, that is, a corrugated shape. The shape holding part 11 is formed from a square-shaped frame part 12 and an adhesive member 13 provided between the frame part 12 and the filter medium part 10. That is, the frame portion 12 is positioned on the periphery of the pleated filter medium portion 10, and the pleated filter medium portion 10 is fixed to the frame portion 12 by the adhesive member 13.

  The filter medium part 10 includes a base material part 14 and a fine fiber layer 15 provided on the upstream side surface of the air flow blown to the base material part 14. An example of the base material part 14 is a nonwoven fabric whose material is glass or resin. The fine fiber layer 15 is formed of fine fibers having a diameter of nanometer. Specifically, one fine fiber is entangled to form the fine fiber layer 15.

  The feature in this embodiment is in the fine fiber layer 15 of the air filter 3. That is, the thickness dimension of the fine fiber layer 15 of the tip part 16 in the peak part on the upstream side of the air flow of the base part 14 is larger than the thickness dimension of the fine fiber layer 15 on both side parts of the peak part. Is a point.

  That is, a pleated filter medium part 10 and a shape holding part 11 for holding the filter medium part 10 in a pleated shape are provided. The filter medium part 10 includes a base material part 14 and an air flow blown to the base material part 14. Since the fine fiber layer 15 reduces the size of the eyes and improves the collection efficiency, and the filter medium portion 10 is formed into a pleated shape, the fine fiber layer 15 Since the surface area of 15 increases, the increase in ventilation resistance can be suppressed.

  However, when the filter medium part 10 is bent into a pleated shape, the fine fiber layer 15 at the tip 16 in the peak part on the upstream side of the air flow of the base part 14 may be pulled, and the fine fiber layer 15 may be cut. Thereby, the collection efficiency in the front-end | tip part 16 in the peak part of the base material part 14 falls.

  Therefore, the thickness dimension of the fine fiber layer 15 of the tip part 16 at the peak part on the upstream side of the air flow of the base part 14 is made larger than the thickness dimension of the fine fiber layer 15 on both side parts of this peak part. Thereby, even if the fine fiber layer 15 at the tip portion at the peak portion on the upstream side of the air flow of the base material portion 14 is pulled by bending the filter medium portion 10 into a pleat shape, the upstream of the air flow of the base material portion 14 It can suppress that all the fine fiber layers 15 of the front-end | tip part 16 in the side peak part are pulled and cut completely.

  As a result, the collection efficiency can be improved and an increase in ventilation resistance can be suppressed.

  Further, the filter medium part 10 is bent into a pleat shape, and the tip part 16 in the peak part on the upstream side of the air flow of the base part 14 is formed between the base part parts 14 on both sides of the peak part by the air flow. The distance tends to be narrow. In other words, the airflow resistance is likely to increase when both sides of the peak portion are pushed by the air flow and the air that has passed through the tip portion 16 of the peak portion of the base material portion 14 passes through the inside of the peak portion of the base material portion 14. Is. Here, by making the thickness dimension of the fine fiber layer 15 of the tip part 16 in the peak part on the upstream side of the air flow of the base material part 14 larger than the thickness dimension of the fine fiber layer 15 on both side parts of this peak part, Even if both side portions of the mountain portion are pushed by the air flow, the distance between the base material portions 14 on both side portions of the mountain portion is not easily reduced, so that the air that has passed through the tip 16 in the mountain portion of the base material portion 14 is It is possible to suppress an increase in ventilation resistance when passing through the inside of the peak portion of the base material portion 14.

  Further, the fine fiber layer 15 will be described. The fine fiber layer 15 corresponds to a first fine fiber layer 17 provided on substantially the entire surface of the base material portion 14 and a peak portion of the first fine fiber layer 17. It is formed from the second fine fiber layer 18 provided in the portion. Thereby, the thickness dimension of the fine fiber layer 15 of the front-end | tip part 16 in the peak part of the upstream of the air flow of the base material part 14 is made larger than the thickness dimension of the fine fiber layer 15 of the both sides of this peak part. .

  The first fine fiber layer is located on the upstream side of the air flow blown to the base material part 14 from the second fine fiber layer. That is, the first fine fiber layer 17 is provided on substantially the entire upstream surface of the air flow of the base portion 14, and the second fine fiber layer 18 is upstream of the air flow of the first fine fiber layer 17. It is provided on the side corresponding to the mountain part. Thereby, since the 2nd fine fiber layer 18 is only entangled with the 1st fine fiber layer 17, the 2nd fine fiber layer of the front-end | tip part 16 in the peak part of the upstream of the airflow of the base material part 14 is shown. Compared with the first fine fiber layer 17, even when the base material portion 14 is bent into a pleat shape, 18 is pulled by the base material portion 14 because the first fine fiber layer 17 is interposed, and the distance is shortened and cut. This can be suppressed. As a result, a decrease in collection efficiency can be suppressed.

  The fine fiber diameter of the first fine fiber layer 17 is substantially the same as the fine fiber diameter of the second fine fiber layer 18. As a result, the second fine fiber layer 18 of the tip portion 16 at the peak portion on the upstream side of the air flow of the base material portion 14 is bent in a pleated shape compared to the first fine fiber layer 17. However, since the first fine fiber layer 17 is interposed, the distance is shortened by being pulled by the base material portion 14, and the fine fiber diameter of the first fine fiber layer 17 is smaller than that of the second fine fiber layer 18. Since it is substantially the same as the fiber diameter, it can be suppressed that the fiber portion is pulled by the base material portion 14 and cut.

  The fiber diameter of the second fine fiber layer 18 may be larger than the fine fiber diameter of the first fine fiber layer 17. Thereby, even if it is pulled by the base material part 14, the second fine fiber layer 18 is more difficult to cut than the first fine fiber layer 17, so that the tip part at the peak part on the upstream side of the air flow of the base material part 14 It is possible to prevent the 16 second fine fiber layers 18 from being cut and the collection efficiency from being lowered.

  Here, the manufacturing method of an air filter is demonstrated. As shown in FIG. 4, the manufacturing facility includes a transport unit 19 that transports the base material part 14 in the horizontal direction, a first nozzle 20 and a second nozzle 21 that are positioned above the transport unit 19, The electrode plate 22 is located on the back surface side which is the lower surface of the conveying means 19.

  The first nozzle 20 and the second nozzle 21 discharge fine fibers to the surface side, which is the upper surface of the plate-like base material portion 14 conveyed by the conveying means 19. The first nozzle 20 and the second nozzle 21 are arranged at a predetermined interval in the transport direction of the base material part 14, and the first nozzle 20 transports the base material part 14 from the second nozzle 21. It is located upstream in the direction. The electrode plate 22 has a substantially rectangular shape and is disposed to face the second nozzle 21.

  In the manufacture of the air filter, first, the fine fiber is discharged from the first nozzle 20 toward the base material part 14 while the flat base part 14 is transported by the transport means 19. Here, a voltage of about +20 KV is applied to the first nozzle 20, and the conveying means 19 is grounded. Due to this potential difference, the fine fibers discharged from the first nozzle 20 are formed on the base portion 14. The first fine fiber layer 17 is formed on the entire surface. Next, the fine fibers are discharged from the second nozzle 21 to the base material portion 14 from above the first fine fiber layer 17 at predetermined time intervals, and about −10 KV is applied to the electrode plate 22. As a result, the fine fibers emitted from the second nozzle 21 gather on the surface side that is the upper surface facing the electrode plate 22 to form the second fine fiber layer 18. That is, the second fine fiber layer 18 is formed on the upper surface of the first fine fiber layer 17 by discharging the fine fibers from the second nozzle 21 at a predetermined interval on the upper surface of the first fine fiber layer 17. Is. Next, the filter medium part 10 which is the base material part 14 provided with the first fine fiber layer 17 and the second fine fiber layer 18 is bent into a pleat shape. Here, the second fine fiber layer 18 is bent by a folding machine (not shown) so as to be located outside the tip of the pleated ridge. Finally, the pleated filter medium part 10 is fixed to the frame part 12 by the adhesive member 13.

(Embodiment 2)
Hereinafter, an air filter according to a second embodiment of the present invention, a method for manufacturing the air filter, and an air purifier equipped with the air filter will be described with reference to the drawings. In addition, about the thing which has the structure similar to the structure of Embodiment 1, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

  As shown in FIG. 5, the difference from the first embodiment is that the first fine fiber layer 17 is located on the upstream side of the air flow blown from the second fine fiber layer 18 to the base material portion 14. This is the configuration.

  That is, the second fine fiber layer 18 is provided in a portion corresponding to the peak portion on the upstream side of the air flow of the base material portion 14, and the first fine fiber layer 17 is formed of the second fine fiber layer. The layer 18 is provided on substantially the entire surface upstream of the air flow. Thereby, the second fine fiber layer 18 is located between the base material portion 14 and the first fine fiber layer 17. That is, since the first fine fiber layer 17 whose contact area with the base material portion 14 is larger than the second fine fiber layer 18 covers the second fine fiber layer 18, it is prevented from peeling from the base material portion 14. be able to.

  Here, the manufacturing method of an air filter is demonstrated. As shown in FIG. 6, the manufacturing facility includes a transport unit 19 that transports the base material part 14 in the horizontal direction, a first nozzle 20 and a second nozzle 21 that are located above the transport unit 19, and The electrode plate 22 is located on the back surface side which is the lower surface of the conveying means 19.

  The first nozzle 20 and the second nozzle 21 discharge fine fibers to the surface side, which is the upper surface of the plate-like base material portion 14 conveyed by the conveying means 19. The first nozzle 20 and the second nozzle 21 are arranged at a predetermined interval in the transport direction of the base material portion 14, and the second nozzle 21 transports the base material portion 14 from the first nozzle 20. It is located upstream in the direction. The electrode plate 22 has a substantially rectangular shape and is disposed to face the second nozzle 21.

  In the manufacture of the air filter, first, the fine fiber is discharged from the second nozzle 21 to the base material portion 14 at a predetermined time interval while the flat plate-like base material portion 14 is transported by the transport means 19, and at the electrode plate 22. Apply about -10KV. As a result, the fine fibers emitted from the second nozzle 21 gather on the surface side, which is the upper surface of the base member 14 facing the electrode plate 22, to form the second fine fiber layer 18. Next, the fine fibers are discharged from the first nozzle 20 toward the base material portion 14. Here, a voltage of about +20 KV is applied to the first nozzle 20, and the conveying means 19 is grounded. Due to this potential difference, the fine fibers discharged from the first nozzle 20 are separated from the base material portion 14 and the first nozzle 20. The first fine fiber layer 17 is formed by adhering to the entire surface of the second fine fiber layer 18. That is, the first fine fiber layer 17 is formed above the base material portion 14 and the second fine fiber layer 18. Next, the filter medium part 10 which is the base material part 14 provided with the first fine fiber layer 17 and the second fine fiber layer 18 is bent into a pleat shape. Here, it is bent by a folding machine (not shown) so that the overlapping layer of the first fine fiber layer 17 and the second fine fiber layer 18 is located at the tip of the pleated ridge. Finally, the pleated filter medium part 10 is fixed to the frame part 12 by the adhesive member 13.

(Embodiment 3)
Hereinafter, an air filter according to a third embodiment of the present invention, a method for manufacturing the air filter, and an air purifier equipped with the air filter will be described with reference to the drawings. In addition, about the thing which has the structure similar to the structure of Embodiment 1 and Embodiment 2, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

  Here, the manufacturing method of an air filter is demonstrated. As shown in FIG. 7, the manufacturing facility includes a transport unit 19 that transports the base material portion 14 in the horizontal direction, and a first nozzle 20 and a second nozzle 21 that are located above the transport unit 19. It is composed.

  The first nozzle 20 and the second nozzle 21 discharge fine fibers to the surface side, which is the upper surface of the plate-like base material portion 14 conveyed by the conveying means 19. The first nozzle 20 and the second nozzle 21 are arranged at a predetermined interval in the transport direction of the base material portion 14, and the second nozzle 21 transports the base material portion 14 from the first nozzle 20. It is located upstream in the direction.

  The air filter is manufactured by first discharging the fine fibers from the second nozzle 21 to the base material portion 14 at a predetermined time interval while transporting the flat plate-like base material portion 14 by the transporting device 19. Apply about -10KV. Thereby, the fine fibers discharged from the second nozzle 21 gather on the surface side, which is the upper surface of the base material portion 14 facing the conveying means 19, to form the second fine fiber layer 18. Next, the fine fibers are discharged from the first nozzle 20 toward the base material portion 14. Here, a voltage of about +20 KV is applied to the first nozzle 20, and the conveying means 19 is changed to the ground connection by the switching means 23 only at that time, and the first nozzle 20 is discharged from the first nozzle 20 due to this potential difference. The fine fibers adhere to the entire surface of the base material portion 14 and the second fine fiber layer 18 to form the first fine fiber layer 17. That is, the first fine fiber layer 17 is formed above the base material portion 14 and the second fine fiber layer 18.

  As a result, it is possible to prevent the phenomenon in which the voltage applied to the transport means 19 from about -10 KV does not drop immediately even when the power is stopped, by ground connection.

  Next, the filter medium part 10 which is the base material part 14 provided with the first fine fiber layer 17 and the second fine fiber layer 18 is bent into a pleat shape. Here, it is bent by a folding machine (not shown) so that the overlapping layer of the first fine fiber layer 17 and the second fine fiber layer 18 is located at the tip of the pleated ridge. Finally, the pleated filter medium part 10 is fixed to the frame part 12 by the adhesive member 13.

  As described above, the present invention can improve the collection efficiency and suppress an increase in ventilation resistance.

  That is, a pleat-shaped filter medium part and a shape holding part for holding the filter medium part in a pleated shape are provided, and the filter medium part is provided on the upstream surface of the base material part and the air flow blown to the base material part. Since the fine fiber layer reduces the size of the eyes and improves the collection efficiency, and the filter medium part is pleated, the surface area of the fine fiber layer is increased, so that the ventilation resistance is reduced. The increase can be suppressed.

  However, when the filter medium part is bent into a pleat shape, the fine fiber layer at the tip of the peak part on the upstream side of the air flow of the base part may be pulled, and the fine fiber layer may be cut. Thereby, the collection efficiency in the front-end | tip part in the peak part of a base material part falls.

  Therefore, the thickness dimension of the fine fiber layer at the tip of the peak part on the upstream side of the air flow of the base part is made larger than the thickness dimension of the fine fiber layer on both side parts of the peak part. Thereby, even if the fine fiber layer of the tip part in the peak part on the upstream side of the air flow of the base part is pulled by bending the filter medium part into a pleat shape, the peak part on the upstream side of the air flow of the base part It can suppress that all the thin fiber layers of the front-end | tip part are pulled and cut completely.

  As a result, the collection efficiency can be improved and an increase in ventilation resistance can be suppressed.

  Therefore, it is expected to be utilized as an air filter for home use or office use, a method for manufacturing the air filter, and an air purifier equipped with the air filter.

DESCRIPTION OF SYMBOLS 1 Main body case 2 Air blower 3 Air filter 4 Intake port 5 Exhaust port 6 Wind direction louver 7 Casing 8 Blade 9 Electric motor 10 Filter material part 11 Shape holding part 12 Frame part 13 Adhesive member 14 Base material part 15 Fine fiber layer 16 Tip part 17 1 fine fiber layer 18 second fine fiber layer 19 conveying means 20 first nozzle 21 second nozzle 22 electrode plate 23 switching means

Claims (9)

A pleat-shaped filter medium part and a shape holding part for holding the filter medium part in a pleated shape are provided, and the filter medium part is provided on a base part and an upstream side surface of an air flow blown to the base part. And the thickness dimension of the fine fiber layer at the tip of the peak portion on the upstream side of the air flow of the base material portion is larger than the thickness dimension of the fine fiber layer on both side portions of the peak portion. An air filter characterized by that. The fine fiber layer includes a first fine fiber layer provided on substantially the entire surface of the base material portion, and a second fine fiber layer provided in a portion corresponding to the peak portion of the first fine fiber layer; The air filter according to claim 1, wherein the air filter is formed from. 3. The air filter according to claim 2, wherein the second fine fiber layer is located on an upstream side of an air flow blown to the base portion from the first fine fiber layer. The air filter according to any one of claims 2 to 3, wherein the fine fiber diameter of the first fine fiber layer is substantially the same as the fine fiber diameter of the second fine fiber layer. 4. The air filter according to claim 2, wherein the fine fiber diameter of the second fine fiber layer is larger than the fine fiber diameter of the first fine fiber layer. 5. A method for producing an air filter according to any one of claims 1 to 5,
The first nozzle that discharges the fine fibers on the surface side of the flat plate-like base material portion, and the second nozzle are arranged at a predetermined interval in the transport direction of the base material portion,
An electrode plate is placed opposite to the back side,
Forming the first fine fiber layer on the entire surface of the base material portion with the first nozzle while transporting the base material portion,
Next, the second fine fiber layer is formed on the upper surface of the first fine fiber layer by discharging the fine fibers from the second nozzle at a predetermined interval on the upper surface of the first fine fiber layer. A method for manufacturing an air filter. A method for producing an air filter according to any one of claims 1 to 5,
The first nozzle that discharges the fine fibers on the surface side of the flat plate-like base material portion, and the second nozzle are arranged at a predetermined interval in the transport direction of the base material portion,
An electrode plate is placed opposite to the back side,
Discharging the fine fibers at a predetermined interval of the base material portion with a second nozzle while transporting the base material portion to form the second fine fiber layer;
Next, the second fine fiber layer and the first fine fiber layer are formed by discharging the fine fibers from the first nozzle onto almost the entire surface of the second fine fiber layer and the base material portion. Manufacturing method of air filter to be formed. A body case with intake and exhaust ports;
Air blowing means provided in the main body case;
An air purifier in which the air filter according to any one of claims 1 to 5 is attached to the intake port of the main body case. A method for producing an air filter according to any one of claims 1 to 5,
The first nozzle that discharges the fine fibers on the surface side of the flat plate-like base material portion, and the second nozzle are arranged at a predetermined interval in the transport direction of the base material portion,
It comprises a transport means for transporting the base material part, and the first fine fiber layer is formed on the entire surface of the base material part with the first nozzle while transported by the transport means,
Next, when discharging the fine fibers from the second nozzle at a predetermined interval on the upper surface of the first fine fiber layer,
In the case where the fine fibers are discharged from the first nozzle or the second nozzle, the switching means for changing the voltage of the conveying means is provided on the upper surface of the first fine fiber layer. An air filter manufacturing method for forming a fine fiber layer.

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