JP2020062590A - Filter frame and air filter - Google Patents

Filter frame and air filter Download PDF

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JP2020062590A
JP2020062590A JP2018195085A JP2018195085A JP2020062590A JP 2020062590 A JP2020062590 A JP 2020062590A JP 2018195085 A JP2018195085 A JP 2018195085A JP 2018195085 A JP2018195085 A JP 2018195085A JP 2020062590 A JP2020062590 A JP 2020062590A
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filter
frame
frame member
layer
air
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JP7221643B2 (en
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和也 関
Kazuya Seki
和也 関
健太郎 茅嶋
Kentaro Kayashima
健太郎 茅嶋
弘邦 佐藤
Hirokuni Sato
弘邦 佐藤
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Nippon Muki Co Ltd
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Nippon Muki Co Ltd
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Abstract

To provide a filter frame made of resin foam having high strength and air-tightness, and to provide an air filter.SOLUTION: A filter frame 2 includes frame materials 20 which are assembled rectangularly so as to surround a filter pack 60 and are arranged in a first direction orthogonal to an air current which passes through the filter pack 60 and frame materials 30 arranged in a second direction orthogonal to the first direction. Therein, the filter frame 2 is made of resin foam having a cured coating film layer 71 and the cured coating film layer 71 is provided on at least inner circumferential surfaces 23, 33 of the frame material 20 arranged in the first direction and the frame material 30 arranged in the second direction.SELECTED DRAWING: Figure 1

Description

本発明は、フィルタ枠およびエアフィルタに関する。   The present invention relates to a filter frame and an air filter.

製品の軽量化や加工性の向上を図るため、金属製や木製のフィルタ枠の代替品として発泡樹脂製のフィルタ枠が提案されている(例えば、特許文献1参照)。   In order to reduce the weight of products and improve workability, a filter frame made of foam resin has been proposed as a substitute for a metal or wooden filter frame (see, for example, Patent Document 1).

実用新案登録第3119338号Utility model registration No. 3119338

しかし、特許文献1のフィルタ枠に用いられる発泡樹脂材は、中心部から表層部に至る全体が発泡層のみで形成されていることから剛性が低く、エアフィルタの強度を担保できる十分な強度を有するフィルタ枠は得られなかった。さらに、特許文献1の発泡樹脂材は、個々の発泡ビーズの集合体であるため、ビーズ間の隙間がリークの原因となっていた。   However, the foamed resin material used for the filter frame of Patent Document 1 has low rigidity because the whole from the central portion to the surface layer portion is formed of the foamed layer, and has sufficient strength to ensure the strength of the air filter. No filter frame was obtained. Further, since the foamed resin material of Patent Document 1 is an aggregate of individual foamed beads, the gap between the beads causes a leak.

本発明はこのような事情を考慮してなされたもので、強度および気密性の高い発泡樹脂製のフィルタ枠およびエアフィルタを提供することを目的とする。   The present invention has been made in view of such circumstances, and an object thereof is to provide a filter frame and an air filter made of foamed resin having high strength and airtightness.

本発明に係るフィルタ枠は、上述した課題を解決するために、フィルタパックを囲むように矩形に組み合わされ、前記フィルタパックを通過する気流に直交する第一の方向に配置される枠材と、前記第一の方向に直交する第二の方向に配置される枠材と、を備えたフィルタ枠において、前記フィルタ枠は、皮膜硬化層を有する発泡樹脂からなり、前記第一の方向に配置される枠材および前記第二の方向に配置される枠材の少なくとも内周面に前記皮膜硬化層が設けられる。   In order to solve the above problems, the filter frame according to the present invention is combined in a rectangular shape so as to surround the filter pack, and a frame member arranged in a first direction orthogonal to the airflow passing through the filter pack, In a filter frame provided with a frame member arranged in a second direction orthogonal to the first direction, the filter frame is made of foamed resin having a film hardening layer, and is arranged in the first direction. The film hardening layer is provided on at least the inner peripheral surface of the frame member and the frame member arranged in the second direction.

本発明に係るフィルタ枠およびエアフィルタにおいては、エアフィルタの強度を担保できる十分な強度を有し、高い気密性を維持することができる。   The filter frame and the air filter according to the present invention have sufficient strength to ensure the strength of the air filter and can maintain high airtightness.

本発明の実施形態に係るエアフィルタを示す分解斜視図である。It is an exploded perspective view showing an air filter concerning an embodiment of the present invention. 本発明の実施形態に係るフィルタ枠に用いられる発泡樹脂材の断面拡大図である。It is a cross-sectional enlarged view of the foaming resin material used for the filter frame which concerns on embodiment of this invention. 図1に示すフィルタ枠の要部拡大図である。It is a principal part enlarged view of the filter frame shown in FIG.

本発明に係るフィルタ枠およびエアフィルタの実施形態を図面に基づいて説明する。   An embodiment of a filter frame and an air filter according to the present invention will be described with reference to the drawings.

図1は、本発明の実施形態に係るエアフィルタ1を示す分解斜視図であり、図2は本発明の実施形態に係るフィルタ枠2に用いられる発泡樹脂材の断面拡大図である。
本実施形態に係るエアフィルタ1は、フィルタパック60と、フィルタパック60を内部に収納する矩形のフィルタ枠2から構成される。
FIG. 1 is an exploded perspective view showing an air filter 1 according to an embodiment of the present invention, and FIG. 2 is an enlarged cross-sectional view of a foamed resin material used in a filter frame 2 according to the embodiment of the present invention.
The air filter 1 according to this embodiment includes a filter pack 60 and a rectangular filter frame 2 that houses the filter pack 60 therein.

フィルタパック60は、プリーツ加工された濾材40を有している。濾材40は、気体中の微粒子を捕集する、プリーツ加工された部材である。濾材40には、例えば、ガラス繊維または樹脂繊維の繊維材料からなる不織布または織布が用いられる。濾材40の具体例として、粒径0.3μmの粒子に対する捕集効率が、90〜99.99%であり、厚みが0.4〜0.9mmである。このような濾材40は、HEPAフィルタ(粒径0.3μmの粒子に対して99.97%以上の捕集効率を有し、かつ初期の圧力損失が245Pa以下であるフィルタ)、あるいは、HEPAに準じる性能のフィルタ(粒径0.3μmの粒子に対して90〜99.99%の捕集効率を有するフィルタ)として用いることができる。
濾材40は、濾材シートを、山折りおよび谷折りを交互に繰り返し行うことによりジグザグ形状(V字が連続した形状)に形成されている。山折りおよび谷折りの折り目は、気流の上流側および下流側にそれぞれ表れる。特に制限されないが、フィルタパック60の外寸は、例えば、縦(図1のZ方向長さ)580mm×横(図1のY方向長さ)580mm×奥行き(図1のX方向長さ)50〜290mmである。フィルタパック60のプリーツ間隔は2〜10mm、折り幅は40〜260mm、プリーツ数は60〜240である。
The filter pack 60 has a pleated filter medium 40. The filter medium 40 is a pleated member that collects fine particles in the gas. For the filter material 40, for example, a non-woven fabric or a woven fabric made of a fiber material of glass fiber or resin fiber is used. As a specific example of the filter medium 40, the collection efficiency for particles having a particle size of 0.3 μm is 90 to 99.99%, and the thickness is 0.4 to 0.9 mm. Such a filter medium 40 is a HEPA filter (a filter having a collection efficiency of 99.97% or more for particles having a particle size of 0.3 μm and an initial pressure loss of 245 Pa or less), or a HEPA filter. It can be used as a filter having a similar performance (a filter having a collection efficiency of 90 to 99.99% for particles having a particle diameter of 0.3 μm).
The filter medium 40 is formed in a zigzag shape (a continuous V-shape) by alternately repeating mountain folds and valley folds of the filter medium sheet. The folds of the mountain fold and the valley fold appear on the upstream side and the downstream side of the air flow, respectively. Although not particularly limited, the outer dimensions of the filter pack 60 are, for example, 580 mm in length (length in Z direction in FIG. 1) × width (length in Y direction in FIG. 1) 580 mm × depth (length in X direction in FIG. 1) 50. ~ 290 mm. The pleat spacing of the filter pack 60 is 2 to 10 mm, the folding width is 40 to 260 mm, and the number of pleats is 60 to 240.

フィルタパック60は、さらに、プリーツ間隔の間隔保持材としてセパレータ50を有していることが好ましい。セパレータ50は、濾材40の隣り合う2つのプリーツ(山折りされた山部)の間のスペースごとに配置された複数の部材である。セパレータ50の材料としては、アルミニウム、ステンレスなどの金属、あるいは紙が用いられる。セパレータ50は、プリーツ同士の間隔(図1のY方向に沿った間隔)を保持する部材である。セパレータ50は、波形状に折り曲げられて形成され、プリーツの折り目が延びる方向(図1のZ方向)と略平行な方向に延びるよう配置されている。フィルタパック60の第一の方向(図1のY方向)の両端には、濾材40が位置していることが好ましい。また、間隔保持材はホットメルト、スタビライザ、濾材40のエンボス加工などでも良い。   It is preferable that the filter pack 60 further includes the separator 50 as a space retaining material for the pleats. The separator 50 is a plurality of members arranged in each space between two adjacent pleats (mountain parts that are mountain-folded) of the filter medium 40. As the material of the separator 50, metal such as aluminum and stainless steel, or paper is used. The separator 50 is a member that holds the space between the pleats (the space along the Y direction in FIG. 1). The separator 50 is formed by being bent in a wave shape, and is arranged so as to extend in a direction substantially parallel to the direction in which the pleats fold (Z direction in FIG. 1). It is preferable that the filter media 40 be located at both ends of the filter pack 60 in the first direction (Y direction in FIG. 1). The spacing material may be hot melt, a stabilizer, embossing of the filter medium 40, or the like.

フィルタ枠2は、矩形の各辺を構成する4つの枠材20、30で形成される。枠材20、30は、フィルタパック60を通過する気流に直交する第一の方向(以下、図1および図3のY方向をいう)に2つの枠材20が対向して配置され、第一の方向に直交する第二の方向(以下、図1および図3のZ方向をいう)に2つの枠材30が対向して配置される。   The filter frame 2 is formed of four frame members 20 and 30 that form each side of a rectangle. The frame members 20 and 30 are arranged such that two frame members 20 face each other in a first direction (hereinafter, referred to as a Y direction in FIGS. 1 and 3) orthogonal to an air flow passing through the filter pack 60. Two frame members 30 are arranged to face each other in a second direction (hereinafter referred to as the Z direction in FIGS. 1 and 3) orthogonal to the direction.

本発明の実施形態に係るフィルタ枠2は発泡樹脂材7から形成される。発泡樹脂材7は、発泡性原料を溶融固化させた完全樹脂層である皮膜硬化層71と、部分的に溶融固化した中間層72と、発泡層73から構成される。
皮膜硬化層71と発泡層73の間に存在する中間層72は、発泡層73の発泡率よりも小さい発泡率を有するように発泡性原料を発泡溶着させて成形している。これにより、高硬度の皮膜硬化層71と高発泡率の発泡層73を強く接合することができる。
The filter frame 2 according to the embodiment of the present invention is formed from the foamed resin material 7. The foamed resin material 7 is composed of a film hardening layer 71 which is a complete resin layer obtained by melting and solidifying a foaming raw material, an intermediate layer 72 which is partially melted and solidified, and a foaming layer 73.
The intermediate layer 72 existing between the film hardening layer 71 and the foam layer 73 is formed by foam-welding a foaming raw material so as to have a foaming rate smaller than that of the foaming layer 73. Thereby, the hardened film hardening layer 71 and the high foaming rate foamed layer 73 can be strongly bonded.

第一の方向に配置される枠材(第一の枠材)20および第二の方向に配置される枠材(第二の枠材)30の内周面23、33に皮膜硬化層71が配置され、外周面24、34および側面(内周面23、33および外周面24、34以外の面)25、35は中間層72または発泡層73が配置される。   The film hardening layer 71 is provided on the inner peripheral surfaces 23 and 33 of the frame member (first frame member) 20 arranged in the first direction and the frame member (second frame member) 30 arranged in the second direction. The intermediate layer 72 or the foam layer 73 is disposed on the outer peripheral surfaces 24 and 34 and the side surfaces (the surfaces other than the inner peripheral surfaces 23 and 33 and the outer peripheral surfaces 24 and 34) 25 and 35.

第一の枠材20の内周面23には、第二の枠材30の溝部31と嵌合するためのリブ21bと、第一の枠材20の内周面23に塗布されたシール材22の垂れを防止するための舟21aが設けられている。リブ21bおよび舟21aの詳細については、後述する。
第二の枠材30のZ方向の両端面には、第一の枠材20のリブ21bと嵌合するための溝部31が第二の枠材30の短手方向(以下、図1および図3のX方向をいう)に沿って設けられている。
On the inner peripheral surface 23 of the first frame member 20, ribs 21b for fitting with the groove portions 31 of the second frame member 30, and a sealing material applied to the inner peripheral surface 23 of the first frame member 20. A boat 21a for preventing the drooping of the boat 22 is provided. Details of the rib 21b and the boat 21a will be described later.
Grooves 31 for fitting with the ribs 21b of the first frame member 20 are formed on both end faces of the second frame member 30 in the Z direction in the lateral direction of the second frame member 30 (hereinafter, refer to FIG. 1 and FIG. 3 in the X direction).

リブ21bは、第一の枠材20の短手方向(以下、図1および図3のX方向をいう)に延びており、第一の枠材20のX方向の長さと同一である。舟21aは第一の枠材20の長手方向に沿う内周面23の縁からフィルタパック60の気流が通過する面に沿うように突出している。互いに対向する舟21aの両端はリブ21bと接続し、矩形の環状体(シール材垂れ防止用リブ21)を形成している。シール材垂れ防止用リブ21の内側には、フィルタパック60のZ方向の両端部がそれぞれ収容される。   The rib 21b extends in the lateral direction of the first frame member 20 (hereinafter referred to as the X direction in FIGS. 1 and 3) and has the same length as the first frame member 20 in the X direction. The boat 21a projects from the edge of the inner peripheral surface 23 along the longitudinal direction of the first frame member 20 along the surface of the filter pack 60 through which the air flow passes. Both ends of the boat 21a facing each other are connected to the ribs 21b to form a rectangular annular body (the rib 21 for preventing the sagging of the sealing material). Both ends in the Z direction of the filter pack 60 are housed inside the ribs 21 for preventing the sagging of the sealing material.

リブ21bおよび舟21aは、第一の枠材20の内周面23に一体成形されることが好ましい。リブ21bおよび舟21aが第一の枠材20の内周面23に一体成形されることにより、リブ21bおよび舟21aの別体を第一の枠材20の内周面23に接着する場合に比べ、加工点数の削減を図ることができるからである。さらに、リブ21bおよび舟21aの内周面23との接着不良により生じる隙間を無くすことができるため、リークの発生を防止することができる。   The rib 21b and the boat 21a are preferably integrally formed on the inner peripheral surface 23 of the first frame member 20. When the rib 21b and the boat 21a are integrally formed on the inner peripheral surface 23 of the first frame member 20, the ribs 21b and the boat 21a are bonded separately to the inner peripheral surface 23 of the first frame member 20. Compared with this, it is possible to reduce the number of processing points. Furthermore, since the gap caused by the poor adhesion between the rib 21b and the inner peripheral surface 23 of the boat 21a can be eliminated, the occurrence of leak can be prevented.

図3は、図1のフィルタ枠2の要部拡大図である。
フィルタ枠2を形成する際には、まず、エアフィルタ1の下辺をなす第一の枠材20のシール材垂れ防止用リブ21の内側にシール材22を塗布し、フィルタパック60のZ方向の端部をシール材垂れ防止用リブ21の内側に収容し、固定する。次に、第二の枠材30の溝部31をリブ21bに嵌合させて、フィルタパック60の横方向(濾材40の折り目と直交する方向)の両側に第二の枠材30を配置し、フィルタ枠組立体を作製する。このとき、フィルタパック60と第二の枠材30とは、接着剤により固定されている。
最後に、フィルタ枠組立体を上下反転させ、シール材22が塗布されたエアフィルタ1の上辺をなす第一の枠材20のシール材垂れ防止用リブ21の内側にフィルタパック60のZ方向の端部を収容させつつ、溝部31をリブ21bに嵌合させる。
FIG. 3 is an enlarged view of a main part of the filter frame 2 of FIG.
When the filter frame 2 is formed, first, the seal material 22 is applied to the inside of the seal material sag prevention rib 21 of the first frame material 20 that forms the lower side of the air filter 1, and the filter pack 60 is applied in the Z direction. The end is housed and fixed inside the rib 21 for preventing the sagging of the sealing material. Next, the groove portions 31 of the second frame member 30 are fitted into the ribs 21b, and the second frame member 30 is arranged on both sides of the filter pack 60 in the lateral direction (direction orthogonal to the fold line of the filter medium 40). Create a filter frame assembly. At this time, the filter pack 60 and the second frame member 30 are fixed by an adhesive.
Finally, the filter frame assembly is turned upside down, and the Z-direction end of the filter pack 60 is placed inside the seal material dripping prevention rib 21 of the first frame material 20 forming the upper side of the air filter 1 to which the seal material 22 is applied. The groove portion 31 is fitted into the rib 21b while accommodating the portion.

このような本実施形態におけるフィルタ枠2およびエアフィルタ1は、エアフィルタ1の強度を担保できる十分な強度を有し、高い気密性を維持することができる。具体的には、内周面23、33に高硬度の皮膜硬化層71を配置することにより、フィルタパック60に当接する第一の枠材20および第二の枠材30の内周面23、33から中間層72および発泡層73の隙間を通ってフィルタ枠2の下流側の側面25b、35bに空気が抜けることを防止することができる。   The filter frame 2 and the air filter 1 in the present embodiment as described above have sufficient strength to ensure the strength of the air filter 1 and can maintain high airtightness. Specifically, by disposing the high-hardness coating hardened layer 71 on the inner peripheral surfaces 23 and 33, the inner peripheral surfaces 23 of the first frame member 20 and the second frame member 30 that come into contact with the filter pack 60, It is possible to prevent air from passing through the gap between the intermediate layer 72 and the foam layer 73 to the side surfaces 25b, 35b on the downstream side of the filter frame 2 from 33.

本発明の第1の変形例として、第一の枠材20および第二の枠材30の内周面23、33および側面25、35に皮膜硬化層71が配置され、外周面24、34は発泡層73が配置されてもよい。内周面23、33および側面25、35に皮膜硬化層71を配置することにより、上記実施形態の効果に加え、第一の枠材20および第二の枠材30の外周面24、34および上流側の側面25a、35aの表面の隙間から入り込んだ空気が中間層72および発泡層73の隙間を通ってフィルタ枠2の下流側の側面25b、35bに抜けることを防止することができる。   As a first modified example of the present invention, the film hardening layer 71 is arranged on the inner peripheral surfaces 23, 33 and the side surfaces 25, 35 of the first frame member 20 and the second frame member 30, and the outer peripheral surfaces 24, 34 are The foam layer 73 may be arranged. By disposing the film hardened layer 71 on the inner peripheral surfaces 23, 33 and the side surfaces 25, 35, in addition to the effects of the above-described embodiment, the outer peripheral surfaces 24, 34 of the first frame member 20 and the second frame member 30 and It is possible to prevent air that has entered through the gaps on the surfaces of the upstream side surfaces 25a and 35a from passing through the gaps between the intermediate layer 72 and the foam layer 73 to the downstream side surfaces 25b and 35b of the filter frame 2.

本発明の第2の変形例として、第一の枠材20および第二の枠材30の全面に皮膜硬化層71が配置されてもよい。この場合、枠材20、30の中心部が発泡層73であり、中心部から表層部に向かって発泡層73、中間層72、皮膜硬化層71の順序に配置される。高硬度の皮膜硬化層71が全面に配置されることにより、上記実施形態および第1の変形例の効果に加え、フィルタ枠2の強度を高めることができる。さらに、枠材20、30のいずれの表面にも発泡層73による隙間が存在しないため、エアフィルタ1の気密性を高めることができる。   As a second modified example of the present invention, the film hardening layer 71 may be arranged on the entire surfaces of the first frame member 20 and the second frame member 30. In this case, the central portions of the frame members 20 and 30 are the foam layer 73, and the foam layer 73, the intermediate layer 72, and the cured film layer 71 are arranged in this order from the center portion to the surface layer portion. By disposing the hardened film hardened layer 71 on the entire surface, the strength of the filter frame 2 can be increased in addition to the effects of the above-described embodiment and the first modification. Furthermore, since there is no gap due to the foam layer 73 on either surface of the frame members 20 and 30, the air tightness of the air filter 1 can be enhanced.

本発明のフィルタ枠およびエアフィルタは上記実施形態に限定されず、本発明の主旨を逸脱しない範囲において、種々の改良や変更を行うことができる。
例えば、リブおよび舟は、第一の枠材に限らず、第二の枠材に設けてもよく、全ての枠材に設けてもよい。
The filter frame and the air filter of the present invention are not limited to the above embodiments, and various improvements and changes can be made without departing from the spirit of the present invention.
For example, the ribs and boats are not limited to the first frame member, but may be provided in the second frame member or in all the frame members.

1 エアフィルタ
2 フィルタ枠
20 第一の方向に配置される枠材(第一の枠材)
30 第二の方向に配置される枠材(第二の枠材)
7 発泡樹脂材
71 皮膜硬化層
72 中間層
73 発泡層
1 Air Filter 2 Filter Frame 20 Frame Material Arranged in First Direction (First Frame Material)
30 Frame material arranged in the second direction (second frame material)
7 foamed resin material 71 film hardening layer 72 intermediate layer 73 foamed layer

Claims (4)

フィルタパックを囲むように矩形に組み合わされ、前記フィルタパックを通過する気流に直交する第一の方向に配置される枠材と、前記第一の方向に直交する第二の方向に配置される枠材と、を備えたフィルタ枠において、
前記フィルタ枠は、皮膜硬化層を有する発泡樹脂からなり、
前記第一の方向に配置される枠材および前記第二の方向に配置される枠材の少なくとも内周面に前記皮膜硬化層が設けられることを特徴とするフィルタ枠。
A frame member which is combined in a rectangular shape so as to surround the filter pack and is arranged in a first direction orthogonal to the airflow passing through the filter pack, and a frame which is arranged in a second direction orthogonal to the first direction. In a filter frame provided with a material,
The filter frame is made of a foamed resin having a cured film layer,
A filter frame, wherein the film-cured layer is provided on at least the inner peripheral surfaces of the frame member arranged in the first direction and the frame member arranged in the second direction.
前記第一の方向に配置される枠材および前記第二の方向に配置される枠材の前記内周面および側面に前記皮膜硬化層が設けられることを特徴とする請求項1に記載のフィルタ枠。   The filter according to claim 1, wherein the film hardening layer is provided on the inner peripheral surface and the side surface of the frame member arranged in the first direction and the frame member arranged in the second direction. frame. 前記第一の方向に配置される枠材および前記第二の方向に配置される枠材の全面に前記皮膜硬化層が設けられることを特徴とする請求項1に記載のフィルタ枠。   The filter frame according to claim 1, wherein the film-cured layer is provided on the entire surfaces of the frame member arranged in the first direction and the frame member arranged in the second direction. 請求項1から請求項3のいずれか一項に記載のフィルタ枠を備えたエアフィルタ。   An air filter comprising the filter frame according to any one of claims 1 to 3.
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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6343615U (en) * 1986-09-04 1988-03-23
JP2001174014A (en) * 1999-12-17 2001-06-29 Kyosei Uehara Filter-mounting structure
JP2018141505A (en) * 2017-02-27 2018-09-13 ダイキン工業株式会社 Pipe joint and air-conditioning system

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6343615U (en) * 1986-09-04 1988-03-23
JP2001174014A (en) * 1999-12-17 2001-06-29 Kyosei Uehara Filter-mounting structure
JP2018141505A (en) * 2017-02-27 2018-09-13 ダイキン工業株式会社 Pipe joint and air-conditioning system

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