JP3666590B2 - Method for producing wire-made porous material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a wire-made porous material such as a filter element used for fluid filtration.
[0002]
[Prior art]
Filter elements used for fluid filtration are used in various materials and structures depending on the application. For example, in the case of a fine filter such as a filter for melt spinning that requires a certain thickness, a laminate of a large number of metal meshes, a sintered metal, or a nonwoven fabric is used.
[0003]
Further, a porous material having a structure similar to that of a filter is used in various applications. As an example, the applicant of the present application proposed in Japanese Patent No. 2617277 to use as a high-frequency leakage prevention gasket for a magnetron.
[0004]
Further, as another use of the porous material, for example, a silencing material (silencer) incorporated in the pipe to prevent or suppress the generation of sound in a gas pipe such as air, or a photocatalyst or combustion gas Various things, such as a supporting member for supporting various catalysts such as a purification catalyst, are conceivable.
[0005]
[Problems to be solved by the invention]
As such a porous material, when a wire material is used as in the above-mentioned Patent No. 2617277, the manufacturing process is remarkably simplified as compared with the case where a wire mesh is laminated, and the end of the wire material is formed on the outer periphery as in the case of punching the wire mesh. Since the portion is not exposed, there is an advantage that safety is high when a person handles it by hand.
[0006]
An object of the present invention is to provide a highly versatile porous material by further developing the technical idea of Japanese Patent No. 2617277.
[0007]
[Means for Solving the Problems]
[0008]
The present invention uses one or a plurality of elongated metal wires as a raw material, bends the wire in a spiral or zigzag shape, and then forms the lump by twisting and twisting the wires to make them round, Next, the lump is formed into a plate shape by a forming means such as a press device.
[0009]
Various materials and diameters of the wire can be used depending on the application. Of course, the degree of the air gap can be variously set as required.
[0010]
[Operation and effect of the invention]
Since the porous material manufactured by the manufacturing method of the present invention is bent finely and intricately intertwined, the shape is kept constant even though it is a porous material in which innumerable voids are open vertically and horizontally. Therefore, it is possible to provide a porous material that is highly safe when handled.
[0011]
In addition, in the case of a porous material in which a metal mesh is laminated, there is a loss of material because a wide material must be punched into a desired shape. However, in the present invention, since all of the wire material is used for the porous material, the material (wire material) There is no loss. Thus, it can be manufactured at a low cost in combination with the absence of material loss and the need for a shape-retaining rim (frame).
[0012]
In addition, since the wire is twisted in the three-dimensional direction, the voids are also intricately included. For this reason, when used as a filter, the entire layer (thickness) can be used for collection. As a result, the filtration performance can be remarkably improved.
[0013]
Furthermore, when the wires are rolled up (kneaded) in a complicated manner and then pressed into a plate shape, the degree of voids (roughness of the eyes) is adjusted by adjusting the degree of pressing force (thickness). Therefore, it is possible to easily manufacture porous materials having different eye roughness.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the drawings.
[0015]
(1). First embodiment (FIGS. 1 to 4)
1 to 5 show the first embodiment. In the present embodiment, the present invention is applied to a method for producing a silencer disposed in a pipeline of an air conditioner. First, based on FIGS. 1-2, the outline | summary of an air-conditioner and a refrigerating cycle are demonstrated. FIG. 3 is a perspective view of the filter and the silencer.
[0016]
a . Outline of Air Conditioner The air conditioner shown in FIG. 1 includes an outdoor unit 1 and an indoor unit 2. The outdoor unit 1 includes a compressor 3, a four-way valve 4, an outdoor heat exchanger 5, and a fan 6 that compress refrigerant. The indoor unit 2 includes an indoor heat exchanger 7 and a fan 8.
[0017]
The four-way valve 4 includes a first port 9 dedicated to inflow, and second to fourth ports 10, 11, and 12 that switch in and out. The first port 9 and the compressor 3 are connected by a first pipe 13. The second port 10 and the outdoor heat exchanger 5 are connected by a second pipeline 14, and both outdoor units 1 are connected by a third pipeline 15, and the indoor heat exchanger 5 and the fourth port 12 are connected. Are connected by a fourth line 16, and the third port 11 and the compressor 3 are connected by a fifth line 17.
[0018]
During cooling, the first port 9 and the second port 10 communicate with each other and the third port 11 and the fourth port 12 communicate with each other inside the four-way valve 4 as indicated by a solid line. Accordingly, the refrigerant compressed and liquefied by the compressor 3 flows in the order of the first pipe 13 → the second pipe 14 → the third pipe 15 → the fourth pipe 16 → the fifth pipe 17. It has vaporized when it reaches the 5 pipeline 17.
[0019]
During cooling, heat is radiated from the indoor heat exchanger 7 (that is, warm air is released into the room), and the outdoor heat exchanger 5 absorbs atmospheric heat (the arrows in both heat exchanges 5 and 7 indicate the flow of air. Rather, it shows the direction of heat balance.)
[0020]
During heating, the first port 9 and the fourth port 12 communicate with each other and the second port 10 and the third port 11 communicate with each other inside the four-way valve 4 as indicated by a one-dot chain line. Accordingly, the refrigerant flows in the order of the first pipe line 13 → the fourth pipe line → the third pipe line 15 → the second pipe line 14 → the fifth pipe line 17, and is absorbed from the atmosphere in the outdoor heat exchanger 5, The indoor heat exchanger 5 radiates heat indoors.
[0021]
The refrigerant flow direction is constant in the first pipe line 13 and the fifth pipe line 17 during cooling and heating. A filter 18 is built in the first pipeline 13 and other locations.
[0022]
b . The circuit of the refrigeration cycle in the refrigeration cycle diagram 2 in the air-conditioner or the like that have theoretically shown.
[0023]
In this refrigeration cycle, after being compressed by the compressor 3 and passing through the first pipe line 13, the flow divider 20, condenser (condenser: outdoor heat exchanger) 21, header 22, liquid receiver (receiver) 23, sight glass 24, It flows through a filter (strainer) 25, a dryer 26, an evaporator (evaporator: indoor heat exchanger) 27, a reducer (not shown), and an accumulator 28, and returns to the compressor 3 again.
[0024]
The first pipe 13 is provided with a filter 18 similar to that shown in FIG. The filter 18 includes a wire mesh filter element 29 and a metal plate rim 30 that holds the filter element 29.
[0025]
c . Silencer In the first duct 13, noise may be generated by the compressed refrigerant. Conventionally, an expansion chamber having a large cross-sectional area is provided in the first pipe 13 as a method for noise reduction. In the present embodiment, a silencer (silencer), which is an embodiment of the present invention, is provided inside the filter 18. Body) 32 is fitted.
[0026]
The sound deadening material 22 is made of a very thin anticorrosive wire (such as a diameter of about 0.1 to 0.2 mm) such as stainless steel, and one or more long wires are finely bent. The thickness direction and the surface direction are intricately entangled in a three-dimensional manner. Therefore, it has an appearance like a nonwoven fabric.
[0027]
d . Next, a method for manufacturing the sound deadening material 32 will be described. As shown in FIG. 4, in the present embodiment, a line 34 wound around a reel 33 is used as a material. For example, a cylindrical intermediate body 36 as shown in an enlarged view in (C) is obtained by winding the filament 34 in a state where, for example, a thin round bar 35 is packed, and then pulling out the round bar 35.
[0028]
In the case of the present embodiment, which is the sound deadening material 32 of the home air conditioner, the outer diameter of the cylindrical intermediate body 36 is set to about 1.3 to 1.4 mm.
[0029]
The cylindrical intermediate body 36 is cut into a predetermined length (or a predetermined weight) for manufacturing one silencer 32. And what was cut | disconnected to predetermined length is formed into the spiral intermediate body 37 by extending | stretching to the state with large eyes open as shown to (D) (After forming into the spiral intermediate body 37, it cut | disconnects. However, as shown in FIG. 4 (F), the wires are intertwined in a complicated manner to obtain the ball-shaped intermediate 38.
[0030]
As a method of forming the spiral intermediate body 37 into the ball-shaped intermediate body 38, in this embodiment, as shown in FIG. 5 (E), the spiral intermediate body 37 is placed between two discs 39 and 40 that rotate eccentrically. The discs 39 and 40 are eccentrically rotated while applying an appropriate pressure.
[0031]
Thus, by the synergistic action of the pressing force and the rotating action by the two discs 39 and 40, the spiral intermediate body 37 is plastically deformed so that the material is kneaded by hand to form a dango or a round rod. It continues and curls as a whole. In addition, since the wire is originally bent in a spiral shape, it is intertwined in a complicated manner in the process of rounding as a whole. A friction plate 41 such as rubber is stretched on the opposing surfaces of the discs 39 and 40 in order to facilitate the deformation of the wire (may be a rough surface instead of the friction plate).
[0032]
As shown in FIG. 5G, the ball-shaped intermediate body 38 is formed into a disk shape by the press device 42, whereby the sound deadening material 32 is completed. The press device 42 includes a cylinder 43, a movable cradle 44, and a movable pusher 45, and the molded sound deadening material 32 is taken out by raising the movable cradle 44.
[0033]
Depending on the time for applying the kneading action by the discs 39 and 40 and the way of controlling the degree of clamping force, it is possible to use a flat intermediate body instead of the ball-shaped intermediate body 38. In this case, it can be said that the molding by the press device 42 has a function of adjusting the shape, and the sound deadening material 32 is almost completed by processing with the discs 39 and 40.
[0034]
Further, in the drawings, for the convenience of explanation, a process in which the sound deadening material 32 is manufactured with one spiral intermediate body 37 is illustrated, but a plurality of (for example, about 2 to 5) spiral intermediate bodies 37 are formed. Needless to say, they can be rounded together. When a plurality of wires are used, the shape retention function can be improved by entanglement with each other.
[0035]
As a method of forming the spiral intermediate body 37 into the ball-shaped intermediate body 38, it may be performed manually without using a machine.
[0036]
When the cylindrical intermediate body 36 is first manufactured as in this method, a large number of cylindrical intermediate bodies 36 can be transported or stored in a cardboard box, a tray, or the like without being entangled. Therefore, it is useful, for example, when the step of bending the wire and the step of rounding the wire are performed at different locations or at different times.
[0037]
(2). Second to fourth embodiments (FIGS. 6 to 8)
In the first embodiment, the spiral intermediate body 37 is manufactured from the cylindrical intermediate body 36. However, when the spiral intermediate body 37 is manufactured as a series of processes in one factory, the spiral intermediate body 37 may be manufactured directly from the roll wire. Is possible.
[0038]
In this regard, in the second embodiment shown in FIG. 6, the spiral intermediate body 37 is drawn by pulling the round bar 35 after spirally winding the filament 34 in a state in which the eyes are widened with respect to the round bar 35. It has gained.
[0039]
Further, in the second embodiment shown in FIG. 7 ((B) is a sectional view taken along the line BB of (A)), the filament 44 is wound into the spiral groove 47 of the round bar 46, and a pair of pressing rolls 48 are rounded. By rotating the rod 46, the spiral intermediate body 37 is continuously drawn out. The spiral intermediate body 37 is cut into a predetermined length by a cutter 49.
[0040]
In the third embodiment shown in FIG. 7, two wires are wound in a doubled state. Of course, it is also possible to use a spiral intermediate body 37 made of three or more wires.
[0041]
(3). Fifth to sixth embodiments (FIGS. 9 to 10)
9 and 10 show another structure of the porous material. Among these, in the fifth embodiment shown in FIG. 9, a plurality of types of porous materials 49 having different wire thicknesses and densities are stacked, and the whole is fixed by a frame 50.
[0042]
In the sixth embodiment shown in FIG. 9, the porous material 49 is formed in a wide area and the edge is held by the frame 50. Further, it is pressed and fixed by a thin bar 51. This form is suitable as a filter disposed in a flow path having a large cross-sectional area and a low flow rate, such as a filter for a clean room.
[0043]
(4). Seventh to eighth embodiments (FIG. 11)
FIG. 11 shows another example of a method and apparatus for automatically rounding the spiral intermediate 37. Of these, in the seventh embodiment shown in (A), a case 43 is rotatably provided in a part of the horizontally rotating disc 52 that is separated from the center of progress, so that the case 53 revolves while rotating by the gear 54. Is set.
[0044]
Due to the complicated action of the rotation and revolution of the case 53, the spiral intermediate body 37 is subjected to a complicated bending action due to its own weight and rounded into a ball shape. Needless to say, the lid 55 can be freely opened and closed. A friction material 41 such as rubber is provided on the inner surface of the case 53.
[0045]
In the eighth embodiment shown in FIG. 7B, a vibrator (vibration motor) attached to the vibrator 57 is formed by forming a large number of recesses 58 into which the spiral intermediate body 37 enters the vibrator 47 supported by a coil spring 56 at a plurality of locations. ) Etc. is driven to vibrate the diaphragm 57 in the shape of an elliptical locus as shown by the arrow, thereby rounding the spiral intermediate body 37 in the recess 58. ing.
[0046]
(5). Others present invention, Ru can be in addition to various embodied also in the above embodiment.
[0047]
You may punch out what was formed in plate shape in desired shapes, such as disk shape. Also in this case, unlike a simple wire mesh laminate, it does not fall apart and the shape is maintained.
[Brief description of the drawings]
FIG. 1 is a principle diagram of an air conditioner to which a first embodiment is applied.
FIG. 2 is a circuit diagram showing a refrigeration cycle.
FIG. 3 is a perspective view in which a silencer, which is an example of a porous material, is separated from a filter.
FIG. 4 is a diagram showing a first half of a manufacturing process.
FIG. 5 is a diagram showing the latter half of the manufacturing process.
FIG. 6 is a diagram showing a second embodiment.
FIG. 7 is a diagram showing a third embodiment.
FIG. 8 is a diagram showing a fourth embodiment.
FIG. 9 is a diagram showing a fifth embodiment.
FIG. 10 is a diagram illustrating a sixth embodiment.
FIG. 11 is a diagram illustrating a seventh embodiment and an eighth embodiment.
[Brief description of symbols]
DESCRIPTION OF SYMBOLS 1 Outdoor unit of air-conditioner 2 Indoor unit of air-conditioner 3 Compressor 18 Filter 22 Silencer as an example of porous material 26 Cylindrical intermediate 27 Spiral intermediate 28 Ball-shaped intermediate 29, 30 Disc 32 Press device

Claims (1)

Using one or a plurality of elongated metal wires as a raw material, the wire is bent into a spiral shape or a zigzag shape, and then formed into a lump shape by twisting and twisting the wire rods so as to be rolled, Is formed into a plate shape by a molding means such as a press device,
A method for producing a wire- made porous material.

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