JP4113621B2 - Filter element with pre-filter - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a filter element with a prefilter in which a prefilter is disposed on the upstream side of a main filter.
[0002]
[Prior art]
This type of element with a prefilter is also known from the disclosure in Japanese Patent Laid-Open No. 10-85539. An element with a prefilter disclosed in this publication includes a folded main filter, a prefilter made of a non-woven fabric having a large porosity disposed upstream of the main filter, and a folded shape of the main filter. The resin frame is provided with an engaging projection that holds the prefilter and protrudes toward the upstream side from the end face facing the prefilter.
[0003]
The locking protrusion has a shaft portion that penetrates the prefilter, and is formed on the tip side of the shaft portion, and is positioned on the upstream side of the prefilter and has a large tip diameter portion that fixes the prefilter. Formed of a material having a melting point higher than the melting point of the resin constituting the resin frame, and has an outer diameter larger than the outer diameter of the tip end diameter of the locking projection and an inner diameter larger than the outer diameter of the shaft portion of the locking projection. A ring member having an annular member disposed between the upstream side surface of the pre-filter and the large-diameter portion of the pre-filter, having a tip-bending holding portion for fixing the pre-filter, or having an umbrella-like gripping portion for fixing the pre-filter Or a resin frame having a locking hole for attaching the pre-filter on the end surface facing the pre-filter.
[0004]
In addition, the prefilter has a coupling convex portion in which a portion facing the locking hole of the resin frame is convexly cured, and the coupling convex portion is detachably inserted into the locking hole, The prefilter is fixed to a resin frame.
[0005]
[Problems to be solved by the invention]
However, there have actually been technical problems described below. That is, in the above-described conventional filter element with a prefilter, the means for attaching the prefilter to the main filter is complicated and the parts cost is high, and it takes time to assemble and increases the cost. In addition, since the parts of the attachment means are exposed on the surface of the prefilter, there is a problem that the aesthetic appearance is impaired.
[0006]
The present invention solves the above-mentioned problems, and the means for attaching the prefilter to the main filter is simplified and the cost can be reduced, and the parts of the attaching means are not exposed on the surface of the prefilter, so the appearance is beautiful. An object of the present invention is to provide a filter element with a pre-filter.
[0007]
[Means for Solving the Problems]
(1) In order to achieve the above object, the present invention is a filter element with a prefilter for an air cleaner in which a prefilter made of a non-woven fabric having a large porosity is arranged upstream of a main filter , the main filter Is a flat board frame, a pair of resin end face frames standing on both ends of the board frame, and a pair of end face frames standing on the board frame and parallel to the end face frame. An intermediate frame made of resin disposed on the substrate frame, and a bellows-shaped filter material provided on the substrate frame and held between the end surface frame and the intermediate frame and between the intermediate frames , upstream end face of the end face frame and the intermediate frame are projected to the upper surface of at least the filtering material, said end Together with the frame or projected column on top of the intermediate frame is provided, the cut portion is provided at a lower portion of the pre-filter to a height of protruding posts, in a state in which the projected column is inserted into the cut portion, projecting pillars And the prefilter are fixed by ultrasonic welding.
[0008]
According to the above configuration, since the end face frame or the intermediate frame and the prefilter are fixed by ultrasonic welding, the means for attaching the prefilter to the main filter is simplified and the cost is reduced, and the attaching means is attached to the surface of the prefilter. Since the parts are not exposed, a filter element with a prefilter having an aesthetic appearance can be provided.
Further, according to such a configuration, even when the prefilter is thick, a notch is provided in the lower part of the prefilter up to the height of the projecting column, and the projecting column is inserted into the notch in the lower part of the prefilter. Since the column and the pre-filter were fixed by ultrasonic welding, it was possible to provide a filter element with a pre-filter that was easy to attach the pre-filter and prevented the deformation of the pre-filter due to the pre-filter attachment.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
[0012]
=== Embodiment 1 ===
As shown in FIG. 2, the filter element 1 with the prefilter shown in FIG. 1 folds the filter medium 2 such as filter paper or nonwoven fabric into a bellows and protrudes to the upper surface of the resin substrate frame 3 and the filter medium 2. The end face frame 4 and the intermediate frame 5 fixed together are used as a main filter 6 (the end face frame 4 and the intermediate frame 5 project from the upper surface of the filter medium 2 to about 2 to 3 mm in the sense that it takes a melting margin. It is desirable that the present invention includes those having no upper protrusion), and the upstream side of the main filter 6 is made of fibers such as polyester, nylon, acrylic, rayon, cotton, and the basis weight is 100 to 600 g / m ^2. The ultrasonic wave is placed on the upper portion of the prefilter 7 corresponding to the position where the end face frame 4 or the intermediate frame 5 is provided by placing the prefilter 7 having a porosity of 95 to 99%. Put the horn 8 of the wearing device by applying an ultrasonic wave, a portion of the end surface frame 4 or the intermediate frame 5 and the pre-filter 7 is manufactured by fixing the both by solidified melt.
[0013]
In the above configuration, the ultrasonic wave is applied by placing the horn 8 of the ultrasonic welder on the upper portion of the prefilter 7 corresponding to the position where the end frame 4 or the intermediate frame 5 is provided, so that the end frame 4 or the intermediate frame 5 is provided. Since both the frame 5 and the prefilter 7 are melted and solidified, the two are fixed, so the number of parts is reduced, and the cost of the prefilter 7 is reduced. It becomes. Further, when the end face frame 4 and the intermediate frame 5 having the protruding portions 4a and 5a protruding upward by about 2 to 3 mm from the upper surface are used, there is a space between the upper surface of the main filter 6 and the lower surface of the prefilter 7. Thus, the entire surface of the main filter 6 can be utilized more effectively.
[0014]
A filter element 1 with a prefilter shown in FIG. 3 is for an air cleaner, similar to that described in Japanese Patent Laid-Open No. 10-85539 described above, and the filter medium 2 is accordion folded to form a resin substrate frame 3. 4 is fixed to the end face frame 4 and the intermediate frame 5 protruding up to the upper surface of the filter medium 2 to form a main filter 6, and at least four positions of the end face frame 4 or the intermediate frame 5 are projected pillars 9 as shown in FIG. 5, a notch 10 provided at the same height as the protruding column 9 is provided at the lower part of the prefilter 7, and the protruding column 9 is inserted into the notched part 10 at the lower part of the prefilter 7. By compressing the pre-filter 7 in 10 and placing a horn 8 of an ultrasonic welder on the pre-filter 7 at the position of the protruding column 9 to give ultrasonic waves, the protruding column 9 and a part of the pre-filter 7 are provided. Melts and hardens A pre-filter with filter element 1 by fixing the both the Rukoto. The main filter 6 includes a flat substrate frame 3, a pair of resin end face frames 4 erected on both end sides of the substrate frame 3, and the pair of resin frames erected on the substrate frame 3. An intermediate frame 5 made of resin disposed between the end face frames 4 and 4 in parallel with the end face frames 4 and 4, and between the end face frame 4 and the intermediate frame 5 provided on the substrate frame 3 and the intermediate And a bellows-folded filter medium 2 held between the frames 5 and 5, respectively.
[0015]
According to the above configuration, even when the thickness of the prefilter 7 is thick, the cut portion 10 is provided in the lower portion of the prefilter 7 up to the same height as the protruding column 9, and the protruding column 9 is formed in the lower cut portion 10 of the prefilter 7. The pre-filter 7 in the notch 10 is compressed and ultrasonically welded so that both are fixed, so that the pre-filter can be easily attached and the pre-filter can be prevented from being deformed by the pre-filter. In addition, since the parts of the attachment means are not exposed on the surface of the pre-filter 7, the appearance is beautiful.
[0016]
In addition, in Embodiment 2, although the thing without an upper protrusion is shown, it can replace with what has an upper protrusion like Embodiment 1. FIG.
[0017]
【The invention's effect】
According to the above configuration, as described above, the filter element with a prefilter according to the present invention is divided into an end surface frame and an intermediate frame having an end surface frame and an intermediate frame in which the filter medium protrudes upward (preferably 2 to 3 mm). When the pre-filter is placed on the upstream side of the main filter as the main filter by fixing, by applying an ultrasonic wave by placing the horn of the ultrasonic welder on the upper part of the pre-filter at the position of the end face frame or the intermediate frame, Since the end frame or intermediate frame and a part of the pre-filter are melted and solidified, the two are fixed, so the number of parts is reduced and the cost is reduced. Will be prepared.
In addition, the filter element with a prefilter of the present invention is provided with a notch in the lower part of the prefilter up to the same height as the protruding column even when the prefilter is thick, and the protruding column is inserted into the notched part in the lower part of the prefilter. By compressing the prefilter in the notch and placing the horn of the ultrasonic welder on the prefilter at the position of the protruding column, and applying ultrasonic waves, a part of the prefilter and the protruding column on the upper side of the protruding column Since both of them are fixed by melting and hardening, it is easy to attach the pre-filter, the deformation of the pre-filter due to the pre-filter attachment can be prevented, and the parts of the attachment means are not exposed on the surface of the pre-filter. It will have an aesthetic appearance.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a filter element with a prefilter according to a first embodiment of the present invention.
FIG. 2 is a perspective view showing a main filter of the filter element with the prefilter.
FIG. 3 is a perspective view showing a filter element with a prefilter according to a second embodiment of the present invention.
FIG. 4 is a cross-sectional view showing an intermediate frame portion of the filter element with the prefilter.
FIG. 5 is a cross-sectional view showing a cut portion of a prefilter in the filter element with the prefilter.
[Explanation of symbols]
2 Filter material 3 Substrate frame 4 End face frame 5 Intermediate frame 6 Main filter 7 Pre-filter 8 Horn 9 Projection column 10 Cut portion

Claims (1)

A filter element with a prefilter for an air cleaner in which a prefilter made of a non-woven fabric with a large porosity is arranged on the upstream side of the main filter ,
The main filter includes a flat substrate frame, a pair of resin end surface frames standing on both ends of the substrate frame, and an end surface between the pair of end surface frames standing on the substrate frame. An intermediate frame made of resin disposed in parallel with the frame, and a bellows-shaped filter medium provided on the substrate frame and held between the end surface frame and the intermediate frame and between the intermediate frames, respectively. is configured, the end surface frame and the upstream end face of the intermediate frame are projected to the upper surface of at least the filtering material, with projected column is provided on top of the end surface frame or the intermediate frame, up to the height of the projecting column cut portion is provided at a lower portion of the pre-filter, in a state in which the projected column is inserted into the cut portion, wherein the projecting post pre Prefilter with filter element for an air cleaner and filter is characterized in that it is fixed by ultrasonic welding.

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