JP4733340B2 - Foldable air filter and method for manufacturing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to, for example, a folding air filter for air conditioning and a method for manufacturing the same.
[0002]
[Prior art]
As a filter element such as a folding-type air filter that does not use a separator, a pleated filter is generally used. Pleated filters include embossed filters and mini-pleated filters that are not embossed.
[0003]
In a conventional embossing filter, embossing is performed with a predetermined interval in the length direction of a filter medium sheet made of a nonwoven fabric having a thermoplastic resin binder, and a crease line is provided in the width direction of the filter medium sheet (scoring). What was zigzag-folded along this crease line is known (for example, refer to Patent Documents 1 and 2).
[0004]
In Patent Document 1, in order to maintain each plane forming the pleat at a constant interval, the filter medium sheet is folded along the crease line, and then connected to the folds on the primary side and the secondary side by a resin bead in a direction perpendicular to the crease line. ing.
[0005]
In Patent Document 2, a filter medium sheet is embossed by an embossing roll, and then a resin bead is applied to the top of the filter material sheet and folded.
[0006]
[Patent Document 1]
Japanese Utility Model Publication No. 61-75819 (claim for utility model registration, Fig. 1)
[0007]
[Patent Document 2]
JP-A-9-220427 (Claims, FIG. 1)
[0008]
[Problems to be solved by the invention]
However, the thing of patent document 1 is used only for the light load of a low wind speed, since the plane from a mountain line to a valley line will bend and shape resistance will increase rapidly when the filtration speed of airflow becomes high at high wind speed. .
[0009]
Patent Document 2 cannot be embossed unless a special filter medium capable of embossing is used. In addition, the embossing roll is expensive, and it is necessary to prepare a plurality of embossing rolls every time the embossing interval is different or the fold height is different, which causes an increase in cost.
[0010]
The present invention has been made paying attention to the above circumstances, and the purpose thereof is to maintain the flatness of each plane of the filter medium and maintain a low shape resistance even when the flow rate is high and the filtration speed is high. A foldable air filter that does not require an expensive embossing roll required for each folding ridge height and can use a general filter medium that does not have embossing workability, and a manufacturing method thereof. It is to provide.
[0011]
[Means for Solving the Problems]
In order to achieve the above-described object, the invention of claim 1 is provided on each of a filter medium sheet formed in a zigzag shape along a crease line to form ridges, and a ridge face facing at least a primary side of the filter medium sheet. A plurality of beads arranged at predetermined intervals along the direction of the crease line, and arranged to maintain the interval between the opposing ridges by adhering or contacting the tops facing each other, The bead is on the top protruding from the surface. , In a direction parallel to the direction of the crease line Of the bead portion whose width is located on the heel side , In a direction parallel to the direction of the crease line Smaller than the width of the bead portion , In a direction parallel to the direction of the crease line The folding type air filter is characterized in that the width is formed in a size approximately proportional to the distance between the flange surfaces in the portion.
[0012]
Claim 2 Invention The bead is approximately proportional to the distance from the crease line. Gradients with different heights and slopes at the tops according to the distance between the opposite ridges of the filter media sheet The foldable air filter according to claim 1, wherein the foldable air filter is a bead.
[0013]
Claim 3 Invention The bead has a height such that the distance between the opposing rib surfaces of the filter medium sheet is substantially proportional to the distance from the crease line. Different multiple 2. The folding type air filter according to claim 1, wherein the air filter is an intermittent bead formed by a dod.
[0014]
Claim 4 Invention The bead is the primary side of each opposing trough of the filter media sheet Minoh And secondary side Minoh The bead on the primary side and the bead on the secondary side are disposed at positions shifted from each other in the crease line direction of the filter medium sheet. 3 A foldable air filter according to any one of the above.
[0015]
The invention of claim 5 includes a first step of forming a crease line on the filter medium sheet, and a plurality of steps arranged at predetermined intervals along the direction of the crease line on the ridge surface located at least on the primary side of the filter medium sheet. The bead material is supplied from the discharge nozzle to the top surface of the filter medium sheet facing upward, and the top of the bead protruding from the top surface of the filter medium sheet is changed by changing the relative moving speed of the filter medium sheet and the discharge nozzle. , In a direction parallel to the direction of the crease line Of the part where the width is located on the surface side , In a direction parallel to the direction of the crease line Smaller than the width of the portion located on the side of the heel surface , In a direction parallel to the direction of the crease line A second step of forming beads such that the width varies according to the size of the ribs, and forming the zigzag wrinkles by folding the filter material sheet along the crease line, and each other between the zigzag wrinkles And a third step of maintaining the distance between the opposing ridge surfaces by adhering or contacting the tops of the facing beads to each other.
[0016]
The invention of claim 6 includes a first step of forming a crease line on the filter medium sheet, and a plurality of sheets arranged at predetermined intervals along the direction of the crease line on at least a primary side of both surfaces of the filter medium sheet. The material of the bead is supplied from the discharge nozzle to the ridge surface of the filter material sheet facing upward, and the top portion protruding from the surface of the filter material sheet is supplied. , In a direction parallel to the direction of the crease line The width of the part located on the surface side of the filter media sheet , In a direction parallel to the direction of the crease line The bead material is discharged from the discharge nozzle so as to be different in height in proportion to the distance from the opening side of the ridge so as to be smaller than the width and to maintain the interval between the opposite ridge surfaces, so that a plurality of dodd shapes are discharged. A second step of forming a resin bead and the filter medium sheet are folded at the crease line to form a zigzag ridge, and the tops of the beads facing each other are bonded or contacted to maintain the distance between the opposing ridge surfaces. And a third step of forming the foldable air filter.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
[0018]
1 to 4 show a first embodiment, and FIG. 1A is an overall configuration diagram of a folding filter manufacturing apparatus. Reference numeral 10 denotes a filter medium sheet supply unit. A band-shaped filter medium sheet 12 is wound around a filter medium stand 11 and is rotatably supported. The filter medium sheet 12 is fed from the filter medium sheet supply unit 10 and is conveyed through the conveyance path 13. In addition, 12a is a preliminary | backup filter material sheet | seat, and when all the front filter media sheets 12 are drawn out, the front-end | tip part of the preliminary | backup filter media sheet | seat 12a will be combined with the terminal part, and it will pay out similarly.
[0019]
A cutting mechanism 20 that cuts the filter medium sheet 12 into a predetermined width is provided on the conveyance path 13 adjacent to the filter medium sheet supply unit 10. The cutting mechanism 20 is provided with a pair of feed rollers 21 that convey the filter medium sheet 12 while sandwiching it. A cutter 23 is provided for the receiving roller 22 on the inlet side of the feeding roller 21. The cutter 23 is cut into a predetermined width while conveying the filter medium sheet 12 by pressing the filter medium sheet 12 against the roller 22 by the cylinder 23a. Here, the piece (scrap) 12b of the filter medium sheet 12 is discharged, and when two filter medium sheets 12 are taken, they are simultaneously conveyed in parallel.
[0020]
A reciprocating type creasing mechanism 30 for attaching streaks 30a (see FIG. 1 (b)) to the filter medium sheet 12 cut to a predetermined width on the conveying path 13 adjacent to the cutting mechanism 20 at a predetermined interval in the width direction. Is provided. The creasing mechanism 30 is provided with a pair of feed rollers 31 that convey the filter medium sheet 12 while sandwiching it. A tapping member 32 is provided on the inlet side of the feed roller 31 to apply a tapping force to the filter medium sheet 12 from above and below.
[0021]
When the filter medium is a synthetic nonwoven fabric, a first crease with a heater is provided on the conveyance path 13 adjacent to the creasing mechanism 30 along the streaks 30a of the filter medium sheet 12 in a zigzag manner and with a crease. A mechanism 40 is provided. A tension roller 41 is provided on the inlet side of the first crease mechanism 40. The tension roller 41 is arranged so that a plurality of rollers 42 are overlapped, and a predetermined tension is applied by passing the filter medium sheet 12 therebetween.
[0022]
On the outlet side of the tension roller 41, a pair of folding blades 43 are provided that fold the filter medium sheet 12 in zigzag along the streaks by pressing the filter medium sheet 12 from the vertical direction toward the crease. Further, a guide member 44 for guiding the zigzag filter medium sheet 12 is provided behind the pair of folding blades 43, and a heater 45 is provided on the guide member 44. Then, the zigzag filter medium sheet 12 is heated by the heater 45 so that the bent portion is bent.
[0023]
A bead coating mechanism 50 is provided on the conveyance path 13 adjacent to the first crease mechanism 40 to apply a resin bead on both surfaces of the filter medium sheet 12 with the folding crease once stretched flat. It has been. When the filter medium is other than the synthetic nonwoven fabric, a bead coating mechanism 50 is provided on the conveyance path 13 adjacent to the creasing mechanism 30.
[0024]
A tension mechanism 51 is provided on the inlet side of the bead coating mechanism 50, and a feed roll 52 is provided on the outlet side. The bead coating mechanism 50 is configured as shown in FIG. That is, in the inside of the main body 53 of the bead coating mechanism 50, a pair of upper and lower first guide rollers 54 that are biased and installed on one side, and the upper side of the first guide roller 54 and the opposite side are biased. A pair of upper and lower second guide rollers 55 installed, and a pair of upper and lower third guide rollers 56 installed at the same height as the second guide roller 55 and biased to the left. .
[0025]
Then, the filter medium sheet 12 carried out from the tension mechanism 51 is passed over the first guide roller 54, then folded back by the first direction changing portion and passed over the second guide roller 55. Further, the second guide roller 55 is folded back by the second direction changing section and is passed over the third guide roller 56. Therefore, the filter medium sheet 12 is horizontal between the first and second guide rollers 54 and 55, and the back surface is upward, and the filter medium sheet 12 is horizontal and between the second and third guide rollers 55 and 56, and the surface. Becomes upward.
[0026]
A plurality of first resin discharge nozzles 57 are provided in the width direction of the filter medium sheet 12 between the first and second guide rollers 54 and 55 so as to face the back surface of the filter medium sheet 12, A plurality of second resin discharge nozzles 58 are provided between the three guide rollers 55 and 56 in the width direction of the filter medium sheet 12 toward the surface of the filter medium sheet 12.
[0027]
The first and second resin discharge nozzles 57 and 58 are connected to a resin supply source (not shown) through a resin pipe 59 so as to supply a heat-melted resin. An electromagnetic valve 60 is provided in the middle of the resin pipe 59. When the electromagnetic valve 60 is opened, molten resin is discharged from the first and second resin discharge nozzles 57 and 58. Resin beads are applied at predetermined intervals in the length direction and width direction of the filter medium sheet 12 by the first and second resin discharge nozzles 57 and 58, and are carried out by the feed roll 52.
[0028]
The first to third guide rollers 54 to 56 and the feed roll 52 are grooved rollers so that the resin beads 57 a and 58 a do not come into contact with the first to third guide rollers 54 to 56 and the feed roll 52. Is formed.
[0029]
When the resin beads 57a and 58a are bonded on the conveyance path 13 adjacent to the bead coating mechanism 50, the resin beads 57a and 58a applied to the filter medium sheet 12 are not bonded but are contacted without contacting. In this case, a second crease mechanism 70 is provided that folds in a zigzag shape along the crease after sufficiently drying. A tension roller 71 is provided on the inlet side of the second crease mechanism 70. The tension roller 71 is arranged so that a plurality of rollers 72 are overlapped, and a certain tension is applied by passing the filter medium sheet 12 therebetween.
[0030]
A pair of folding blades 73 are provided on the outlet side of the tension roller 71 to fold the filter medium sheet 12 in zigzag along the streaks by pressing the filter medium sheet 12 from the vertical direction toward the crease. Therefore, the filter media sheet 12 folded in a zigzag shape is bonded when both are adhered by the resin beads 57a and 58a, but when they are dried, a space is formed by contact. . Further, a carry-out conveyor 74 including a pitch-out conveyor for carrying out the zigzag filter medium sheet 12 is provided behind the pair of folding blades 73.
[0031]
Next, the operation of the first embodiment will be described.
[0032]
When the feed roller 21 of the cutting mechanism 20 rotates, the filter medium sheet 12 of the filter medium sheet supply unit 11 is fed out and carried into the cutting mechanism 20. Since the cutter 23 of the cutting mechanism 20 presses the filter medium sheet 12 against the roller 22 by the cylinder 23a, the filter medium sheet 12 is cut to a predetermined width while being conveyed. Here, the piece (scrap) 12b of the filter medium sheet 12 is discharged, and when two filter medium sheets 12 are taken, they are simultaneously conveyed in parallel.
[0033]
Next, the filter medium sheet 12 cut to a predetermined width is conveyed by the feed roller 31 of the creasing mechanism 30, and the tapping member 32 applies a tapping force to the filter medium sheet 12 from above and below during the conveyance. Streaks 30a are attached in the width direction at regular intervals in the longitudinal direction of the filter medium sheet 12.
[0034]
The filter medium sheet 12 with the streaks 30a is given a certain tension by a tension roller 41 provided on the inlet side of the first crease mechanism 40, and then the pair of folding blades 43 are moved up and down to filter medium. The sheet 12 is pressed toward the line 30a of the sheet 12 to crease the filter sheet 12 along the line 30a in a zigzag shape.
[0035]
The zigzag filter medium sheet 12 is heated by the heater 45 while passing through the guide member 44, and is prevented from being restored by attaching a crease to the crease. However, the first crease mechanism 40 is used only for a material in which heating is effective such as a synthetic nonwoven fabric, and is not used for a glass nonwoven fabric.
[0036]
The filter medium sheet 12 with the bent crease is conveyed to the bead coating mechanism 50. Here, the film is once transported in a flat stretched state, and resin beads are applied to both sides thereof. Since a tension mechanism 51 is provided on the inlet side of the bead coating mechanism 50, a constant tension is applied by the feed roll 52.
[0037]
The filter material sheet 12 to which the tension is applied is passed over the first guide roller 54, then folded back and passed over the second guide roller 55. Further, it is folded back from the second guide roller 55 and passed over the third guide roller 56. Accordingly, the resin beads 57a are applied between the first and second guide rollers 54 and 55 on the back surface of the filter medium sheet 12 by the first resin discharge nozzle 57 at a predetermined interval in the length direction and at a predetermined interval in the width direction. The Further, a resin bead 58a is applied between the second and third guide rollers 65 and 66 on the surface of the filter medium sheet 12 by a second resin discharge nozzle 58 at a predetermined interval in the length direction and at a predetermined interval in the width direction. Is done.
[0038]
Here, the application method of the resin beads 57a and 58a will be described. A normal resin bead has a constant pressure discharged from a resin discharge nozzle, and is continuously or intermittently discharged, and a filter medium sheet passing at a constant speed. It is applied on top. However, since it has been confirmed that the height (thickness) of the resin bead changes when the feed speed of the filter medium sheet is changed while the resin is being discharged from the resin discharge nozzle, the present invention is capable of changing the speed of the filter medium sheet 12. The height of the resin beads 57a and 58a is grasped in advance, and the feed roll 52 on the outlet side of the bead applicator 50 is periodically controlled to control the rotational speed so that the filter medium sheet 12 is composed of gradient beads (taper beads). Resin beads 57a and 58a can be formed. The same gradient bead can be formed even when the speed of the filter medium sheet 12 is made constant and the first and second resin discharge nozzles 57 and 58 are moved with a speed difference in the transport direction of the filter medium sheet 12. .
[0039]
When the resin beads 57a and 58a are applied after the resin beads 57a and 58a are applied to both surfaces of the filter medium sheet 12 by the bead application mechanism 50, the resin beads 57a and 58a are bonded to the streaks 30a before the resin beads 57a and 58a are hardened. A second crease mechanism 70 that folds along the zigzag pattern is conveyed. A constant tension is applied to the filter medium sheet 12 by the tension roller 71. In the case where the resin beads 57a and 58a are brought into contact with each other without being adhered, the gap is formed by bringing both into contact with each other after drying.
[0040]
The filter medium sheet 12 to which tension is applied is pressed from the vertical direction toward the crease fold by a pair of folding blades 73 and is folded in a zigzag shape. The filter media sheet 12 folded in a zigzag shape is joined by resin beads 57a and 58a applied on the front and back surfaces thereof, and is carried out by a carry-out conveyor 74 which is a pitch-out conveyor.
[0041]
3 (a) and 3 (b) show the manufactured folding filter 75, (a) is a side view, and (b) is a view as seen from the direction of the arrow XX. The filter media sheet 12 has a crest 75a and a trough 75b that are folded in a zigzag shape at regular intervals. Between the crests 75a and the trough 75b, the tops of the resin beads 57a and 58a applied to the front and back surfaces of the filter media sheet 12 are formed. Are adhered or contacted. The produced folding filter 75 is bonded or brought into contact with the primary side and the secondary side by resin beads 57a and 58a applied to the front and back surfaces of the filter material sheet 12.
[0042]
When the relative speed between the first and second resin discharge nozzles 57 and 58 and the filter medium sheet 12 is high, the height of the resin beads 57a and 58a is low, and when the relative speed is low, the height is high, but the high portion is solidified. In the process of progressing, it is crushed by its own weight and widens and the height decreases. Therefore, as shown in FIG. 3 (b), the thicker ones of the resin beads 57a and 58a have a rounded trapezoidal shape, while the thinner ones are almost circular, and the middle part is shown in FIG. 3 (a). As shown by hatching, it has an intermediate cross-sectional shape.
[0043]
As shown in FIG. 4, the folding filter is a plane in which the fold of the filter medium sheet 12 is sharp and the inclination of the surface from the mountain fold line to the valley fold line maintains a constant angle θ with respect to the airflow. However, in the present invention, since the primary side and the secondary side are bonded or contacted by the gradient beads of the resin beads 57a and 58a, the filter medium sheet 12 is rigid, has a high flow rate, and has a high filtration rate. The flatness of each plane can be maintained, and a low shape resistance can be maintained.
[0044]
5 and 6 show a second embodiment, FIG. 5 is a longitudinal side view of a bead coating machine, FIG. 6 shows a folding filter, (a) is a side view, and (b) is an arrow YY line. It is an arrow view seen from the direction, and the same component as 1st Embodiment attaches | subjects the same number, and abbreviate | omits description.
[0045]
This embodiment is different from the first embodiment only in the bead coating machine. That is, between the first and second guide rollers 54 and 55, the back surface of the filter material sheet 12 is opposed, and the first-stage resin discharge nozzle 76 and the second-stage resin are directed from the upstream side to the downstream side of the filter medium sheet 12. Discharge nozzles 77 and third-stage resin discharge nozzles 78 are arranged at predetermined intervals. A plurality of first, second and third stage resin discharge nozzles 76, 77 and 78 are arranged in the width direction of the filter medium sheet 12.
[0046]
Further, between the second and third guide rollers 55 and 56, the surface of the filter medium sheet 12 is opposed, and the first stage resin discharge nozzle 76 a and the second stage resin are formed from the upstream side to the downstream side of the filter medium sheet 12. Discharge nozzles 77b and third-stage resin discharge nozzles 78c are arranged at predetermined intervals. A plurality of first, second and third stage resin discharge nozzles 76 a, 77 a and 78 a are arranged in the width direction of the filter medium sheet 12.
[0047]
Then, by controlling the application timing by the electromagnetic valve 60, the first stage resin discharge nozzles 76, 76a are the longest in the conveying direction of the filter medium sheet 12, and the lower stage over substantially the entire length between the streaks 30a and 30a. A resin bead 79a is applied. The second-stage resin discharge nozzles 77 and 77a are arranged so that the middle-stage resin bead 79b is placed on the lower-stage resin bead 79a over the length of approximately half of the lower-stage resin bead 79a applied by the first-stage resin discharge nozzles 76 and 76a. Apply to the top. The third-stage resin discharge nozzles 78, 78a are arranged so that the upper-stage resin beads 79c are placed on the middle-stage resin beads 79b over approximately half the length of the middle-stage resin beads 79b applied by the second-stage resin discharge nozzles 77, 77a. Apply to the top.
[0048]
When the middle resin bead 79b is applied over the lower resin bead 79a and when the upper resin bead 79c is applied over the middle resin bead 79b, it is desirable that the resin bead is somewhat cured. By appropriately arranging the nozzles or cooling the resin beads with a fan or the like, the resin beads can be prevented from being crushed by their own weight.
[0049]
In FIG. 6, one of the opposing surfaces is coated with a middle resin bead 79b superimposed on the lower resin bead 79a, and the other is coated with a middle resin bead 79b on the lower resin bead 79a. An upper resin bead 79c is applied on 79b in an overlapping manner.
[0050]
According to this embodiment, since the lower resin beads 79a, the middle resin beats 79b, and the upper resin beats 79c having different lengths are applied on the filtration sheet 12, the gradient beads are formed by the resin beads 79a, 79b, and 79c. It is formed. And, since the primary side and the secondary side are bonded or bonded by this gradient bead, the flatness of each plane of the filter medium sheet 12 is maintained, even if it is rigid, has a high flow rate, and a high filtration rate, and has a low shape. Can keep resistance.
[0051]
7 to 9 show a third embodiment, FIG. 7 is a longitudinal side view of a bead coating machine, FIG. 8 is a side view of a state in which a filter medium sheet is stretched flat, and FIG. 9 is a side view of a folding filter. Yes, the same components as those in the first and second embodiments are denoted by the same reference numerals and description thereof is omitted.
[0052]
This embodiment is different from the first and second embodiments only in the bead coating machine. That is, a first resin discharge nozzle 80a, a second resin discharge nozzle 80b, and a third resin discharge nozzle 80c are provided between the first and second guide rollers 54 and 55 so as to face the back surface of the filter medium sheet 12. Arranged at intervals. A plurality of the first to third resin discharge nozzles 80 a, 80 b and 80 c are arranged in the width direction of the filter medium sheet 12.
[0053]
Further, between the second and third guide rollers 55 and 56, the first resin discharge nozzle 80a ′, the second resin discharge nozzle 80b ′, and the third resin discharge nozzle 80c are opposed to the surface of the filter medium sheet 12. 'Is arranged at a predetermined interval. A plurality of the first to third resin discharge nozzles 80 a ′, 80 b ′, 80 c ′ are arranged in the width direction of the filter medium sheet 12. The first to third resin discharge nozzles 80a, 80b, 80c and 80a ′, 80b ′, 80c ′ have different nozzle diameters, the first resin discharge nozzles 80a, 80a ′ have a large diameter, and the first resin discharge nozzles. 80b and 80b ′ are formed with a medium diameter, and the third resin discharge nozzles 80c and 80c ′ are formed with a small diameter.
[0054]
Then, the resin is applied between the streaks 30a and 30a of the filter medium sheet 12 by controlling the opening and closing by a discharge pump (not shown) for discharging the resin and the electromagnetic valve 60, and intermittent beads, for example, resin large dots 81a, In-resin dots 81b and small resin dots 81c can be formed.
[0055]
FIG. 8 shows the surface of the filter media sheet 12 First to third resin discharge nozzles 80a, 80b, 80c The resin large dot 81a, the resin middle dot 81b, and the resin small dot 81c are formed. The resin large dot 81a and the resin middle dot are sequentially formed from the mountain fold line to the valley fold line and from the valley fold line to the mountain fold line. The case of forming 81b and resin small dots 81c will be described. First, a large resin dot 81a is formed on the filter medium sheet 12 by the first resin discharge nozzle 80a, a medium resin dot 81b is formed by the second resin discharge nozzle 80b, and a small resin dot 81c is formed by the third resin discharge nozzle 80c. . Next, resin small dots 81c, resin middle dots 81b, and resin large dots 81a are formed intermittently from the valley fold line to the mountain fold line. Next, the resin large dots 81a, the resin middle dots 81b, and the resin small dots 81c are formed intermittently from the mountain fold line to the valley fold line. By repeating this action, the resin can be applied by periodically changing the size of the resin dots on the filter medium sheet 12.
[0056]
According to this embodiment, by folding the filter medium sheet 12 in a zigzag shape, the resin large dots 81a, the resin middle dots 81b, and the resin small dots 81c are bonded or contacted to form a gradient bead. And since the primary side and the secondary side are adhered or contacted by this gradient bead, the flatness of each plane of the filter medium sheet 12 is maintained, even if it is rigid, has a high flow rate and a high filtration rate, and has a low shape. Can keep resistance.
[0057]
10 (a) and 10 (b) show a fourth embodiment of the folding filter manufacturing apparatus, where the same components as those in the first embodiment are given the same reference numerals, and description thereof is omitted.
[0058]
In the present embodiment, a tension adjuster 90 and a meandering correction mechanism 91 are provided between the filter medium sheet supply unit 10 and the cutting mechanism 20. The tension adjuster 90 applies tension to the filter medium sheet 12 by overlapping the tension rollers 92 with each other, and conveys them to the meandering correction mechanism 91. The meandering correction mechanism 91 includes a plurality of guide rollers 93, and corrects the filter medium sheet 12 so as not to be displaced in the width direction during conveyance, and conveys it to the cutting mechanism 20.
[0059]
The creasing mechanism 30 includes a pair of rolls 94a and 94b arranged above and below, and sandwiches and conveys the filter medium sheet 12. The rolls 94a and 94b are provided with ridges 95 and recesses 96 alternately on the circumference at regular intervals, and the upper roll 94a and the lower roll 94b are engaged with the ridges 95 and 96. It is designed to rotate synchronously. Accordingly, when the filter medium sheet 12 is nipped and conveyed by the pair of rolls 94a and 94b, the filter medium sheet 12 bites between the ridges 95 and the ridges 96, and the filter medium sheet 12 is streaked at regular intervals in the longitudinal direction and in the width direction. It is like that. Note that an elastic body such as rubber may be embedded in the recess 96.
[0060]
The first crease mechanism 40 includes a folding roller 40a. The filter medium sheet 12 with the streaks 30a is folded into the guide member 44 by the folding roller 40a, and the filter medium sheet 12 is buckled to make a crease. It is like that.
[0061]
Further, the bead coating mechanism 50 is provided with a tension roller 98 at the lower portion of the main body 97 and a feed roller 99 at the upper portion. Between the tension roller 98 and the feed roller 99, there is provided a direction changing roller 100 that changes the direction of the filter medium sheet 12 conveyed from the tension roller 98 by approximately 90 °.
[0062]
Further, resin discharge nozzles 101 and 102 are provided between the tension roller 98 and the direction changing roller 100 toward the front and back surfaces of the filter medium sheet 12. A plurality of resin discharge nozzles 101 and 102 are arranged at regular intervals in the width direction of the filter medium sheet 12, and resin beads are arranged at predetermined intervals in the length direction of the filter medium sheet 12 and at predetermined intervals in the width direction by the resin discharge nozzles 101 and 102. It is to be applied.
[0063]
The second crease mechanism 70 includes a folding roller 70a, and the filter medium sheet 12 with the streaks 30a is buckled by the folding roller 70a so as to be creased.
[0064]
According to the fourth embodiment, when the resin beads are applied to the front and back surfaces of the filter material sheet 12, there is no need to detour and convey the filter material sheet 12 in an S shape by a large number of guide rollers, and the direction of approximately 90 °. Conversion is enough.
[0065]
Note that the present invention is not limited to the above-described embodiment as it is, and can be embodied by modifying the constituent elements without departing from the scope of the invention in the implementation stage. Moreover, various inventions can be formed by appropriately combining a plurality of constituent elements disclosed in the embodiment. For example, some components may be deleted from all the components shown in the embodiment. Furthermore, you may combine suitably the component covering different embodiment.
[0066]
【The invention's effect】
As described above, according to the present invention, the beads provided in a plurality of rows at predetermined intervals along the crease line are formed on at least the secondary side of the opposing surfaces of the ridges of the filter media sheet, and the filter media sheet is folded. Since the tops of the beads are bonded or brought into contact with each other so that the distance between the opposing surfaces constituting the ridges is maintained in a tapered shape, the flatness of each plane of the filter medium is high even when the flow rate is high and the flow rate is high. Can maintain a low shape resistance, and does not require expensive embossing rolls required for each height of the folding folds, and can use a general filter medium without embossability, so the cost can be greatly reduced. it can.
[Brief description of the drawings]
1A and 1B show a filter element manufacturing apparatus according to a first embodiment of the present invention, in which FIG. 1A is a configuration diagram of the entire apparatus, and FIG.
FIG. 2 is a perspective view of a bead coating mechanism according to the embodiment.
FIG. 3 shows the same embodiment, showing a folding filter, in which (a) is a side view, and (b) is an arrow view as seen from the XX line direction.
FIG. 4 is an explanatory view of a folding filter according to the embodiment.
FIG. 5 is a longitudinal sectional side view of a bead coating machine according to a second embodiment of the present invention.
6A and 6B show the embodiment, showing a folding filter, in which FIG. 6A is a side view, and FIG. 6B is an arrow view as viewed from the YY line direction.
FIG. 7 is a longitudinal side view of a bead applicator showing a third embodiment of the present invention.
FIG. 8 is a side view showing the embodiment and a state in which a filter medium sheet is stretched flat.
FIG. 9 is a side view of the folding filter according to the embodiment.
10A and 10B show a third embodiment of the present invention, wherein FIG. 10A is a configuration diagram of a folding filter manufacturing apparatus, and FIG. 10B is an enlarged side view of a roll.
[Explanation of symbols]
12 ... Filter media sheet, 57a, 58a ... Resin bead, 81a ... Resin large dot, 81b ... Resin medium dot, 81c ... Resin small dot

Claims (6)

A filter material sheet that is folded in a zigzag shape along the crease line to form a ridge,
The filter sheet is provided on each of the opposite flange surfaces on at least the primary side, and is arranged so as to face each other so as to adhere or contact the top portions to maintain the distance between the opposite flange surfaces and along the direction of the crease line. A plurality of beads arranged at predetermined intervals,
Including
The bead has a width in a direction parallel to the direction of the crease line of a top portion protruding from the ridge surface, which is smaller than a width in a direction parallel to the direction of the crease line of the bead portion located on the ridge surface side, A foldable air filter characterized in that a width of a bead portion located on the side of the ridge is parallel to the direction of the crease line and is approximately proportional to the distance between the ridges in that portion.   The bead is a gradient bead having a height different according to the interval between the opposing rib surfaces of the filter medium sheet so as to be approximately proportional to the distance from the crease line, and having a gradient at the top. The folding type air filter according to claim 1.   2. The bead is an intermittent bead formed by a plurality of dods having different heights so that an interval between the opposite rib surfaces of the filter medium sheet is substantially proportional to a distance from the crease line. Folding type air filter as described in 1.   The beads are formed on the primary side and secondary side side surfaces of each opposite side of the filter media sheet, and the primary side beads and the secondary side beads are shifted from each other in the crease line direction of the filter media sheet. The foldable air filter according to any one of claims 1 to 3, wherein the foldable air filter is disposed at a position. A first step of forming a crease line in the filter medium sheet;
A plurality of bead materials arranged at predetermined intervals along the direction of the crease line are supplied from a discharge nozzle to the ridge surface of the filter material sheet facing upward on the ridge surface positioned at least on the primary side of the filter material sheet. In addition, the width of the top of the bead protruding from the saddle surface of the filter medium sheet by changing the relative moving speed of the filter medium sheet and the discharge nozzle is located on the surface side of the filter medium sheet. The width of the portion that is smaller than the width in the direction parallel to the direction of the crease line and that is in the direction parallel to the direction of the crease line of the portion located on the side of the crease line depends on the size of the gap. A second step of forming the beads differently;
The filter media sheet is folded at the crease line to form zigzag wrinkles, and the tops of the beads facing each other are bonded or brought into contact with each other between the zigzag wrinkles to maintain the distance between the faces of the opposite wrinkles. A third step of
The manufacturing method of the folding type | formula air filter characterized by including. A first step of forming a crease line in the filter medium sheet;
A material of a plurality of beads arranged at a predetermined interval along the direction of the crease line on at least a primary surface of both surfaces of the filter material sheet is supplied from a discharge nozzle to a flange surface of the filter material sheet facing upward. The width of the top portion protruding from the surface of the filter material sheet is smaller than the width of the portion parallel to the direction of the crease line of the portion located on the surface side of the filter material sheet. In addition, a plurality of dod-like resin beads are formed by discharging the bead material from the discharge nozzle so that the height differs in proportion to the distance from the opening side of the ridge so as to maintain the interval between the opposite ridge surfaces. A second step;
A third step of forming the zigzag folds by folding the filter material sheet at the crease line, and bonding or contacting the tops of the beads facing each other to maintain the interval between the ridges facing each other;
The manufacturing method of the folding type | formula air filter characterized by including.

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