JP5585998B2 - Air filter manufacturing method and air filter mold - Google Patents

Description

  The present invention relates to an air filter mold for molding an air filter frame with a casting resin to obtain an air filter, and a method for manufacturing an air filter using the mold.

  For example, in a small type air filter for an air supply mask or the like, a filter frame may be formed with a casting resin. Conventionally, this type of air filter is generally manufactured by setting a fold-folded filter medium in a cavity formed by an upper mold and a lower mold and then pouring a casting resin around the filter medium. is there. In the mold used in such a manufacturing method, a plurality of liquid-proof plates arranged in parallel as many as the pleats of the filter medium are erected on each of the bottom surfaces of the upper mold and the lower mold facing each other.

  In manufacturing an air filter, first, a filter medium fold is inserted between each lower mold liquid-proof plate, and the filter medium is mounted on the lower mold. Next, the upper mold is overlaid on the lower mold to which the filter medium is attached, and each liquid-proof plate of the upper mold is inserted and arranged inside the folds of each filter medium, and then the casting resin is poured into the outer periphery of the filter medium. In this method, since each pleat mountain of the filter medium is sandwiched between the lower mold liquid-proof plate and the upper mold liquid-proof plate, the filter frame can be formed without flowing resin into the filter medium from the fold mountain. It becomes possible.

  However, the fold-folded filter medium is usually highly stretchable in a direction perpendicular to the crease direction, and therefore, when the filter medium is attached to the lower mold, there is a problem that it is difficult to place pleats between the liquid-proof plates.

  On the other hand, the filter medium can lower the stretchability in the orthogonal direction by fixing the pleat mountain with a separator interposed between the pleat mountains. However, such a filter medium has not been conventionally used for the resin molded type air filter because the insertion is hindered by the separator when the pleats are inserted between the liquid-proof plates.

  The present invention has been made in view of the above problems, and a method of manufacturing an air filter capable of easily attaching a fold-folded filter medium to a lower mold, and air used in the manufacturing method. It aims at providing the shaping | molding die for filters.

  A method of manufacturing an air filter according to the present invention includes a lower mold and an upper mold that are arranged to face each other, and each of the lower mold and the upper mold has a plurality of protections that stand up toward the upper mold and the lower mold. A liquid plate is provided, and each of the plurality of liquid-proof plates of the upper mold and the lower mold includes a plurality of first short plates arranged in parallel in a predetermined direction and a plurality of second short plates arranged in parallel in the predetermined direction, The 1st short width board group which consists of a plurality of 1st short width boards, and the 2nd short width board group which consists of a plurality of 2nd short width boards are formed by arranging in a perpendicular direction perpendicular to a predetermined direction via a gap. This is done using a mold. In this method, a first step of preparing a filter medium folded in a fold so that folds are substantially parallel to each other and a large number of pleats are formed, and the filter medium is disposed on the bottom surface of the lower mold, Each of the one end portions in the fold line direction of the folds is inserted between the first short width plates adjacent to each other in the predetermined direction of the lower mold, and each of the other end portions of each fold mountain is adjacent to each other in the predetermined direction of the lower mold. A second step of inserting between the plates, and the first and second short plates of the upper mold are inserted into one end and the other end of each pleat mountain, respectively, and a plurality of liquid-proof plates of the lower mold and the upper mold A third step of arranging the filter media so as to engage with each other while sandwiching the filter medium; and a fourth step of pouring a casting solution into the outer periphery of the filter medium and forming a filter frame on the outer periphery of the filter medium. And, the pleat outer surfaces facing each other or the inner pleat inner surfaces facing each other inside the pleats are fixed so as to be separated by the separator, and in the second step, the separator is It is arranged in the lower mold cavity.

  Each of the plurality of liquid-proof plates of the lower mold and the upper mold further includes a pair of opposed plates facing in the predetermined direction, and the first short width plate group includes one end of the pair of opposed plates (one end in the orthogonal direction). While arrange | positioned between each other, the 2nd short width board group may be arrange | positioned between the other ends of a pair of opposing board. Then, in the third step, one of the pair of opposing plates of the lower mold and the upper mold and the other are arranged so as to be adjacent to each other, and between them, one end of the filter medium in a direction perpendicular to the crease direction and Each of the other end portions is preferably sandwiched.

  In this case, it is preferable that the separator is not provided at both ends of the filter medium in the direction orthogonal to the crease direction. On the other hand, when the separator is provided from one end to the other end in the direction perpendicular to the crease direction, the fixed state between the pleat outer surfaces or the inner pleat inner surfaces by the separator is before the second step. It is preferable to be released at both ends in a direction orthogonal to the direction. In this case, the separator may extend in a wave shape continuously from one end to the other end of the filter medium, but may be provided discontinuously. The gap width between one or the other of the pair of opposing plates is 0.8 to 1.0 times the thickness of the filter medium when separators are not provided at both ends, and when separators are provided at both ends. Is about 3 to 6 times.

  For example, the separator is provided on at least one surface of the filter medium, and extends in a wave shape along a direction orthogonal to the crease direction. The separator may be provided on both sides of the filter medium.

  The mold for air filter according to the present invention is such that a casting liquid is poured into the outer periphery of a filter medium folded in a pleat shape so that folds are substantially parallel to each other and a large number of pleats are formed, and a filter frame is formed on the outer periphery of the filter medium. Is for molding. The mold includes a lower mold and an upper mold facing each other, and a plurality of liquid-proof plates erected from the lower mold and the upper mold toward the upper mold and the lower mold, respectively. Is arranged so as to mesh with the plurality of liquid-proof plates of the lower mold while sandwiching the filter medium therebetween. A plurality of liquid-proof plates for each of the upper mold and the lower mold include a pair of opposed plates opposed to each other in a predetermined direction, and a plurality of first short plates arranged in parallel in a predetermined direction between one ends of the pair of opposed plates, A plurality of second short plates arranged in a predetermined direction between the other ends of the pair of opposing plates. And the 1st short width board group which consists of a plurality of 1st short width boards, and the 2nd short width board group which consists of a plurality of 2nd short width boards are arranged in the direction orthogonal to a predetermined direction via a gap. It is characterized by that.

  According to another aspect of the present invention, there is provided a method for manufacturing an air filter, comprising: a first liquid-proof part group having a plurality of liquid-proof parts arranged in a predetermined direction and having a comb-tooth shape; and a plurality of liquid-proof parts in the predetermined direction. The liquid parts are arranged side by side and are provided with a second liquidproof part group having a comb-teeth shape, and the first and second liquidproof part groups are arranged with a gap in a direction perpendicular to the predetermined direction. This is a method using a mold. The method includes a first step of preparing a filter medium that is formed by folding a sheet-like filter medium into a pleated shape, and is provided with a separator that fixes the folded sheet-like filter medium at a predetermined interval. The second step of fitting both ends in the crease direction of the filter medium into the first and second liquidproof part groups while being placed in the gap, and pouring the casting liquid into the outer periphery of the filter medium, and forming the filter frame on the outer periphery of the filter medium And a third step.

  The mold for air filter according to the present invention is such that a casting liquid is poured into the outer periphery of a filter medium folded in a pleat shape so that folds are substantially parallel to each other and a large number of pleats are formed, and a filter frame is formed on the outer periphery of the filter medium. And a plurality of liquid-proofing portions for supporting the filter medium in which the pleats are inserted therebetween, and the plurality of liquid-proofing portions face each other in a predetermined direction. A pair of opposing portions, a plurality of first short width portions that are arranged in parallel in the predetermined direction between one end of the pair of opposing portions, and have a comb-tooth shape, and the predetermined interval between the other ends of the pair of opposing portions A plurality of second short width portions that are arranged in parallel and have a comb-teeth shape, a first short width portion group that includes a plurality of first short width portions, and a second short width that includes a plurality of second short width plates. The width portion group is arranged in an orthogonal direction orthogonal to the predetermined direction with a gap interposed therebetween.

  In the present invention, since it is possible to manufacture a cast resin type air filter using a filter medium in which folds are fixed by a separator, it is possible to easily attach the filter medium to the lower mold.

It is a perspective view which shows a metal mold | die. It is a perspective view which shows a filter medium. It is sectional drawing which shows the manufacturing process of an air filter. It is sectional drawing which shows the mode of the filter medium edge part when a casting liquid is filled. It is a front view which shows an air filter.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing a mold according to an embodiment of the present invention. The mold 10 of the present embodiment includes a lower mold 11 and an upper mold 21 provided so as to face each other.

  The lower mold 11 is provided with a recess 12 that is recessed from the upper surface 15 thereof. The recess 12 is formed by a bottom surface 13 and a side wall 14. The side wall 14 of the recess 12 includes first and second side wall portions 14A and 14B facing the predetermined direction X, and third and fourth side wall portions 14C and 14D facing the orthogonal direction Y orthogonal to the predetermined direction. Composed. The upper die 21 has its bottom surface 23 overlapped with the upper surface 15 of the lower die 11 to close the upper portion of the recess 12 and form a cavity for molding a filter frame between the upper die 21 and the lower die 11.

  A plurality of plate-shaped lower mold liquid-proof plates are erected on the bottom surface 13 of the recess 12 toward the upper mold 21, and a plurality of upper molds are disposed on the bottom surface 23 of the upper mold 21 toward the lower mold 11. A liquid-proof plate is erected. The upper mold liquid-proof plate is disposed inside the recess 12 in a state where the upper mold 21 is superimposed on the lower mold 11.

  The plurality of lower mold liquid-proof plates includes a pair of opposing plates 16 and 17 and a plurality of short-width plates 18 and 19 disposed between the opposing plates 16 and 17. Each of these plates 16 to 19 is a plate-like member whose thickness direction substantially coincides with the predetermined direction X. Each of the pair of opposing plates 16 and 17 is adjacent to the side wall portions 14A and 14B via predetermined gaps 31 and 32, and has a substantially rectangular shape extending in the orthogonal direction Y. The pair of opposed plates 16 and 17 are opposed to the predetermined direction X.

  A plurality of first short-width plates 18 arranged in parallel in the predetermined direction X with an interval between them are disposed between one ends 16A and 17A in the longitudinal direction (orthogonal direction Y) of the pair of opposing plates 16 and 17. The plurality of first short width plates 18 (first short width plate group 18A) have a comb-teeth shape. In addition, a plurality of second short plates 19 arranged in parallel in the predetermined direction X with a space therebetween are provided between the other ends 16B, 17B in the longitudinal direction of the opposing plates 16, 17, and the plurality of second plates 19 are erected. The two short width plates 19 (second short width plate group 19A) have a comb shape. The short plates 18 are provided in the same number as the second short plates 19, and the first short plates 18 are arranged in positions corresponding to the second short plates 19 in the predetermined direction X.

  The lengths of the first and second short plates 18 and 19 in the orthogonal direction Y are sufficiently shorter than the length of the opposing plates 16 and 17 in the orthogonal direction Y. Therefore, the first and second short plate groups 18 </ b> A and 19 </ b> A are arranged in the orthogonal direction Y via the gap 20. The gap 20 is a space where no liquid-proof plate is provided, and the length in the orthogonal direction Y is larger than the length in the orthogonal direction Y of the short width plate group 18A (or the short width plate group 19A).

  The end surfaces of both end portions 16A, 16B, 17A, and 17B in the orthogonal direction Y of the opposing plates 16 and 17 are opposed to the third side wall portion 14C and the side wall portion 14D of the fourth side through gaps 33 and 34, respectively. Similarly, one end face of each of the short plates 18 and 19 in the orthogonal direction Y faces the third side wall portion 14C and the side wall portion 14D of the fourth side through gaps 33 and 34, respectively. The gaps 31 to 34 serve as a rectangular frame-shaped flow path 35 through which the casting solution is injected. The bottom surface 23 of the upper mold 21 is provided with a plurality of injection / exhaust ports 36 communicating with at least four corners of the rectangular frame-shaped flow path 35.

  In addition, although the position of the end surface of the plates 16-18 which oppose the side wall part 14C may mutually correspond in the orthogonal direction Y, you may shift | deviate. In this embodiment, in order to secure a space where the flow path 35 communicates with the inlet / exhaust port 36, about 1 to 3 sheets disposed on the end surfaces of the opposing plates 16 and 17 and on the most opposing plates 16 and 17 side. The position of the end face of the short plate 18 is arranged on the inner side of the position of the end face of the other short plate 18. The same applies to the positions of the end faces of the plates 16, 17, and 19 facing the side wall portion 14D.

  The plurality of upper liquid-proof plates include a pair of opposing plates 26 and 27, a plurality of first short-width plates 28, and a plurality of second short-width plates 29 corresponding to the lower-type liquid-proof plates. The plurality of first short width plates 28 (first short width plate group 28 </ b> A) and the plurality of second short width plates 29 (second short width plate group 29 </ b> A) are arranged in the orthogonal direction Y through the gap 30. In addition, since these plates 26-29 have the same shape as the plates 16-19, the description is abbreviate | omitted. However, as will be described later, the number of the first and second short plates 28 and 29 is set so that each of the opposing plates 26 and 27 is disposed inside each of the opposing plates 16 and 17 of the lower mold 11. One less than each of the short plates 18 and 19.

  The positions of the plates 26 to 29 of the upper mold 21 are slightly shifted from the positions of the respective plates 16 to 19 of the lower mold 11. When the upper mold 21 is overlapped with the lower mold 11, the plates 26 to 29 are the plates. It arrange | positions so that it may mesh | engage 16-19. Specifically, each of the opposing plates 26 and 27 of the upper mold 21 includes the opposing plate 16 of the lower mold 11 and the short plates 18 and 19 adjacent thereto, and the opposing plate 17 and the short plates 18 adjacent thereto, 19 are arranged respectively. Each of the first short plates 28 of the upper mold 21 is disposed between two adjacent first short plates 18 and 18, and the first short plate group 28 </ b> A includes the first short plate group 18 </ b> A. Arranged so as to mesh with each other. Similarly, the second short width plate group 29A of the upper die 21 is disposed so as to mesh with the second short width plate group 19A of the lower die.

  Moreover, although each liquid-proof board was typically shown planar in FIG. 1, actually, as shown in FIG. 3, it exhibits a cross-sectional triangle and its thickness decreases toward the tip. . Moreover, as shown in FIG. 3, the base ends of the lower mold liquid-proof plates (plates 16 to 19) are connected to each other and integrated to form one member 25A. The integrated member 25A is attached to the bottom surface 13. Similarly, the upper liquid-proof plate (plates 26 to 29) is attached to the bottom surface 23 as one member 25B.

  FIG. 2 shows the filter medium 40 used in this embodiment. The filter medium 40 is formed by folding a sheet-shaped filter medium so that the folds 40E are substantially parallel to each other, and a large number of pleats 42 are provided. Each pleat 42 is composed of two substantially planar folding walls 41, 41 facing each other. A sheet-like filter medium is comprised by the filter paper, nonwoven fabric, etc. which are formed from glass fiber and a synthetic fiber, for example.

  A separator 45 is bonded on each of the front surface 43 and the back surface 44 of the filter medium 40. The separator 45 extends in a wavy shape along the direction perpendicular to the crease direction (that is, the direction in which the pleats 42 are arranged) in accordance with the filter medium 40 having a wavy shape. The separator 45 is a yarn separator whose outer periphery is coated with an adhesive such as a synthetic resin. However, as the separator, a separator made of hot melt resin instead of a thread separator, a tape coated with an adhesive on both sides, or the like may be used. Moreover, the separator does not need to be continuous in the direction orthogonal to the crease direction, and may be formed discontinuously, for example, by intermittently applying a resin such as a hot melt resin.

  Between the adjacent pleat peaks 42 and 42 of the fold-folded filter medium 40, the front surfaces 43 are opposed to each other (that is, the outer surfaces of the pleat mountains), and the back surfaces 44 are opposed to each other inside the pleat mountains 42 (that is, the inner surface of the pleat mountain). Are made to face each other. The separator 45 on the surface 43 adheres to the separator 45 on the opposite surface 43 of the adjacent pleat 42, and the outer surfaces (folded walls 41, 41) of the pleats 42, 42 are fixed at a predetermined interval. Is done. The separator 45 on the back surface 44 adheres to the separator 45 on the opposite back surface 44 inside each pleat ridge 42, and the inner surface (folded walls 41, 41) of the pleat ridges 42 is at a predetermined interval in each pleat ridge 42. And are fixed apart. The separators 45 on the front surface 43 and the back surface 44 are arranged at the same position in the crease direction.

  The separators 45 on the front surface 43 and the back surface 44 are not provided on the front and back surfaces of the pleats 42 and 42 provided on the most end portions 40A and 40B (both ends in the direction orthogonal to the crease direction) of the filter medium 40. Therefore, the folding wall 41 (the inner surface of the folds) on the most end portions 40A, 40B side is not fixed to the folding wall 41 (the inner surface of the folds) adjacent thereto. Two separators 45 are provided on each of the front surface 43 and the back surface 44, but are not provided on both end portions 40 </ b> C and 40 </ b> D in the fold direction of the filter medium 40. That is, in the present embodiment, the separator 45 is not provided at the end portions 40 </ b> A to 40 </ b> D of the filter medium 40.

  In addition, the number of pleats of the filter medium matches the number of plates 26 to 28 (or plates 26, 27, 29) of the upper mold 21 arranged in the predetermined direction X. Further, the distance between the tops 47 of the adjacent pleats 42, 42 is determined by the separator 45 so that two plates (for example, the short-width plate 18) adjacent to each other in the predetermined direction X of the lower mold 11 (or the upper mold 21). , 18) are held so as to be substantially equal to the distance between them.

  Next, the manufacturing method of the air filter which concerns on this embodiment is demonstrated. In this embodiment, as shown in FIG. 3, first, the filter medium 40 is disposed on the bottom surface 13 of the lower mold 11. At this time, each pleat mountain 42 has a second short width in which one end portion 42C in the fold direction is inserted between the adjacent first short plates 18 and 18, and the other end portion 42D in the fold direction is adjacent. It is inserted between the plates 19 and 19 (see FIGS. 1 and 2). However, the folds 42 and 42 provided on the most end portions 40A and 40B side are inserted between the opposing plate 16 and the short plates 18 and 19, and between the opposing plate 17 and the short plates 18 and 19, respectively. The The filter medium 40 attached to the lower mold 11 has a crease direction that coincides with the orthogonal direction Y, and a direction in which the pleats 42 are arranged coincides with the predetermined direction X.

  The filter medium 40 attached to the lower mold 11 is arranged in the gap 20 except for the end portions 40A to 40D. Therefore, the separator 45 of the filter medium 40 is disposed in the gap 20, and when the filter medium 40 is inserted into the lower mold 11, the insertion is not interfered by the separator 45.

  Next, the upper mold 21 is moved downward, and the upper mold 21 is overlaid on the lower mold 11. Here, each of the pair of opposing plates 26 and 27 of the upper mold 21 is between the opposing plates 16 and 17 on the lower side 11 and the short width plates 18 and 19, that is, the folds 42 on the most end portions 40 </ b> A and 40 </ b> B side. , 42 is inserted into each of them. As described above, the separator 45 is not provided on the folds 42 and 42 on the most end portions 40A and 40B side, and the inner surfaces of the folds are not fixed. Therefore, the insertion of the opposing plates 26 and 27 is not hindered by the separator 45.

  In addition, by inserting the opposing plates 26 and 27 into the pleats 42 and 42, one opposing plate 26 of the upper mold 21 sandwiches the folding wall 41 closest to the end portion 40 </ b> A with the lower mold 11. Next to the one opposing plate 16. Similarly, the other opposing plate 27 of the upper die 21 is adjacent to the other opposing plate 17 of the lower die 11 with the folding wall 41 closest to the end portion 40B interposed therebetween.

  Each of the first short plates 28 of the upper mold 21 is inserted into each of the one end portions 42C of the pleats 42. Further, each of the second short width plates 29 of the upper mold 21 is inserted into each of the other end portions 42 </ b> D of the folds 42. Thereby, 1st short width board group 18A, 28A is arrange | positioned so that it may mutually mesh | interpose, pinching | interposing the one end part 40C in the fold direction of a filter medium. Similarly, the second short-width plate groups 19A and 29A are arranged so as to mesh with each other while sandwiching the other end portion 40D in the fold direction of the filter medium 40 therebetween.

  Further, a portion of the upper mold 21 corresponding to the gap 20 of the lower mold 11 is a gap 30 where the upper mold liquid-proof plate is not provided. Therefore, even if the upper mold 21 and the lower mold 11 are overlapped, the separator 45 of the filter medium 40 does not contact or interfere with the upper mold liquid-proof plate. The position of the end face of the end portion 40C (or 40D) of the filter medium 40 is the end face of each short width plate 18, 28 (or 19, 29) in the orthogonal direction Y (end face facing the side wall portions 14C, 14D). It may be coincident with the position or may be shifted. In the state where the upper mold 21 is overlapped with the lower mold 11, the gap width between the upper mold liquid-proof plate and the lower mold liquid-proof plate adjacent in the predetermined direction X (gap widths W and W ′ described later, FIG. 4). Reference) may be about 0.8 to 1 times the thickness of the filter medium.

  Next, the casting solution is injected into the flow path 35 surrounding the outer periphery of the filter medium 40 from one or more injection / exhaust ports 36. At this time, air inside the flow path 35 is discharged from one or more of the injection / exhaust ports 36. As the casting solution, a known liquid or fluid resin is used. As shown in FIG. 4, the casting liquid 39 fills the gaps 31 and 32 so as to contact both end portions 40A and 40B of the filter medium 40 (the end portions of the folding walls 41 and 41 on the most end portions 40A and 40B side). Is done. However, the casting liquid 39 does not enter the inside of the filter medium 40 through the gap between the opposing plates 16 and 26 (or between the opposing plates 17 and 27). As shown in FIGS. 3 and 4, a folding wall 41 of the filter medium 40 is arranged between the opposing plates 16 and 26 (or between the opposing plates 17 and 27). This is because the inflow of water is inhibited.

  The casting liquid 39 is filled in the gaps 33 and 34 so as to come into contact with both end portions 40C and 40D in the fold direction of the filter medium 40, but between the adjacent short plates 18 and 18 (or the short plate 19). , 19) from inside the filter medium 40. In the gaps between the adjacent short width plates 18 and 18 (or short width plates 19 and 19), the folds 42 of the filter medium 40 and the short width plate 28 (or the short width plate 29) of the upper die 21 were inserted. It is because it is sealed by this.

  The casting solution injected into the flow path 35 is solidified or hardened to obtain an air filter 60 as shown in FIG. The air filter 60 is formed of a filter medium 40, a casting liquid that is solidified or cured, and includes a square frame-shaped filter frame 50 that surrounds the outer periphery of the filter medium 40, and a separator 45. Note that the casting liquid filled in the flow path 35 is solidified or hardened in contact with the end portions 40A to 40D of the filter medium 40, so that the end portions 40A to 40D of the filter medium 40 are formed on the inner surface of the filter frame 50. It is glued to.

  As described above, in the present embodiment, the air filter 60 is manufactured by inserting the filter medium 40 in which the space between the folds 42 and 42 (folded walls 41 and 41) is fixed to the lower mold 11. Such a filter medium 40 has low stretchability in a direction orthogonal to the crease direction, and further, the interval between the pleats 42 and 42 is widened in advance, so that it is easy to insert into the lower mold 11.

  Moreover, in this embodiment, although the edge parts 40A-40D of the filter medium 40 are supported by the liquid-proof board of the lower mold | type 11 and the upper mold | type 21, other parts (center part of the filter medium 40) are liquid-proof boards. Not supported. The separator 45 is provided only in the central portion of the filter medium 40 that is not supported by the liquid-proof plate (that is, the portion disposed in the gap 20). Therefore, the attachment of the filter medium 40 to the mold 10 is not interfered by the separator 45.

  In the present embodiment, when the upper mold 21 is overlaid on the lower mold 11, the opposing plates 26 and 27 of the upper mold 21 are configured to be disposed outside the opposing plates 16 and 17 of the lower mold 11. May be. In this case, the folding walls 41 and 41 on the most end portions 40A and 40B side are arranged on the outer sides of the opposing plates 16 and 17 and are sandwiched between the opposing plates 16 and 26 and between the opposing plates 17 and 27, respectively. It is. Also in this case, the separator 45 is not provided on the two folded walls 41 and 41 (that is, one ridge mountain) on the end portions 40A and 40B side. Therefore, when the opposing plates 16 and 17 are inserted into the inside of the pleats formed by the two folding walls 41 and 41, the separator 45 does not hinder the insertion.

  In the present embodiment, the separator 45 is not provided on one pleat 42 (two fold walls 41, 41) provided on the most end portions 40A, 40B side. Also, a separator 45 may be provided. That is, the separator 45 may be provided from the end 40A to the end 40B on the front surface 43 and the back surface 44 of the filter medium. In this case, the two folding walls 41, 41 on the most end portions 40 </ b> A, 40 </ b> B side are bonded and fixed by the separator 45. Therefore, before inserting the filter medium 40 into the lower mold 11, it is necessary to pull the one folding wall 41 to release the fixed state between the two folding walls 41, 41. This prevents the separator 45 from inhibiting the insertion of the opposing plates 26 and 27 into the pleat 42.

  However, in this case, the width W (see FIG. 4) between the adjacent opposing plates 16 and 26 (or the opposing plates 17 and 27) in a state where the upper die 21 is superimposed on the lower die 11 also inserts a separator. For this reason, it is necessary to increase the thickness, preferably 3 to 6 times the thickness of the filter medium, more preferably about 5 times. Further, the width W is larger than a gap width W ′ between another upper liquidproof plate and a lower liquidproof plate (for example, the first short plate 18 and the first short plate 28) adjacent in the predetermined direction X. It is preferable.

10 Mold (mold for air filter)
11 Lower mold 12 Recess 13, 23 Bottom 16, 17, 26, 27 Opposing plate 18, 28 First short plate 18 A, 28 A First short plate group 19, 29 Second short plate
19A, 29A 2nd short board group 20, 30 Cavity 21 Upper mold | type 40 Filter medium 40A-40D End part 42 of a filter medium 42 Hidayama

Claims (5)

Each of the lower mold and the upper mold includes a plurality of liquid-proof plates that are erected toward the upper mold and the lower mold and that have a triangular cross section. The plurality of liquid-proof plates of the upper die and the lower die each include a plurality of first short plates arranged in parallel in a predetermined direction and a plurality of second short plates arranged in parallel in the predetermined direction, A first short plate group composed of a plurality of first short plates and a second short plate group composed of the plurality of second short plates are arranged in an orthogonal direction perpendicular to the predetermined direction with a gap. A method of manufacturing an air filter using a mold,
A first step of preparing a filter medium folded in a pleat shape so that folded walls are substantially parallel to each other and a large number of pleats are formed;
The filter medium is disposed on the lower mold, and one end in the crease direction of each pleat is inserted between the first short plates adjacent to the predetermined direction of the lower mold, and each pleat A second step of inserting each of the other end portions of the lower mold between the second short plates adjacent to each other in the predetermined direction;
The upper mold first and second short-width plates are respectively inserted into the one end and the other end of each of the folds, and the lower mold and the upper mold liquid-proof plates are connected to the filter medium. a third step of arranging so as to mesh with each other while sandwiching between the,
Pouring a casting liquid around the outer periphery of the filter medium, and a fourth step of forming a filter frame around the outer periphery of the filter medium,
At least one of the pleat outer surfaces facing each other and the inner pleat inner surfaces facing each other inside the pleats is fixed so as to be separated by a separator,
In the second step, the separator is disposed in the gap of the lower mold,
Each of the plurality of liquid-proof plates of the lower mold and the upper mold further includes a pair of opposed plates opposed to the predetermined direction,
The first short plate group is disposed between one ends of the pair of counter plates, and the second short plate group is disposed between the other ends of the pair of counter plates. ,
In the third step, one and the other of the pair of opposing plates of the lower mold and the upper mold are arranged adjacent to each other, and one end portion of the filter medium in the direction orthogonal to the crease direction and the other between them Each end is sandwiched,
The separator is coated with an adhesive, and provided from one end of the filter medium to the other end in a direction perpendicular to the crease direction;
Before the second step, the fixing state of the outer surfaces of the pleats or the inner surfaces of the pleats by the separator is released at both ends of the filter medium in a direction perpendicular to the crease direction. A method for manufacturing an air filter.   The method for manufacturing an air filter according to claim 1, wherein a gap width between one or the other of the pair of opposing plates is 3 to 6 times the thickness of the filter medium.   The method for producing an air filter according to claim 1, wherein the separator is provided on at least one surface of the filter medium and extends in a wave shape along a direction orthogonal to the crease direction.   The method for manufacturing an air filter according to claim 1, wherein the separator is provided on both surfaces of the filter medium. A first liquidproof part group having a comb-like shape configured by arranging a plurality of liquidproof parts having a triangular cross section in a predetermined direction and a plurality of liquidproof parts having a triangular cross section in the predetermined direction are arranged. And a second liquid-proof part group having a comb-teeth shape, and the first and second liquid-proof part groups are arranged in a direction perpendicular to the predetermined direction via a gap. A method of manufacturing an air filter using
A first step of preparing a filter medium provided with a separator that is formed by folding a sheet-like filter medium into a pleated shape and fixes adjacent folding walls in a substantially parallel manner with a predetermined interval;
While placing the separator to the air gap, a second step of the both ends in the fold direction of the filter medium, are input fitting to said first and second liquid-proof unit group,
Pouring a casting solution around the outer periphery of the filter medium, and forming a filter frame around the outer periphery of the filter medium, and
The lower mold and the upper mold include a pair of opposed plates opposed to the predetermined direction,
The first liquidproof part group is disposed between one ends of the pair of opposed plates, and the second liquidproof part group is disposed between the other ends of the pair of opposed plates. And
In the third step, one and the other of the pair of opposing plates of the lower mold and the upper mold are arranged adjacent to each other, and one end portion of the filter medium in the direction orthogonal to the crease direction and the other between them Each end is sandwiched,
The separator is coated with an adhesive, and provided from one end of the filter medium to the other end in a direction perpendicular to the crease direction;
Before the second step, the fixed state of the pleat outer surfaces in the separator or the inner surfaces of the pleat inner surfaces with an adhesive is released at both ends of the filter medium in a direction orthogonal to the fold direction. A method for manufacturing an air filter.

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