JP5651425B2 - Heat resistant filter and method for producing heat resistant filter - Google Patents

Description

  The present invention relates to a heat-resistant filter that can be used in a high-temperature range, for example, for circulating air cleaning such as a dryer, or for exhaust gas treatment of an incinerator, and a method for producing the heat-resistant filter.

When manufacturing a normal HEPA filter, a two-component urethane resin sealant is poured into the upper and lower frames, and the filter pack is immersed in the sealant in the upper and lower frames to be dried and solidified. However, when manufacturing a heat-resistant filter, it is necessary to place a heat-resistant sealing material at the time of manufacture, so the silicone resin instead of the urethane resin sealant is manually applied to the end of the filter pack by the operator. After painting, the filter pack may be framed into the filter frame.
Furthermore, a structure has been proposed in which an inorganic adhesive, a high-density sheet-like sealing material, and a low-density sheet-like cushion material are arranged at the end of the filter pack without using a silicone resin. This type of heat-resistant filter is described in Patent Document 1.

Japanese Patent No. 4283705

However, the urethane resin sealant is poured into the upper and lower frames of the filter pack temporarily assembled, and then reversed, the urethane resin sealant is poured into the other upper and lower frames, and the ends of the filter pack are immersed and dried and solidified. This method has a problem that it cannot be used because the sealing agent has no heat resistance.
In addition, in the method in which the filter pack is framed on the filter frame using the silicone resin, in the 150 ° C. heat resistant filter, the operator pours the two-pack silicone resin sealant into the temporarily assembled upper and lower frames, and then reverses. On the other hand, a two-component silicone resin sealant is poured into the upper and lower frames and the ends of the filter pack are immersed and dried and solidified.
However, in a 250 ° C heat-resistant filter, an operator manually applies a one-part silicone resin to the end of the filter pack with a brush, but in order to provide heat resistance, the viscosity of the silicone resin is increased. Therefore, it takes time to manually apply the silicone resin at the filter assembly manufacturing site, and the workability at the site is very poor. In addition, since the worker manually applies the silicone resin, the amount of silicone resin to be applied tends to increase. If an attempt is made to reduce the amount of silicone resin used, there will be a problem of air leakage failure in the heat-resistant filter due to uneven coating of the silicone resin.

Further, in the method of disposing an inorganic adhesive, a high density sheet-like sealing material, and a low density sheet-like cushion material at the end of the filter pack without using a silicone resin, the operator can use the zigzag end face of the filter pack. After applying the inorganic adhesive manually, and after applying the inorganic adhesive manually and before the inorganic adhesive dries, the high-density sheet-like sealing material and the low-density sheet Since the cushion materials need to be laminated in order, the manual work at the time of manufacturing the filter is troublesome and the workability is poor.
Then, an object of this invention is to provide the manufacturing method of a heat resistant filter and a heat resistant filter which can improve manufacturing operation efficiency using the heat resistant silicone resin.

The heat-resistant filter of the present invention is a heat-resistant filter having a filter pack composed of a folded filter paper and a separator disposed in a folding space of the filter paper, and a filter frame for holding a peripheral portion of the filter pack. A first seal layer disposed between the first end of the filter pack and the filter frame, and a second end opposite to the first end of the filter pack and the filter frame. A sheet-like base material to which a heat-resistant silicone resin sealant has been applied in advance, and the base material and the filter frame. It is comprised by the sheet-like heat-resistant shock absorbing material arrange | positioned between these.
According to the said structure, manufacturing work efficiency can be improved using the heat-resistant silicone resin. That is, when the heat resistant filter is assembled and manufactured, the heat resistant silicone resin having increased viscosity is previously applied to the base material. Since such troublesome manual work is not required, work efficiency when manufacturing a heat-resistant filter is improved.

Preferably, the base material is made of a filter paper made of the same material as the filter paper of the filter pack.
According to the said structure, since the kind of material to be used can be unified, cost reduction can be aimed at.

Preferably, the heat-resistant buffer material is a heat-resistant glass fiber sheet.
According to the above configuration, the heat resistance of the one end portion and the other end portion of the filter pack can be maintained only by placing the glass fiber sheet on the substrate, and the filter frame can be expanded or contracted by the ambient temperature. Since the cushioning material follows the expansion or contraction, the sealing property between the filter pack and the filter frame can be maintained.

The heat-resistant filter manufacturing method of the present invention includes a filter pack composed of a folded filter paper, a separator disposed in a folding space of the filter paper, and a filter frame that holds four peripheral portions of the filter pack. A heat-resistant filter manufacturing method comprising: a sheet-like base material in which a heat-resistant silicone resin sealant is applied in advance between a first end of the filter pack and the filter frame; A first sealing layer is set by disposing a sheet-like heat-resistant cushioning material disposed between the filter frames, the second end of the filter pack opposite to the first end, and the filter By placing a sheet-like base material to which a heat-resistant silicone resin sealant has been applied in advance between the frames, and a sheet-like heat-resistant cushioning material arranged between the base material and the filter frame And sets the second sealing layer.
According to the said structure, manufacturing work efficiency can be improved using the heat-resistant silicone resin. That is, when the heat resistant filter is assembled and manufactured, the heat resistant silicone resin having increased viscosity is previously applied to the base material. Since such troublesome manual work is not required, work efficiency when manufacturing a heat-resistant filter is improved.

  INDUSTRIAL APPLICABILITY The present invention can provide a heat-resistant filter that can improve the manufacturing work efficiency using a heat-resistant silicone resin and a method for producing the heat-resistant filter.

The perspective view which shows preferable embodiment of the heat resistant filter of this invention. The disassembled perspective view which shows the structural example of the filter pack shown in FIG. 1, a 1st seal layer, and a 2nd seal layer. The figure explaining the manufacturing method of the heat-resistant filter shown in FIG. The figure explaining the manufacturing method of the heat-resistant filter shown in FIG. 1 following FIG.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
The embodiments described below are preferred specific examples of the present invention, and thus various technically preferable limitations are given. However, the scope of the present invention is particularly limited in the following description. Unless otherwise stated, the present invention is not limited to these embodiments. FIG. 1 is a perspective view showing a preferred embodiment of the heat-resistant filter of the present invention.
A heat-resistant filter 1 shown in FIG. 1 is a high-temperature filter that can be used in a high-temperature region, and is a heat-resistant HEPA filter that is used at 250 ° C., for example. This HEPA filter (High Efficiency Particulate Air Filter) is a filter used for the purpose of removing dust, dust, etc. from the air to make it clean air. For example, it is used for circulating air cleaning such as dryers and incinerators. Although used for exhaust gas treatment, etc., the heat-resistant filter 1 is not limited to these applications, and can be used for other high-temperature applications.

As shown in FIG. 1, the heat resistant filter 1 includes a heat resistant filter frame 2, a heat resistant filter pack 3, a sheet-like first seal layer 4, and a sheet-like second seal layer 5. The heat-resistant filter frame 2 is a square frame or a rectangular frame having a heat resistance, such as a metal frame such as aluminum or stainless steel.
The heat-resistant filter frame 2 includes a first frame plate 2A, a second frame plate 2B, a third frame plate 2C, and a fourth frame plate 2D. The first frame plate 2A, the second frame plate 2B, and the third frame plate. 2C and the 4th frame board 2D hold | maintain and protect the four surrounding parts of the heat-resistant filter pack 3. FIG. The thickness of the first frame plate 2A, the second frame plate 2B, the third frame plate 2C, and the fourth frame plate 2D is, for example, 15 mm. The heat-resistant filter frame 2 accommodates the heat-resistant filter pack 3 in an airtight state via the first seal layer 4 and the second seal layer 5.

FIG. 2 is a perspective view showing a configuration example of the heat-resistant filter pack 3, the first seal layer 4, and the second seal layer 5 shown in FIG.
With reference to FIG. 2, first, the configuration of the heat resistant filter pack 3 will be described. The heat resistant filter pack 3 is composed of a sheet-like filter paper (also referred to as heat resistant filter paper) 6 and a plurality of corrugated separators 7. The filter paper 6 is a filter paper made of inorganic fibers formed by bonding inorganic fibers with an organic binder, and has heat resistance. The filter paper 6 has a flat portion 6A and a bent portion 6B which is bent by zigzag bending, and a space 6C is formed between the adjacent flat portions 6A and 6A of the filter paper 6. Waveform separators 7 are disposed in the folding spaces 6C, respectively. The corrugated separator 7 is made by bending a heat-resistant metal foil such as aluminum or stainless steel into a corrugated shape.

As shown in FIG. 2, the first seal layer 4 is disposed on the first end 11 side of the filter paper 6 of the heat-resistant filter pack 3, and as shown in FIG. 1, the first seal layer 4 is the first seal layer 4 of the filter paper 6. It arrange | positions between the 1st edge part 11 and the 1st frame board 2A, and seals between the 1st edge part 11 of the filter paper 6 and the 1st frame board 2A. Similarly, as shown in FIG. 2, the second seal layer 5 is disposed on the second end 12 side of the filter paper 6 of the heat-resistant filter pack 3, and as shown in FIG. It arrange | positions between the 2nd edge part 12 of the filter paper 6, and the 2nd frame board 2B, and seals between the 2nd edge part 12 of the filter paper 6, and the 2nd frame board 2B.
The first sealing layer 4 has a sheet-like base material 8 to which a sealing agent 9 is applied in advance, and a sheet-like heat-resistant cushioning material 10. The sheet-like base material 8 and the sheet-like heat-resistant cushioning material 10 are formed in a rectangular shape in accordance with the shape of the first end portion 11 of the filter paper 6.
Similarly, the second sealing layer 5 includes a sheet-like base material 8 on which a sealing agent 9 is applied in advance, and a sheet-like heat-resistant cushioning material 10. The sheet-like base material 8 and the sheet-like heat-resistant cushioning material 10 are formed in a rectangular shape in accordance with the shape of the second end portion 12 of the filter paper 6.
As described above, the sealant 9 is applied in advance to the sheet-like substrate 8 in advance using, for example, a sealant applicator, and is uniformly formed to have a predetermined thickness, for example, preferably 1.5 mm. It is prepared by. The thickness range of the sealant 9 is preferably about 0.5 mm to 3 mm. If the thickness of the sealing agent 9 is less than 0.5 mm, the possibility of occurrence of a leak failure is increased, and this is not preferable. If the thickness is larger than 3 mm, the sealing agent becomes excessive, which is not preferable because the cost increases and the filter weight increases.

  What is used as the sealant 9 is a heat-resistant silicone resin, and the silicone resin has a paste-like property.

A heat-resistant filter paper can be used as the sheet-like base material 8, and the material of the filter paper of the sheet-like base material 8 is, for example, the same material as the filter paper 6 of the heat-resistant filter pack 3. Thereby, the sheet-like base material 8 and the filter paper 6 of the heat-resistant filter pack 3 can use the same filter paper, and the types of materials used can be unified, so that the cost can be reduced. The thickness of the base material 8 is, for example, 0.4 mm.
The sealing agent 9 is applied in advance to one surface 8A of the sheet-like substrate 8. The heat-resistant silicone resin of the sealing agent 9 is in a paste form with increased viscosity so that it can withstand heat at, for example, 250 ° C. or higher. In this manner, a sealant 9 that is a heat-resistant silicone resin having increased viscosity is prepared in advance on one surface 8A of the sheet-like substrate 8.

Thus, when the heat-resistant filter 1 is assembled and manufactured, the sealing agent 9 that is a heat-resistant silicone resin having increased viscosity is applied in advance to the sheet-like base material 8, so that the heat-resistant filter 1 is manufactured. In the field, time-consuming and troublesome manual work for applying the sealant 9 which is a heat-resistant silicone resin to the sheet-like base material 8 becomes unnecessary. Thereby, the work efficiency at the time of manufacturing a heat-resistant filter improves.
That is, in the site where the heat-resistant filter 1 is assembled and manufactured, the time-consuming and cumbersome manual work of applying the sealing agent 9 which is a heat-resistant silicone resin with increased viscosity to the sheet-like base material 8 becomes unnecessary. The work efficiency when manufacturing the heat-resistant filter 1 is excellent, the uneven coating of the heat-resistant silicone resin is eliminated, and the amount of heat-resistant silicone resin used can be reduced, so the weight of the heat-resistant filter 1 can be reduced. The silicone resin for use does not wet the first end portion 11 and the second end portion 12 of the heat-resistant filter pack 3.

  The thickness of the sealing agent 9 applied to one surface 8A of the sheet-like substrate 8 is 0.5 mm to 3 mm, and particularly preferably 1.5 mm. If the thickness of the sealant 9 is smaller than 0.5 mm, there is a problem that the flat variation of the filter papers 6A and 6B cannot be covered, resulting in poor sealing and the possibility of occurrence of leaks. In addition, since the separator is not immersed in the sealant, there is a problem that the filter pack cannot be held, which is not preferable. When the thickness of the sealant 6 is larger than 3 mm, an excessive sealant is used, which increases costs. This is not preferable because the filter weight increases.

As the sealant 9 that is a heat-resistant silicone resin, for example, a sealant KE-3418 manufactured by Shin-Etsu Silicone Co., Ltd. can be used. This heat-resistant silicone has a heat resistance of at least 200 ° C. and a sealing property.
This heat-resistant silicone resin is a “one-component RTV (Room Temperature Valcanizable) rubber”, which is a liquid rubber that has room temperature fluidity and is cured at room temperature, so that it can be easily sealed. The liquid rubber is a polymer having fluidity, has a three-dimensional network structure by an appropriate chemical treatment, and exhibits physical properties similar to those of ordinary crosslinked rubber. There are diene rubbers (butadiene rubber, isoprene rubber, styrene butadiene rubber, nitrile rubber, chloroprene rubber, butyl rubber), urethane rubber, etc., but these rubbers have lower heat resistance than heat resistant silicone resins. The sealing agent 9 is not preferable.

The heat-resistant silicone resin is a room temperature curing type and a one-component condensation reaction type, and the deoxime type has a problem of generating oxime gas (methyl ethyl ketoxime MEKO), so the deacetone type has super heat resistance. Is the best. This heat-resistant silicone resin can be worked simply by extruding it from the container, becomes a rubber elastic body after curing, and adheres well to one end 11 and the other end 12 of the heat-resistant filter pack 3 shown in FIG.
The heat-resistant silicone resin is a “low molecular weight siloxane reduced product”. Low molecular weight siloxane is a non-reactive cyclic dimethylpolysiloxane (generally D3 to D10), and is volatilized in the atmosphere during and after curing due to volatility. Since low-molecular siloxane causes problems (electrical contact failure) in semiconductor manufacturing, a low-molecular siloxane-reduced product is required as a heat-resistant silicone resin.

Next, the sheet-like cushioning material 10 shown in FIG. 2 is a heat-resistant glass fiber sheet disposed on the other surface 8B side of the substrate 8. The cushioning material 10 has heat resistance that can withstand 250 ° C. or more, and is disposed between the other surface 8B of the substrate 8 and the inner surface of the first frame plate 2A shown in FIG. The thickness of the buffer material 10 is, for example, 2 mm.
Thereby, the sheet-like buffer material 10 protects the one end portion 11 and the other end portion 12 of the heat resistant filter pack 3 in the heat resistant filter frame 2 from heat, and the metal heat resistant filter frame 2 shown in FIG. Even if the sheet-like cushioning material 10 follows the expansion or contraction even if it expands or contracts due to temperature, the sealing property between the heat-resistant filter pack 3 and the heat-resistant filter frame 2 can be maintained.
Furthermore, even if the plurality of metal corrugated separators 7 that have received heat extend in the Z direction, which is the direction toward the first end portion 11 and the second end portion 12 of the filter paper 6, Since the sheet-like cushioning material 10 can be absorbed, the heat-resistant filter pack 3 can be prevented from being damaged.

Next, with reference to FIG. 3 and FIG. 4, the manufacturing method of the heat-resistant filter 1 shown in FIG. 1 is demonstrated. 3 and 4 are diagrams showing the procedure of the method for manufacturing the heat-resistant filter 1.
FIG. 3A shows a process for manufacturing the heat-resistant filter pack 3.
In FIG. 3A, when the long and sheet-like filter paper 6 is fed out from the filter paper roll 50, the filter paper 6 is bent in a zigzag shape, whereby a flat surface portion 6A and a bent portion 6B are formed on the filter paper 6. The Then, in the folding space 6C between the adjacent flat portions 6A and 6A of the filter paper 6, the corrugated separators 7 are respectively inserted and arranged along the X direction perpendicular to the Z direction. Is cut by the knife 44, and the heat-resistant filter pack 3 is manufactured. In FIG. 3A, the Z direction of the heat-resistant filter pack 3 is a vertical direction in the drawing.

Next, in FIG. 3B, the heat-resistant filter pack 3 shown in FIG. 3A is disposed between the three second frame plates 2B, the third frame plate 2C, and the fourth frame plate 2D. The state is shown, and the first frame plate 2A has already been removed.
When the heat-resistant filter pack 3 is arranged between the three second frame plates 2B, the third frame plate 2C, and the fourth frame plate 2D in this way, the filter paper 6 is arranged in the Z direction. 6 is placed on the inner surface of the second frame plate 2B, no frame plate is disposed on the first end portion 11 of the filter paper 6, and the first end portion 11 of the filter paper 6 is disposed. Is exposed. The three first frame plates 2B, the third frame plate 2C, and the fourth frame plate 2D are temporarily assembled using screws, for example.

In FIG. 3C, the first seal layer 4 is disposed on the first end portion 11 of the filter paper 6. First, the sheet-like base material 8 to which the sealing agent 9 constituting the first sealing layer 4 is applied in advance is placed on the first end portion 11 of the filter paper 6. 9 is arranged on the downward side so as to directly contact the first end portion 11 of the filter paper 6. Furthermore, a sheet-like heat-resistant cushioning material 10 is disposed on the base material 6 in an overlapping manner. As a result, the first seal layer 4 is disposed on the first end portion 11 of the filter paper 6.
In FIG. 4A, the first frame plate 2A is disposed on the first seal layer 4, and the first frame plate 2A is, for example, relative to the end surfaces of the third frame plate 2C and the fourth frame plate 2D. The assembly 1R of the heat-resistant filter 1 is obtained by being permanently fixed using screws.

Next, FIG. 4B shows a state in which the second seal layer 5 is disposed on the second end portion 12 of the filter paper 6.
In this case, the assembly 1R of the heat-resistant filter 1 shown in FIG. 4A is placed upside down, the second end 12 side of the heat-resistant filter pack 3 is up, and the first end 11 side is down. To. The second frame plate 2B is temporarily removed from the third frame plate 2C and the fourth frame plate 2D to expose the second end 12 of the heat resistant filter pack 3.
The first seal layer 4 is disposed on the second end portion 12 of the filter paper 6. First, the sheet-like base material 8 to which the sealing agent 9 constituting the first sealing layer 4 is applied in advance is placed on the second end portion 12 of the filter paper 6. The filter paper 6 is disposed downward so as to be in direct contact with the second end portion 12 of the filter paper 6. Furthermore, a sheet-like heat-resistant cushioning material 10 is placed on the sheet-like base material 6 so as to overlap therewith.
Thereafter, as shown in FIG. 4C, the second frame plate 2B is disposed on the second seal layer 5, and the second frame plate 2B is composed of the third frame plate 2C and the fourth frame plate 2D. For example, it is fixed to the end surface of the main body using screws.
Through the manufacturing process as described above, the manufacture of the heat-resistant filter 1 shown in FIG. 4C and FIG. 1 is completed.

Conventionally, the silicone resin is applied to the end of the filter pack, and then the filter pack is framed on the filter frame, so that the operator applies the silicone resin to the end of the filter pack in order to provide heat resistance. In addition, since the viscosity of the silicone resin is high, it takes time to apply the silicone resin and the workability is poor. In addition, there is a problem that the amount of silicone resin is large, and if it is attempted to reduce the amount of silicone resin used, coating unevenness occurs and leakage defects occur.
In addition, the conventional method of disposing an inorganic adhesive, a high-density sheet-shaped sealing material, and a low-density sheet-shaped cushion material at the end of the filter pack without using a silicone resin is a zigzag shape of the filter pack. After applying the inorganic adhesive to the end face of the substrate, and after applying the inorganic adhesive, before the inorganic adhesive dries, the high-density sheet-like sealing material and the low-density sheet-like cushioning material are in turn. Therefore, the work at the time of manufacturing the filter is troublesome and the workability is poor.

  On the other hand, when manufacturing the heat-resistant filter 1 according to the embodiment of the present invention, the sealing agent 9 that is a heat-resistant silicone resin having increased viscosity is applied to one surface 8A of the sheet-like substrate 8. When the heat-resistant filter 1 is assembled and manufactured by using a pre-applied one, a sealing agent 9 that is a heat-resistant silicone resin having increased viscosity is applied to the base material 8 in advance. At the manufacturing site of the heat-resistant filter 1, time-consuming and troublesome manual work for applying the sealant 9, which is a heat-resistant silicone resin, to the base material 8 becomes unnecessary. For this reason, the work efficiency at the time of manufacturing a heat-resistant filter improves.

By the way, the present invention is not limited to the above-described embodiments, and various modifications and changes can be made to the present invention, and various modifications can be made within the scope described in the claims.
The number of filter papers 6 folded and the number of corrugated separators 7 shown in FIGS. 1 and 2 are not particularly limited. Each thickness of the sealing agent 9, the base material 8, the buffer material 10, and the heat-resistant filter frame 2 can be arbitrarily selected according to specifications.

  DESCRIPTION OF SYMBOLS 1 ... Heat resistant filter, 2 ... Heat resistant filter frame (filter frame), 2A ... 1st frame board, 2B ... 2nd frame board, 3 ... Heat resistant filter pack (filter pack), 4 ... 1st sheet layer, 5 ... 2nd sheet layer, 6 ... Filter paper, 7 ... Corrugated separator, 8 ... Sheet-like base material, 9 ... Sealing agent (heat resistant silicone resin) ) 10 ... Sheet-like cushioning material (heat-resistant cushioning material), 11 ... First end of the heat-resistant filter pack, 12 ... Second end of the heat-resistant filter pack

Claims (4)

A heat-resistant filter having a filter pack composed of a folded filter paper and a separator disposed in a folding space of the filter paper, and a filter frame for holding a peripheral portion of the filter pack,
A first seal layer disposed between the first end of the filter pack and the filter frame, and a second end of the filter pack opposite to the first end and disposed between the filter frame. Comprising a second sealing layer,
The first seal layer and the second seal layer are a sheet-like base material on which a paste-like heat-resistant silicone resin sealant has been applied in advance, and a sheet shape disposed between the base material and the filter frame. Is made up of heat-resistant cushioning material,
The sheet-like base material of the first seal layer and the second seal layer is obtained by previously applying the heat-resistant silicone resin sealant having a bonding function in a thickness of 0.5 mm to 3 mm. Heat resistant filter. The heat-resistant filter according to claim 1, wherein the heat-resistant buffer material is a heat-resistant glass fiber sheet. The heat-resistant filter according to claim 1 or 2, wherein the heat-resistant silicone resin sealant is a low-molecular-weight siloxane reduced product. A filter pack comprising a folded filter paper and a separator disposed in a folding space of the filter paper, and a method for producing a heat-resistant filter having a filter frame that holds four peripheral portions of the filter pack,
A sheet-like base material in which a paste-like heat-resistant silicone resin sealant having an adhesive function is applied in a thickness of 0.5 mm to 3 mm between the first end of the filter pack and the filter frame. And setting a first seal layer by disposing a sheet-like heat-resistant cushioning material disposed between the base material and the filter frame,
Between the second end opposite to the first end of the filter pack and the filter frame, a sheet-like base material to which a heat-resistant silicone resin sealant is applied in advance, the base and the base A method for producing a heat-resistant filter, characterized in that a second seal layer is set by arranging a sheet-like heat-resistant cushioning material arranged between filter frames.

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