JP5938572B2 - Air filter and air purifier equipped with the air filter - Google Patents

Description

The present invention is, Rue incorporated in such an air conditioner air filter, and an air cleaning apparatus equipped with the air filter.

  A conventional air filter medium has a configuration formed of a base material part and a fine fiber layer provided on the upstream side surface of the air flow blown to the base material part (see, for example, Patent Document 1).

JP 2010-274144 A

  The problem in the above conventional example is that the collection efficiency is lowered.

  That is, the air filter medium was formed from a base material portion and a fine fiber layer provided on the upstream side surface of the air flow blown to the base material portion.

  In this configuration, since the fine fiber layer is exposed on the upstream side of the air flow to be blown, the fine fibers on the surface layer are broken or peeled off due to impact or contact, and the collection efficiency is increased. There was a risk of lowering.

  Then, this invention aims at suppressing the fall of collection efficiency.

In order to achieve this object, the present invention includes a sheet-like base material portion made of an aggregate of fibers, a fine fiber layer made of an aggregate of nanofibers bonded to one surface side of the base material portion, and the fine fiber layer. An air filter is formed by pleating an air filter medium provided with a protective layer formed of a nonwoven fabric on a surface opposite to the base portion of the fiber layer, and the pleat shape is adjacent to the filter medium. a Tei shall be fixed by an adhesive member provided between part, the protective layer is tree fat containing the protective layer are heat-welded with the base portion through the fine fiber layers by heat-melting The protective layer and the base material portion and / or the fine fiber layer are fixed in a linear shape, and a concave surface is formed on the surface of the filter material portion by the thermal welding, and the adhesive member is the concave surface. Ru Tei is applied to the And an air filter, characterized the door, thereby is to achieve the intended purpose.

Air filter has a sheet-like base portion comprising an aggregate of fibers, and fine fiber layer comprising an aggregate of nanofibers bonded to one surface of the substrate portion, wherein the fine fibers of the present invention as described above An air filter is formed by pleating an air filter medium provided with a protective layer made of a nonwoven fabric on a surface opposite to the base part of the layer, and the pleat form is adjacent to the filter medium part a Tei shall be fixed by an adhesive member provided between the protective layer, tree fat containing the protective layer are heat-welded with the base portion through the fine fiber layers by heat-melting, The protective layer and the base material portion and / or the fine fiber layer are fixed in a linear shape, and a concave surface is formed on the surface of the filter material portion by the thermal welding, and the adhesive member is formed on the concave surface. the applied Tei shall Since, in which it is possible to suppress a decrease in collection efficiency.

  That is, in the present invention, by providing a protective layer on the surface of the fine fiber layer opposite to the base portion, the fine fibers on the surface layer are broken or detached due to impact or contact during pleating or transportation. Therefore, it is possible to suppress a decrease in collection efficiency.

  Further, by fixing the protective layer and the base material portion and / or the fine fiber layer in a linear shape, the linear fixed trace becomes a mark of a crease during pleating, and a processed air filter Even when an adhesive layer for holding and forming the filter medium in a pleated shape is provided, it can be used as a mark for alignment, and labor saving can be achieved.

The longitudinal cross-sectional view which shows the air purifier which mounts the air filter concerning Embodiment 1 of this invention. Perspective view of the air filter Cross section of the air filter Cross section of the air filter Schematic showing the manufacturing process of the air filter Perspective view of the air filter manufacturing apparatus Schematic showing the manufacturing process of the air filter Perspective view of the air filter manufacturing apparatus

(Embodiment 1)
An embodiment of the present invention will be described below with reference to the accompanying drawings.

  As shown in FIG. 1, the air cleaning device of this embodiment includes a blower 2 and an air filter 3 in a main body case 1.

  The main body case 1 has a substantially vertically long box shape. The main body case 1 is provided with a substantially square-shaped intake port 4 on the front side surface portion thereof, and the main body case 1 is provided with a substantially square-shaped exhaust port 5. Yes. The exhaust port 5 is provided with a wind direction louver 6.

  The air blowing means 2 is provided in an air passage between the air inlet 4 and the air outlet 5 of the main body case 1, and has a scroll-shaped casing 7 and a blade 8 which is a centrifugal air fan provided in the casing 7. And the electric motor 9 that rotates the blade 8.

The air filter 3 is located downstream of the intake port 4 of the main body case 1.

  In the above configuration, the air that has been sucked into the main body case 1 from the air inlet 4 by the air blowing means 2 is sent to the air outlet 5 through the air filter 3. That is, the indoor air is cleaned by the air filter 3 and blown into the room.

  As shown in FIG. 2, the air filter 3 is formed of a pleated filter medium part 10 bent into a waveform and a shape holding part 11 for holding the filter medium part 10 in a pleated shape.

  In addition, the shape holding part 11 is provided between the frame part 12 and the filter medium part 10, the first adhesive member 13 provided between the filter element parts 10 adjacent to each other in a square shape, the pleat shape. The second adhesive member 17 is formed. That is, the frame portion 12 is positioned at the periphery of the pleated filter medium portion 10, the filter medium portion 10 is fixed in a pleat shape by the first adhesive member 13, and the pleat-shaped filter medium portion 10 is fixed by the second adhesive member 17. Is fixed to the frame portion 12. The first adhesive member 13 and the second adhesive member 17 are adhesives such as hot melt, for example.

  The filter medium portion 10 includes a sheet-like base material portion 14 made of an aggregate of fibers, a fine fiber layer 15 made of an assembly of nanofibers bonded to one surface side of the base material portion 14, and the fine fiber layer 15. It is comprised from the protective layer 16 provided in the surface on the opposite side to the base material part 14. As shown in FIG.

  The base material part 14 and the protective layer 16 are made of pulp fiber, resin fiber, carbon fiber and inorganic fiber, or at least one of them produced by a spunbond method, a dry or wet method, a melt blown method, a spunbond method, an airlaid method, or the like. It is composed of non-woven fabric containing one.

  The fine fiber layer 15 is made of fibers having an average fiber diameter of 50 to 1000 nm obtained by processing a known polymer using a processing technique such as an electrospinning method or a melt spinning method described later. Fibers having an average fiber diameter of 50 to 1000 nm are generally referred to as nanofibers, and since the fiber diameter is thin, the gap between the fibers is reduced and dust collection efficiency is improved. Furthermore, although the gap between the fibers is small, an increase in pressure loss can be prevented by an effect called a slip flow effect. That is, when the pressure loss of a filter medium made of nanofibers having the same dust collection efficiency is compared with that of a filter medium made of fibers exceeding 1000 nm, the pressure loss of the filter medium made of nanofibers is smaller.

  With known processing techniques such as electrospinning and melt spinning, spinning with an average fiber diameter of less than 10 nm is difficult, and fibers with an average fiber diameter of more than 1000 nm have a large gap between the fibers. In order to improve the efficiency, it is necessary to increase the weight per unit area or increase the thickness, thereby increasing the pressure loss, which is not suitable for the present invention. Further, the shape of the fibers forming the fine fiber layer 15 is not particularly limited. However, when a known processing method such as an electrospinning method is used, the cross section is substantially circular or elliptical.

  When the fine fiber layer 15 is produced by a known electrospinning method, it is necessary to use a polymer solution in which a polymer is dissolved in a solvent. Known polymer polymers include polyacrylonitrile, polyethylene, polypropylene, polyethylene oxide, polyethylene glycol, polyethylene terephthalate, polyethylene naphthalate, poly-m-phenylene terephthalate, poly-p-phenylene isophthalate, polymethacrylic acid, polymethyl methacrylate. , Polyvinylidene fluoride, polyvinylidene fluoride-hexafluoropyrene copolymer, polyvinyl chloride, polyvinylidene chloride-acrylate copolymer, polytetrafluoroethylene, polyvinyl alcohol, polyarylate, polyacetal, polycarbonate, polystyrene, polyphenylene sulfide, polyamide , Polyimide, polyamideimide, aramid, polyimidebenzazole, polybenzimidazole , Polyglycolic acid, polylactic acid, polyurethane, cellulose compounds, polypeptides, nucleosides, polynucleotides, proteins, and enzymes, can be used mixtures thereof.

  Here, as a high molecular polymer, polyacrylonitrile is preferable from the viewpoint of easy availability and handling. For example, the polyacrylonitrile preferably includes polyacrylonitrile “Product No .: 181315” manufactured by Sigma-Aldrich Japan.

  The solvent for dissolving the polymer is not particularly limited as long as it is compatible with the polymer and can be dissolved. Examples of these solvents include water, alcohols, organic solvents, etc. Specific alcohols and organic solvents include acetone, chloroform, ethanol, isopropanol, methanol, toluene, tetrahydrofuran, benzene, benzyl alcohol, 1, Highly volatile solvents such as 4-dioxane, propanol, carbon tetrachloride, cyclohexane, cyclohexanone, methylene chloride, phenol, pyridine, trichloroethane, acetic acid, N, N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), N , N-dimethylacetamide (DMAc), 1-methyl-2-pyrrolidone (NMP), ethylene carbonate, propylene carbonate, dimethyl carbonate, acetonitrile, N-methylmorpholine-N-oxide, Tylene carbonate, γ-butyrolactone, diethyl carbonate, diethyl ether, 1,2-dimethoxyethane, 1,3-dimethyl-2-imidazolidinone, 1,3-dioxolane, ethyl methyl carbonate, methyl formate, 3-methyl oxazolidine Examples include solvents having relatively low volatility such as 2-one, methylpropionate, 2-methyltetrahydrofuran, and sulfolane. Alternatively, it is possible to use a mixture of two or more of the above solvents.

  In addition, when polyacrylonitrile is selected as the polymer, the solvent is preferably DMF. When polyvinyl alcohol or polyethylene oxide is selected as the polymer, water is preferably used as the solvent.

  Below, a structure and its effect are demonstrated for every fixing method of the protective layer 16. FIG.

  First, the case where the protective layer 16 includes a low melting point resin and the protective layer 16 and the fine fiber layer 15 are fixed by heat welding will be described.

  When the filter medium part 10 in which the base material part 14, the fine fiber layer 15, and the protective layer 16 are laminated is linearly heat-welded, as shown in FIG. 3, the low melting point resin contained in the protective layer 16 melts and becomes fine. It passes between the fiber layers 15 and directly joins with the base material part 14, and the heat-welded surface of the filter medium part 10 dents (in the figure, two places).

  The first adhesive member 13 that fixes the filter medium portion 10 to the pleated shape is applied to the linear heat-welded surface that is recessed in the concave shape. That is, the linear heat-welded surface 18 of the filter medium part 10 serves as a mark for applying the first adhesive member 13, and labor saving of the application work can be achieved. Here, a first adhesive layer is formed by the first adhesive member 13.

  Further, since the first adhesive member 13 can be applied to the concave surface, the application width does not increase from the width of the concave surface, and the reduction of the ventilation area by the first adhesive member 13, that is, the pressure loss can be reduced.

  Further, in the air purifying apparatus shown in FIG. 1, when the prefilter 19 is provided on the upstream side of the air filter 3, the prefilter 19 needs to be separated from the air filter 3 in order to have a rectifying function. The 13 protrusions (projections) from the protective layer 16 also have a function of maintaining the distance between the pre-filter 19 and the air filter 3.

  Next, the case where the protective layer 16 and the base material part 14 are fixed with the binder 20 is demonstrated.

  As shown in FIG. 4, the base material part 14 and the fine fiber layer 15 are laminated | stacked, the binder 20 is apply | coated to linear form from the fine fiber layer 15, and the protective layer 16 is laminated | stacked from it.

  While the heat welding surface of FIG. 3 is dented, in FIG. 4, the application surface of the binder 20 protrudes in a convex shape (two locations in the figure).

  The first adhesive member 13 that fixes the filter medium part 10 to the pleated shape is applied to the surface of the linearly bonded binder 20 that protrudes in a convex shape. That is, the linear binder 20 application surface of the filter medium portion 10 serves as a mark for applying the first adhesive member 13, and labor saving of the application work can be achieved.

  Further, since the first adhesive member 13 can be applied to the application surface of the linear binder 20 protruding in a convex shape, the application width is wider than that in FIG. 3, and the adhesive area between the protective layer 16 and the first adhesive member 13 is wide. Thus, the first adhesive member 13 can reliably fix the filter medium portion 10 in a pleated shape.

  Further, in the air purifying apparatus shown in FIG. 1, when the prefilter 19 is provided on the upstream side of the air filter 3, the prefilter 19 needs to be separated from the air filter 3 in order to provide the rectifying function. Similarly, the protrusion (projection) of the first adhesive member 13 from the protective layer 16 also has a function of maintaining the distance between the pre-filter 19 and the air filter 3.

  Here, the manufacturing process of the air filter medium to the air filter will be described.

  First, the case where the protective layer 16 and the fine fiber layer 15 are fixed by heat welding will be described.

  As shown in FIG. 5, in the manufacturing process of the air filter medium, first, the base fiber 14a wound around the first rotating roller is conveyed by the conveying means (not shown) while the fine fibers 15a are formed from the nozzle 21. Release toward the material 14a. Here, a voltage of about +20 KV is applied to the nozzle 21, and the conveying means is grounded. Due to this potential difference, the fine fibers 15 a discharged from the nozzle 21 adhere to the entire surface of the base material 14 a and become fine. A fiber layer 15 is formed.

  Subsequently, the protective sheet 16 a wound around the second rotating roller is laminated on the fine fiber layer 15, and the base material 14 a and the protective sheet 16 a are thermally welded by the heating roller 22.

  As shown in FIG. 6, the heating roller 22 is provided with a plurality of rollers having a width of about 5 mm (six in FIG. 6) at regular intervals, and the base material 14a and the protective sheet 16a are arranged in a linear shape of the width of the roller. Can be heat-welded. The heat-welded surface has a concave line shape and has the function and effect described with reference to FIG.

  Next, the case where the protective layer 16 and the base material part 14 are fixed with the binder 20 is demonstrated.

  As shown in FIG. 7, in the air filter medium manufacturing process, first, the base material 14a wound around the first rotating roller is conveyed by a conveying means (not shown) while the fine fibers 15a are formed from the nozzle 21. Release toward the material 14a. Here, a voltage of about +20 KV is applied to the nozzle 21, and the conveying means is grounded. Due to this potential difference, the fine fibers discharged from the nozzle 21 adhere to the entire surface of the base material 14a, and the fine fibers Layer 15 is formed.

  Next, the binder 20 is linearly applied from the adhesive application device 23 onto the base material 14a on which the fine fiber layer 15 is formed. As shown in FIG. 8, the adhesive application device 23 has, for example, seven nozzles, and applies the binder 20 in the form of seven lines on the base material 14 a on which the fine fiber layer 15 is formed.

  Next, the protective sheet 16 a wound around the second rotating roller is laminated on the fine fiber layer 15 coated with the binder 20, and the base material 14 a and the protective sheet 16 a are bonded by the binder 20.

  The surface of the protective sheet 16a applied on the linear binder 20 has a protruding linear shape and has the effects described with reference to FIG.

  Thus, the filter medium part 10 provided with the base material part 14, the fine fiber layer 15, and the protective layer 16 is manufactured by heat welding or the binder 20, and is bent into a pleated shape. Here, it is bent in a direction perpendicular to the linear heat-welded surface or adhesive surface by a bending machine (not shown). Finally, the air filter 3 is manufactured by fixing the filter medium part 10 to the pleat shape by the first adhesive member 13 and fixing the pleat-shaped filter medium part 10 to the frame part 12.

  That is, in the present invention, by providing a protective layer on the surface of the fine fiber layer opposite to the base portion, the fine fibers on the surface layer are broken or detached due to impact or contact during pleating or transportation. Therefore, it is possible to suppress a decrease in collection efficiency.

  Further, by fixing the protective layer and the base material portion and / or the fine fiber layer in a linear shape, the linear fixed trace becomes a mark of a crease during pleating, and a processed air filter To provide an air filter medium and an air filter that can be used as alignment marks even when an adhesive layer for holding and forming the filter medium in a pleated shape is provided, and that can save labor. it can.

As described above, the present invention provides a sheet-like base material portion composed of an aggregate of fibers, a fine fiber layer composed of an assembly of nanofibers bonded to one surface side of the base material portion, and the fine fiber layer described above. a protective layer provided on a surface opposite to the base material portion, since the fixing between the protective layer and the base material portion and / or the fine fiber layer linear suppresses a decrease in collection efficiency It can be done.

  Therefore, it is expected to be utilized as an air filter for home use or office use, a method for manufacturing the air filter, and an air purifier equipped with the air filter.

DESCRIPTION OF SYMBOLS 1 Main body case 2 Air blowing means 3 Air filter 4 Intake port 5 Exhaust port 6 Wind direction louver 7 Casing 8 Blade 9 Electric motor 10 Filter material part 11 Shape holding part 12 Frame part 13 1st adhesive member 14 Base material part 14a Base material 15 Fine fiber Layer 15a Fine fiber 16 Protective layer 16a Protective sheet 17 Second adhesive member 18 Heat welding surface 19 Pre-filter 20 Binder 21 Nozzle 22 Heating roller 23 Adhesive coating device

Claims (2)

A sheet-like base material portion made of an aggregate of fibers, a fine fiber layer made of an aggregate of nanofibers bonded to one surface side of the base material portion, and a side opposite to the base material portion of the fine fiber layer are formed air filter to the air filter medium having a protective layer provided to constitute a non-woven fabric on the surface to the pleated shape, the pleats are Ru is fixed by the adhesive member provided between the filtration portion adjacent Tei are those, the protective layer, the provided tree fat containing a protective layer is thermally welded to the base portion through the fine fiber layers by heat-melting, the protective layer and the base material portion and / or together with the the fine fiber layer is fixed in a linear, concave surface is formed on the surface of the filter medium portion by the thermal welding, the air filter where the adhesive member is characterized Tei Rukoto applied to the concave surface . And a convex portion is formed by bonding member coated on the concave surface of the air filter according to claim 1, further comprising a pre-filter on the upstream side, the air filter part of the tip of the crests on one side of the pleats The air purifier is mounted so that the convex portion keeps a distance from the prefilter.

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