JP6482802B2 - Filter structure and manufacturing method thereof - Google Patents

Description

The present invention relates to a filter structure and a method for manufacturing the same , and more particularly to a filter structure and a method for manufacturing the filter structure for attaching to a suction port of an air conditioner having a structure in which a suction port is provided on the top surface and the front surface is formed into a flat panel shape. It is.

  In recent years, wall-mounted air conditioners (hereinafter abbreviated as “air conditioners” as appropriate) have been well-known and have a structure in which a suction port is provided on the top surface and the front surface is formed into a flat panel, that is, a so-called top surface intake system. Yes.

  Conventionally, it has been proposed to attach a filter made of non-woven fabric to the air inlet of an air conditioner to prevent dust contamination around the air inlet (for example, Patent Document 1).

JP2013-154325A

  The filter described in Patent Document 1 is of a type that is often seen before the above-mentioned top surface intake type is put on the market and is attached to an air conditioner having a slit on the front surface with an adhesive or the like.

  However, in some of the top-intake air conditioners, most of the top surface of the air conditioner is widely opened as a suction port. For this reason, for example, when the above-mentioned filter is affixed to the air inlet of such an upper surface intake type air conditioner, the central portion of the attached filter may bend. In addition, this may cause a situation in which a gap is generated in the bonded portion between the filter and the suction port, and the dustproof effect is reduced. Furthermore, if the center part of the filter bends, when the air conditioner is used in a kitchen or the like, there is a risk that oil stains will concentrate on the center part of the filter and drop into the air inlet of the air conditioner. For this reason, it has been desired to provide a filter suitable for being attached to a top surface intake air conditioner having a large inlet on the top surface.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a filter structure that can suppress the deflection of the filter when attached to the air inlet of the air conditioner top surface, and a method for manufacturing the same. And

In order to achieve the above object, the invention according to claim 1 is a filter structure that is attached so as to cover the suction port provided on the top surface of the air conditioner, and the size of the top surface portion around the suction port. And a flexible sheet-like filter, and a frame attached to one side of the filter and having at least an outer peripheral portion formed corresponding to the outer edge of the filter. The frame body includes a rectangular ring-shaped outer peripheral portion and a lattice-shaped crosspiece integrally connected to the inside of the outer peripheral portion, and the crosspiece portion includes at least one extending in the longitudinal direction. The first perforation of the book and at least one second cross extending in the short-side direction, further comprising a linear perforation formed to remove unnecessary portions, Of the pier and the second pier Without even being formed so as to extend continuously to the outer edge of the outer peripheral portion with along the side edges of the unnecessary portion side of the opposite side edges in one, in perforations, in which protruding portion protruding frame side is formed.

If comprised in this way, the bending rigidity of the outer edge of a filter will improve with a frame. Further, the perforations formed in the frame body are shortened, and the crosspieces remain along the cut portions. Furthermore, when the filter structure is stored in a valley fold on the filter side, it is possible to suppress the occurrence of a large bending stress in the bent portion.

The invention according to claim 2 is a sheet-like sheet that is attached so as to cover the suction port provided on the top surface of the air conditioner, is formed corresponding to the size of the top surface portion around the suction port, and has flexibility. And a frame attached to one side of the filter and having at least an outer peripheral portion formed corresponding to the outer edge of the filter, the filter is formed in a rectangular sheet shape, and the frame is in a rectangular ring shape And at least one first rail extending in the longitudinal direction and at least one extending in the short direction. A straight perforation formed to remove unnecessary portions, the perforation being formed on at least one of the first crosspiece and the second crosspiece on both side edges. Unnecessary part side edge A method of manufacturing a filter structure that is formed so as to extend continuously to the outer edge of the outer peripheral portion with along, is intended to include the step of perforations are formed by punching from the filter side.

If comprised in this way, when a filter structure is folded and stored in the filter side, it can suppress that a big bending stress generate | occur | produces in a bending part.

According to a third aspect of the present invention, in the configuration of the first aspect of the present invention, the outer periphery of the filter and the frame is provided with a notch at a location where the outer edge and the perforation intersect.

  If comprised in this way, it will become easy to cut off the unnecessary part of a filter structure along a perforation from a notch.

According to a fourth aspect of the present invention, in the configuration of the second aspect of the present invention, the outer periphery of the filter and the frame is provided with a notch at a location where the outer edge and the perforation intersect .

If comprised in this way, it will become easy to cut off the unnecessary part of a filter structure along a perforation from a notch.

As described above, according to the first aspect of the present invention, the deflection rigidity of the outer edge of the filter is improved by the frame, so that the deflection amount of the outer edge of the filter can be reduced. In addition, the perforations formed in the frame body are shortened, and the crosspieces remain along the cut portion, so that cutting is facilitated and the amount of deflection of the filter at the cut portion is reduced. Furthermore, when the filter structure is stored in a valley fold on the filter side, it can be prevented that a large bending stress is generated in the bent portion, so that the filter structure may be carelessly broken at the perforation. Can be prevented.

According to the second aspect of the present invention, when the filter structure is stored in a valley shape on the filter side, it is possible to prevent a large bending stress from being generated in the bent portion. Breaking with eyes can be prevented.

According to a third aspect of the invention, in addition to the effect of the first aspect, it becomes easier to cut the unnecessary portion of the filter structure along the perforation from the notch, thereby enhancing usability.

In addition to the effect of the invention of the second aspect , the invention of the fourth aspect makes it easy to cut out unnecessary portions of the filter structure along the perforation from the notch, so that the usability is improved.

It is the top view which showed the external appearance shape of the filter structure by 1st Embodiment of this invention. FIG. 2 is an enlarged view of a “X1” portion of the filter structure shown in FIG. 1. It is an end elevation of the III-III line of the filter structure shown in FIG. FIG. 4 is an enlarged view of an “X2” portion of the end view shown in FIG. 3. It is an end view of the VV line of the filter structure shown in FIG. FIG. 6 is an enlarged view of an “X3” portion of the end view shown in FIG. 5. It is a typical top view which shows the state which cut off some filter structures shown in FIG. 1 using the perforation. It is the schematic diagram which showed the external appearance of the air conditioner which installs the filter structure shown in FIG. (A) is the front view, (b) is the top view, and (c) is the right side view. It is the enlarged plan view which showed the state which installed the filter structure shown in FIG. 1 in the suction inlet of the air conditioner shown in FIG. It is typical sectional drawing shown about the method of forming the perforation of the filter structure shown in FIG. It is the figure which showed the external appearance shape of the filter structure by 2nd Embodiment of this invention, and is an enlarged plan view corresponding to FIG.

  FIG. 1 is a plan view showing the appearance of a filter structure according to the first embodiment of the present invention.

  First, referring to FIG. 1, a filter structure 1 is a so-called external filter that is attached so as to cover a suction port provided on a top surface of an air conditioner (air conditioner). The filter structure 1 includes a rectangular sheet-like filter 10 formed corresponding to the size of the top surface around the air inlet of an air conditioner (which will be described in detail later), and an acrylic adhesive on one surface of the filter 10. Etc. (see also FIGS. 3 to 6), and a frame body 20 having an outer peripheral portion 21 formed corresponding to the outer edge of the filter 10.

  The filter 10 is composed of a flexible nonwoven fabric or the like, and filters dust, oil stains, and the like contained in the gas sucked from the air inlet of the air conditioner.

  The frame 20 is made of paper such as a coated ball, resin, or the like, and is formed in a sheet shape. Further, the outer peripheral portion 21 of the frame 20 has a rectangular ring shape, and includes a lattice-shaped crosspiece 23 integrally connected to the inner side of the outer peripheral portion 21, and an opening 24 between the lattices. Is formed. A detailed configuration of the crosspiece 23 will be described later. Further, in a plan view as shown in FIG. 1, the filter 10 located on the back side of the frame body 20 can be visually recognized through the opening 24 formed in the crosspiece 23 of the frame body 20.

  If comprised in this way, since the flexural rigidity of the outer edge of the filter 10 improves with the frame 20, the amount of deflection of the outer edge of the filter 10 can be reduced.

  Further, the frame body 20 is provided with a mark 22 on the side aligned with the front direction of the air conditioner. The mark 22 can be triangular as shown in the figure, but any sign can be used without particular limitation as long as it indicates the front of the air conditioner.

  The filter structure 1 includes horizontal perforations 51 to 54 that extend linearly in the longitudinal direction and vertical perforations 61 to 66 that extend linearly in the short direction. The horizontal perforations 51 to 54 and the vertical perforations 61 to 66 are formed so as to extend from one outer edge of the outer peripheral portion 21 of the frame body 20 to the other outer edge, respectively. The configuration of the horizontal perforations 51 to 54 and the vertical perforations 61 to 66 will be described in detail below.

  2 is an enlarged view of the “X1” portion of the filter structure shown in FIG. 1. FIG. 3 is an end view taken along line III-III of the filter structure shown in FIG. 3 is an enlarged view of an “X2” portion of the end view shown in FIG. 3, FIG. 5 is an end view of the VV line of the filter structure shown in FIG. 1, and FIG. 6 is shown in FIG. It is an enlarged view of "X3" part of an end view.

  Referring to these drawings, crosspiece 23 includes horizontal crosspieces 31 to 34 (see FIG. 3) extending in the longitudinal direction and vertical crosspieces 41 to 47 (see FIG. 5) extending in the short direction.

  The horizontal perforations 51 to 54 and the vertical perforations 61 to 66 are formed to remove unnecessary portions from the filter structure 1 in accordance with the size of the top surface portion around the air inlet of the air conditioner.

  The horizontal perforation 51 and the vertical perforation 61 are provided on the first long side 21a (see FIGS. 3 and 4) and the first short side 21c (see FIGS. 5 and 6) of the outer peripheral portion 21, respectively.

  Also, as shown in FIG. 4, the horizontal perforation 52 is formed along the side edge 31a on the first long side 21a side, which is an unnecessary part side during cutting, of both side edges 31a and 31b of the horizontal rail 31. The Since the horizontal perforations 53 and 54 are the same as the horizontal perforations 52, the description thereof will not be repeated here.

  Further, as shown in FIG. 6, the vertical perforation 62 is formed along the side edge 41a on the first short side 21c side, which is an unnecessary part side when cutting, out of both side edges 41a and 41b of the vertical rail 41. The Note that the vertical perforations 63 to 66 are the same as the vertical perforations 62, and therefore, description thereof will not be repeated here.

  With this configuration, the filter 10 is formed with perforations in the longitudinal direction or the lateral direction, while the frame 20 does not have perforations formed in the opening portion. Therefore, the total perforation length formed in the frame 20 is shorter than the perforation length formed in the filter 10.

  For example, since the vertical perforation 62 is provided along the vertical rail 41, the frame body 20 is provided at a portion intersecting with the horizontal rails 31 to 34. In addition, since the opening 24 is sandwiched between adjacent ones of the first long side 21a, the horizontal bars 31 to 34, and the second long side 21b, the length of the perforation formed on the frame body 20 itself is equivalent to this. Shorter. For this reason, since it is only necessary to cut the filter 10 at the portion where the opening 24 is present, the filter structure 1 can be easily cut. In addition, since a crosspiece remains along the cut portion, the amount of deflection of the filter 10 at the cut portion is reduced.

  FIG. 7 is a schematic plan view showing a state in which a part of the filter structure shown in FIG. 1 is cut out using a perforation.

  Referring to FIG. 7, when the size of the filter structure 1 is larger than the size of the top surface portion around the air inlet of the air conditioner to be attached, unnecessary portions are appropriately cut out using perforations. Specifically, the portion on the first long side 21a side and the portion on the first short side 21c side of the outer peripheral portion 21 after cutting the filter structure 1 through the perforation are removed as unnecessary portions.

  For example, as shown in FIG. 7, the vertical perforation 62 (not shown, see FIG. 1) is used to cut and remove the small piece 3 in the direction of arrow A from the filter structure 1, and then the horizontal perforation 52 ( The small piece 4 is cut and removed in the direction of arrow B by using (not shown, see FIG. 1), and the size of the filter structure 1 is adjusted.

  In other words, after cutting the filter structure 1 through the perforation, the target portion 2 that becomes the second long side 21b and the second short side 21d of the outer peripheral portion 21 covers the air inlet of the air conditioner. Used for.

  FIG. 8 is a schematic view showing the appearance of an air conditioner in which the filter structure shown in FIG. 1 is installed. (A) is the front view, (b) is the top view, (c) is the right side view, and FIG. 9 shows the filter structure shown in FIG. It is the enlarged plan view which showed the state installed in the suction inlet of the air conditioner shown in FIG.

  8A to 8C, an air conditioner 70 includes a front panel 71 provided on the front surface of the main body, a suction port 75 having a rectangular shape in plan view provided on the top surface 72, and a front surface. And an air outlet 73 provided downward.

  Further, as shown in FIG. 8B and the like, a guide 74 that is integrally connected to the inside of the top surface portion and extends in the short direction is provided on the top surface portion around the suction port 75. Yes. Further, hook-and-loop fasteners 81 a to 81 d for using the filter structure 1 shown in FIG. 1 for attachment are provided at the four corners of the suction port 75.

  Referring to FIG. 9, when attaching the filter structure 1 to the air conditioner 70, the orientation of the filter structure 1 is adjusted so that the mark 22 of the frame 20 is on the front panel 71 side of the air conditioner 70. Position and attach so that the structure 1 covers the air inlet 75 of the air conditioner 70 and the filter 10 (not shown, see FIG. 1 and the like) is hooked on the hook-and-loop fasteners 81a to 81d. If comprised in this way, in order for the hook_and_loop | surface fasteners 81a-81d to contact the filter 10, it suppresses that the filter 10 slip | deviates, Therefore The attachment to the air conditioner 70 of the filter structure 1 is stabilized.

  Furthermore, some air conditioners have a cleaning robot that automatically cleans the built-in filter in the air conditioner body. In such an air conditioner equipped with a cleaning robot, the built-in filter is exposed from the suction port 75, and the brush member of the cleaning robot operates near the suction port 75 above the air conditioner 70 when cleaning the built-in filter. . When the brush member of the cleaning robot operates for cleaning the built-in filter, there is a possibility that the brush member operating near the suction port 75 may come into contact with the filter 10.

  However, according to the filter structure 1 described above, the amount of deflection of the outer edge of the filter 10 can be reduced, so that the brush member is less likely to contact the filter 10. Moreover, if the filter structure 1 is attached by the hook-and-loop fasteners 81a to 81d as described above, the filter structure 1 can be prevented from being displaced even when the brush member is in contact with the filter 10.

  The top surface 72 of the air conditioner 70 is gently inclined downward toward the front as shown in FIG. For this reason, in order to prevent a gap from being formed between the top surface 72 and the filter structure, it is necessary to use a frame 20 having a thickness that exhibits a bending rigidity that bends along this inclination. More preferred.

  FIG. 10 is a schematic cross-sectional view showing a method for forming the perforation of the filter structure shown in FIG.

  Referring to FIG. 10, first, as shown in (1), the Thomson blade 80 is positioned at the perforation formation position from the filter 10 side with respect to the filter structure 1.

  Next, as shown in (2), the perforation through hole 60 is punched out from the filter 10 side to the frame body 20 in the direction of arrow C by the Thomson blade 80 to form the perforation.

  When the perforation is formed in this way, a protrusion 25 that protrudes toward the frame is formed in the vicinity of the perforated through hole 60. Further, in the vicinity of the protrusion 25, the filter structure 1 can be easily valley-folded on the filter 10 side along the perforation, and when the filter structure 1 is valley-folded on the filter 10 side and stored, Generation | occurrence | production of a big bending stress can be suppressed. For this reason, it is possible to prevent the filter structure 1 from being inadvertently broken at the perforation when the filter structure 1 is stored in a valley fold on the filter 10 side during transportation or sales.

  FIG. 11 is a view showing the external shape of the filter structure according to the second embodiment of the present invention, and is an enlarged plan view corresponding to FIG.

  Since the description is basically the same as that according to the first embodiment, the difference will be mainly described.

  Referring to FIG. 11, in the filter structure 1 according to this embodiment, at the outer peripheral portion 21 of the filter 10 and the frame 20, the outer edge of the outer peripheral portion 21 and the horizontal perforations 51 to 54 intersect. Notches 27a to 27d are provided, and notches 28a, 28b, 28c, 28d,... Are provided at locations where the outer edge of the outer peripheral portion 21 and the vertical perforations 61, 62, 63, 64,. (Although not shown, the same applies to the vertical perforations 65 and 66).

  If comprised in this way, since it becomes easy to cut off the unnecessary part of the filter structure 1 along perforation from notches 27a-27d, 28a-28d, etc., usability improves.

  In the above-described embodiments, the filter structure 1 and the air conditioner 70 having a specific shape, size, and material have been described. However, the filter structure 1 and the air conditioner 70 can be attached so as to cover the air inlet provided on the top surface of the air conditioner. If there is no restriction in particular.

  In each of the above embodiments, the frame has a configuration including a rectangular ring-shaped outer peripheral portion and a grid-shaped crosspiece integrally connected to the inner side of the outer peripheral portion. It is not restricted and should just have an outer peripheral part at least.

  Further, in each of the embodiments described above, the crosspiece is configured to include a plurality of horizontal crosspieces and vertical crosspieces. However, the crosspiece is not limited thereto, and the crosspiece includes at least one horizontal crosspiece (the first crosspiece extending in the longitudinal direction). 1 crosspiece) and at least one vertical crosspiece (second crosspiece) extending in the short direction. Moreover, you may be comprised from one of a horizontal beam and a vertical beam.

  Furthermore, in each of the above-described embodiments, the perforation extends along the side edge on the unnecessary portion side of both side edges for both the specific vertical beam (first beam) and the horizontal beam (second beam). However, it is not limited to this. The perforation only needs to be along the side edge of the unnecessary portion among the side edges of at least one of the vertical beam and the horizontal beam.

  Furthermore, in each said embodiment, although the frame was formed in the sheet form, it is not restricted to this, You may form in the three-dimensional shape.

DESCRIPTION OF SYMBOLS 1 ... Filter structure 10 ... Filter 20 ... Frame body 21 ... Outer peripheral part 24 ... Opening part 25 ... Protrusion part 27a-27d, 28a-28d ... Notch 31-34 ... Horizontal rail 31a, 31b ... Side edge 41-47 ... Vertical bars 41a, 41b ... Side edges 51-54 ... Horizontal perforations 61-66 ... Vertical perforations 70 ... Air conditioners 72 ... Top surface 75 ... Suction port In addition, the same code | symbol in each figure shows the same or an equivalent part.

Claims (4)

A filter structure that is attached to cover the air inlet provided on the top of the air conditioner,
A sheet-like filter that is formed corresponding to the size of the top surface portion around the suction port and has flexibility;
A frame that is attached to one surface of the filter and has at least an outer peripheral portion formed corresponding to an outer edge of the filter;
The filter is formed in a rectangular sheet shape,
The frame includes the outer peripheral portion of a rectangular ring shape, and a lattice-shaped crosspiece integrally connected to the inner side of the outer peripheral portion,
The crosspiece is composed of at least one first crosspiece extending in the longitudinal direction and at least one second crosspiece extending in the short direction,
It further comprises a linear perforation formed to remove unnecessary portions,
The perforation is formed so as to continuously extend to the outer edge of the outer peripheral portion along the side edge on the unnecessary portion side among the side edges of at least one of the first crosspiece and the second crosspiece,
In the perforation, a filter structure in which a protruding portion protruding toward the frame is formed . It is attached to cover the air inlet provided on the top of the air conditioner,
A sheet-like filter that is formed corresponding to the size of the top surface portion around the suction port and has flexibility;
A frame that is attached to one surface of the filter and has at least an outer peripheral portion formed corresponding to an outer edge of the filter;
The filter is formed in a rectangular sheet shape,
The frame includes the outer peripheral portion of a rectangular ring shape, and a lattice-shaped crosspiece integrally connected to the inner side of the outer peripheral portion,
The crosspiece is composed of at least one first crosspiece extending in the longitudinal direction and at least one second crosspiece extending in the short direction,
It further comprises a linear perforation formed to remove unnecessary portions,
The perforation is formed so as to extend along the side edge on the unnecessary portion side among the side edges of at least one of the first crosspiece and the second crosspiece and continuously extend to the outer edge of the outer peripheral portion. A structure manufacturing method comprising:
The manufacturing method of a filter structure including the process of the said perforation being punched and formed from the said filter side. Wherein the outer peripheral portion of the filter and the frame body, the outer edge and the perforation and the cutout at the location of intersection is provided, according to claim 1 filter structure according. The method for manufacturing a filter structure according to claim 2 , wherein a cutout is provided at a location where an outer edge and the perforation intersect at the outer periphery of the filter and the frame .

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