JP7364753B1 - Pleated air filter manufacturing device and pleated air filter manufacturing method - Google Patents

Abstract

An object of the present invention is to provide a manufacturing apparatus that can relatively easily manufacture a pleated air filter with a high degree of freedom in shape.
A pleated air filter manufacturing apparatus 100 according to the present invention includes a filter fixing jig 20 provided with a plurality of convex portions 22, and a part of a bellows-shaped filter material 10 set in the filter fixing jig 20. It is equipped with a head 53 that compresses and welds. The plurality of convex portions 22 are provided with groove portions 29 located between the plurality of convex portions 22 . The head 53 is a head corresponding to the outer edge (23, 24) of the filter fixing region 25 constructed by the plurality of convex parts 22 in the filter fixing jig 20.
[Selection diagram] Figure 1

Description

The present invention relates to a pleated air filter manufacturing apparatus and a pleated air filter manufacturing method. In particular, the present invention relates to a manufacturing apparatus and a manufacturing method capable of manufacturing pleated air filters having curved shapes or complicated shapes, or pleated air filters having shape flexibility.

Conventionally, various air filters have been incorporated into air cleaners, air lines of automobiles, and clean rooms in order to remove dust contained in the air (see Patent Document 1, etc.). A conventional pleated air filter has a structure in which a filter material is bent into a bellows shape, as shown in Patent Document 1, for example. Specifically, a conventional pleated air filter has an end plate attached to the end of a filter material bent into a bellows shape using an adhesive.

Japanese Patent Application Publication No. 11-267436

FIG. 18 shows a pleated air filter 1000 studied by the inventor of the present application. The pleated air filter 1000 shown in FIG. 18 is composed of a filter material 112 bent into a bellows shape, and pleated filter end plates 119 adhered to the end surfaces (four sides) of the filter material 112. Grooves 115 are formed in the filter material 112 at equal intervals. Since the pleated filter end plate 119 supports the four sides (four side edges), the pleated air filter 1000 can maintain a firm and flat shape.

Pleated air filters that are popular today have a rectangular (or square) shape as shown in FIG. This is because it is extremely difficult to make the ends of pleated air filters curved or diagonal. The explanation will be continued below.

FIG. 19 schematically shows a pleated air filter 1100 in which the upper end of the filter material 112 has an arcuate shape 133. Note that the arcuate shape 133 is a schematic representation of a shape in which the arcuate shape and the groove portion (unevenness) 115 are easily understood.

Here, in order to manufacture the pleated air filter 1100 shown in FIG. 19, it is necessary to prepare the planar material (developed view) 1110 before folding shown in FIG. 20 and fold the planar material 1110. . At first glance, the end portion 135 of the planar material 1110 seems to be regular, but in reality, the left and right sides 131 and 132 of the end groove 139 are irregular in angle and length. It is extremely difficult to produce the flat material 1110 by accurately cutting the sides 131 and 132 of such an irregular pattern. In other words, it is not realistic to cut the left and right sides 131 and 132 of the end groove 139 uniformly and regularly at first, and then forcefully create the arc-shaped end 133 shown in FIG. 19 by changing the folding method. I can't do it.

In FIGS. 19 and 20, the pleated air filter 1100 having an arcuate shape 133 has been described, but in the case of a pleated air filter 1100 having a rectangular shape cut diagonally (for example, along the diagonal line 113 shown in FIG. 18). Similarly, the developed view of a pleated air filter (in the case of a shape cut by cutting) will be complicated. FIG. 21 is an example of a development view for assembling a pleated air filter in which a rectangular filter is cut diagonally (for example, a line 113 diagonal to the parallel lines of the rectangle). Specifically, FIG. 21 shows a pattern of edges 135 of planar blank 1110, which also differs from the pattern of edges 135 shown in FIG. When manufacturing a pleated air filter that is not rectangular but has a shape (triangle, trapezoid, etc.) that has a diagonal end face (diagonal line), a complicated development view (flat material 1110) that matches the shape and structure is created each time ( cutting) and assembling is not practical, and the left and right sides 131 and 132 of the end groove 139 are initially cut uniformly and regularly, and then somehow forced into a shape with oblique end faces depending on the folding method. In reality, it is not possible to create a pleated air filter (triangular, trapezoidal, etc.).

Furthermore, in the pleated air filter 1000, since the pleated filter end plates 119 support on all sides (four side edges), a firm and flat shape can be maintained. On the other hand, the pleated air filter 1000 does not have shape flexibility, and the pleated air filter 1000 can only be set in a filter storage part with a flat structure. Today, there are products with various shapes such as convex parts, concave parts, curved surfaces, curved parts, and wavy parts, and if only a filter storage part with a flat structure could be provided, this would impose constraints on product design. Very unfavorable. In other words, it would be a great advantage to be able to produce pleated air filters that have the flexibility to change the shape of products with various shapes such as convex parts, concave parts, curved surfaces, curves, and undulations. Moreover, it is meaningless if the manufacturing cost is high, and it is preferable that the manufacturing is easy.

The inventor of the present application has been exploring whether it is possible to easily produce not only the rectangular pleated air filter 1000 but also a pleated air filter having curved or diagonal end portions. Furthermore, we also investigated whether it would be possible to produce a flexible pleated air filter relatively easily. Under such circumstances, the idea of the present invention was conceived and the present invention was completed.

The present invention has been made in view of the above, and its main purpose is to relatively easily manufacture pleated air filters having curved or diagonal end portions and/or flexible pleated air filters. It is an object of the present invention to provide a manufacturing apparatus and a manufacturing method that can be manufactured.

An air filter manufacturing apparatus according to the present invention is an air filter manufacturing apparatus that manufactures a pleated air filter, and includes a filter fixing jig having a plurality of convex portions corresponding to the pitch of the pleated air filter, and a filter fixing jig having a plurality of protrusions corresponding to the pitch of the pleated air filter. It is equipped with a head that compresses and welds a part of the bellows-shaped filter material set in the tool. The plurality of convex portions include a groove portion located between the plurality of convex portions. The head corresponds to an outer edge of a filter fixing area constructed by the plurality of convex portions of the filter fixing jig.

In a preferred embodiment, the head has a collective welding part that welds the outer edge of the filter fixing area all at once.

In a preferred embodiment, the plurality of convex portions of the filter fixing jig are arranged at regular intervals on the filter fixing plate. At least a part of the outer edge of the filter fixing area has a curved shape.

In a preferred embodiment, the plurality of convex portions of the filter fixing jig are arranged at regular intervals on the filter fixing plate. The outer edge of the filter fixing area has a diagonally lined portion.

In a preferred embodiment, the filter fixing plate is made of wood, and a metal plate member is arranged on the filter fixing plate.

In a preferred embodiment, each end of the plurality of convex portions has a tapered shape.

In a preferred embodiment, the head is connected to a mechanism that can be raised and lowered, and the head has a replaceable configuration.

A preferred embodiment further includes a filter cutting jig that cuts unnecessary portions of the bellows-shaped filter material all at once along the outer edge of the filter fixing region.

The air filter manufacturing method according to the present invention is an air filter manufacturing method for manufacturing a pleated air filter, in which a bellows-shaped The method includes a step of arranging a filter material, and a step of welding a part of the bellows-shaped filter material arranged on the filter fixing jig. The filter fixing jig has a filter fixing area constructed by the plurality of convex parts, and at least a part of the outer edge of the filter fixing area has at least a part of a curved shape and a diagonal line shape. ing. In the welding step, at least a portion of the bellows-shaped filter material is welded along the outer edge of the filter fixing region.

In a preferred embodiment, in the welding step, a portion along the outer edge of the filter fixing region is welded all at once.

In a preferred embodiment, each end of the plurality of convex portions has a tapered shape. In the step of welding, an inclined portion is formed at a portion of the bellows-shaped filter material corresponding to the end portion having the tapered shape.

In a preferred embodiment, after the welding step, a step of cutting out an unnecessary portion of the bellows-shaped filter material is performed.

In a preferred embodiment, in the step of cutting off the unnecessary portion, the unnecessary portion is cut off all at once using a filter cutting jig that corresponds to the shape of the outer edge of the filter fixing region.

In a preferred embodiment, after the cutting step, a step of attaching a flexible protective material to the welded portion of the bellows-shaped filter material is performed.

The air filter manufacturing method according to the present invention is an air filter manufacturing method for manufacturing a pleated air filter. and a step of welding a part of the bellows-shaped filter material placed on the filter fixing jig. The filter fixing jig has a filter fixing area constructed by the plurality of convex parts. In the welding step, at least a portion of the bellows-shaped filter material is welded all at once along the outer edge of the filter fixing region.

In a preferred embodiment, each end of the plurality of convex portions has a tapered shape. In the step of welding, an inclined portion is formed at a portion of the bellows-shaped filter material corresponding to the end portion having the tapered shape.

In a preferred embodiment, after the welding step, the bellows-shaped filter material is bent.

In a preferred embodiment, after the welding step, the bellows-shaped filter material is formed into a cylindrical shape.

The pleated air filter according to the present invention includes a bellows-shaped filter material having a convex portion and a welded portion formed around the bellows-shaped filter material. The pleated air filter is bendable in the thickness direction along a direction perpendicular to the direction in which the convex portion extends.

In a preferred embodiment, an inclined portion is formed at an end of the convex portion of the bellows-shaped filter material.

In a preferred embodiment, the welded portion is formed all around the periphery of the bellows-shaped filter material.

In a preferred embodiment, at least a portion of the outer edge of the bellows-shaped filter material surrounded by the welded portion has at least one of a curved shape and a diagonal shape.

In a preferred embodiment, the pleated air filter has a cylindrical shape.

The pleated air filter manufacturing apparatus according to the present invention includes a filter fixing jig having a plurality of convex portions corresponding to the pitch of the air filter, and a head for welding a part of the bellows-shaped filter material. At least a part of the outer edge of the filter fixing region constructed by the convex portions has a curved shape and/or a diagonal shape. Therefore, by welding the bellows-shaped filter material along the outer edge of the filter fixing region, an air filter having curved and/or diagonal end portions can be produced relatively easily.

Further, in the method for manufacturing a pleated air filter according to the present invention, a bellows-shaped filter material is placed on a filter fixing jig having a plurality of convex portions, and then a part of the bellows-shaped filter material is welded. The filter fixing jig has a filter fixing area constructed by a plurality of convex parts, and in the welding process, the bellows-shaped filter material is welded all at once along the outer edge of the filter fixing area (25). do. Thereby, a pleated air filter having flexibility can be produced relatively easily.

1 is a perspective view showing the configuration of a pleated air filter manufacturing apparatus 100 according to an embodiment of the present invention. It is a diagram showing the configuration of a pleated filter fixing jig 20 according to the present embodiment. It is a figure showing the composition of bellows-shaped filter material 10 concerning this embodiment. It is a flow chart explaining the pleated air filter manufacturing method concerning this embodiment. It is a figure for demonstrating the process of compressing and welding a part of bellows-shaped filter material 10. FIG. 7 is a diagram for explaining the process of attaching the protective material (18, 19) to the crimp portion 35 of the bellows-shaped filter material 10. 1 is a perspective view showing the configuration of a pleated air filter manufacturing apparatus 50 according to an embodiment of the present invention. 1 is a perspective view showing the configuration of a pleated air filter manufacturing apparatus 50 according to an embodiment of the present invention. It is a figure showing the composition of cutting jig (cutter) 60 concerning this embodiment. It is a diagram showing the configuration of a pleated air filter 101 according to an embodiment of the present invention. It is a figure showing the composition of pleated cylindrical air filter 200 concerning an embodiment of the present invention. FIG. 1 is a perspective view showing the configuration of a pleated air filter 101 according to an embodiment of the present invention. It is a diagram showing the configuration of a pleated filter fixing jig 20 according to the present embodiment. FIG. 2 is a perspective view showing the configuration of a pleated filter fixing jig 20 according to the present embodiment. FIG. 2 is a perspective view showing the configuration of a pleated filter fixing jig 20 according to the present embodiment. FIG. 1 is a perspective view showing a configuration in which a pleated air filter 101 according to an embodiment of the present invention has a corrugated shape. FIG. 1 is a perspective view showing a configuration of a pleated air filter 101 according to an embodiment of the present invention in a semicircular shape (in a curved state). 1 is a diagram showing the configuration of a pleated air filter 1000 studied by the inventor of the present application. FIG. 3 is a diagram showing the configuration of a pleated air filter 1100 in which the upper end of the filter material 112 has an arcuate shape 133. It is a figure which shows the plane material (developed view) 1110 of the pleated air filter 1100 before bending. It is a figure which shows the plane material (developed view) 1110 before bending in the pleated air filter of the shape which has a diagonal line.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the following drawings, in order to simplify the explanation, the same reference numerals are given to members and parts that have the same function, and overlapping explanations may be omitted or simplified. Further, the dimensional relationships (length, width, thickness, etc.) in each figure may not necessarily accurately reflect the actual dimensional relationships. Additionally, matters other than those specifically mentioned in this specification that are necessary for implementing the present invention can be understood as matters designed by those skilled in the art based on the prior art in the field. The present invention can be implemented based on the contents disclosed in this specification and drawings and common general technical knowledge in the field. In addition, the present invention is not limited to the following embodiments.

FIG. 1 is a diagram (perspective view) schematically showing the configuration of a pleated air filter manufacturing apparatus 100 according to an embodiment of the present invention. Further, FIG. 2 shows a filter fixing jig 20 for fixing a bellows-shaped filter material (10) in manufacturing a pleated air filter. FIG. 3 is a diagram (top view) showing the configuration of the bellows-shaped filter material 10 of this embodiment.

First, as shown in FIG. 1, the pleated air filter manufacturing apparatus 100 of this embodiment includes a filter fixing jig (pleated filter fixing jig) 20, and a bellows-shaped filter material set in the filter fixing jig 20. It is provided with a head 53 that compresses and welds a part of 10. The head 53 is attached as part of the crimping machine 50. Further, as shown in FIG. 2, the filter fixing jig 20 includes a plurality of convex portions 22 corresponding to the pitch of the air filter (pleated air filter).

The bellows-shaped filter material 10 of this embodiment has a structure in which the filter material is folded into a bellows shape, as shown in FIG. The bellows-shaped filter material 10 is formed in a pleated shape, thereby increasing the surface area per volume and improving the filter performance (filtration performance). Specifically, the bellows-shaped filtration material 10 is produced by folding the filtration material 15 so that a filter convex portion (mountain portion including a ridgeline) 12 is formed. The filter protrusions 12 of this embodiment are spaced at equal intervals (or regular intervals), and the pitch is, for example, 2 mm to 10 mm (5 mm±0.5 mm in one example), but is not limited thereto. isn't it. Furthermore, in the configuration of this embodiment, the bellows-shaped filter medium 10 and the filter medium 15 are made of a resin material (for example, polyethylene (PE), polypropylene (PP), vinyl chloride resin (PVC), nylon (PA), etc.), Preferred examples include polyethylene (PE) and polypropylene (PP).The thickness of the filter material 15 is, for example, 0.5 mm to 3.0 mm (1.0 mm±0.2 mm in one example). However, it is not limited to this.

In the filter fixing jig 20 shown in FIG. 2, the pitch of the pleated air filter (here, the pitch of the filter convex portions 12 of the bellows-shaped filter material 10 shown in FIG. 3) is set on the filter fixing plate 21. ) are formed. The filter fixing plate 21 is a member that fixes the plurality of convex parts 22. The filter fixing plate 21 of this embodiment is made of, for example, wood, a metal material, or a resin material, but is not limited thereto, and may be made of other materials (such as a ceramic material). Further, the plurality of convex portions 22 are made of, for example, a metal material, a resin material, or wood, but are not limited thereto, and may be made of other materials (such as a ceramic material). The filter fixing plate 21 made of wood has the advantage of being inexpensive and lightweight. Note that if the part that the head 53 contacts and presses is made of a material that is weak against heat or a material that absorbs vibrations, a member made of a heat-resistant material (for example, metal or thermosetting resin) may be fixed to the filter. It is preferable to use it by attaching it to the plate 21.

In the configuration of this embodiment, the plurality of convex portions 22 are provided with groove portions 29 located between the plurality of convex portions 22 . The filter convex portion 12 of the bellows-shaped filter material 10 is accommodated in this groove portion 29 . In other words, the plurality of protrusions 22 are accommodated in the filter recesses (grooves between the filter protrusions 12) of the bellows-shaped filter material 10.

Further, the filter fixing jig 20 of this embodiment is provided with a filter fixing region 25 constructed by a plurality of convex portions 22. The outer edges (23, 24) of the filter fixing region 25 have a curved shape (23). To explain using the example shown in FIG. 2, the upper outer edge 23 of the filter fixing region 25 in the filter fixing jig 20 has an arcuate curve. The lower outer edge 24 of the filter fixing region 25 in the filter fixing jig 20 is linear. The filter fixing area 25 of this embodiment is not limited to that shown in FIG. The outer edge 23 may be a combination of curved lines and straight lines, or may be composed of only straight lines (for example, diagonal lines (lines inclined with respect to the ridge line 12t)).

The pleated air filter manufacturing apparatus 100 shown in FIG. 1 includes a crimping machine 50. The crimping machine 50 is a device (for example, an ultrasonic welding device, a high frequency welding device, etc.) that can heat and pressurize at the same time. In the illustrated example, the crimping machine 50 is an ultrasonic welding device. In the air filter manufacturing apparatus 100 shown in FIG. 1, an ultrasonic welding main body 55 that supports the ultrasonic head 53 is located above the ultrasonic head 53. ) is provided with a handle 57. A mechanism (cylinder) that can be moved up and down is provided in the ultrasonic welding main body 55, and the head 53 is connected to the mechanism (cylinder) that can be moved up and down. By operating the handle 57, the height of the ultrasonic head 53 can be adjusted to accommodate pleated filters of various thicknesses. By pressing the switch 52, the ultrasonic head 53 descends and applies the pressure and ultrasonic vibration force (the object pressurized by the ultrasonic vibration vibrates) that has been set in advance on the ultrasonic welding main body 55 to generate heat. The energy generated and welded and hardened) is applied to the bellows-shaped filter material 10, and a part of the bellows-shaped filter material 10 set in the filter fixing jig 20 can be compressed and ultrasonically welded. In the configuration of this embodiment, the switch 52 can be used with both hands, but it may be one (one-handed).

In the example shown in FIG. 1, a filter workbench 51 on which the filter fixing jig 20 is placed is provided below the ultrasonic head 53. In the configuration of this embodiment, a filter fixing jig 20 is arranged on a filter workbench 51, and a metal member 30 (for holding a bellows-shaped filter material (pleated filter material) 10) is placed on the pleated filter fixing jig 20. A paperweight or filter holding member) 30 is placed thereon. The metal member 30 has a function of suppressing the amplitude. Further, in the illustrated configuration example, a switch 52 for turning on and off the operation of the ultrasonic head 53 is provided below the filter workbench 51. The metal member 30 may be placed under the bellows-shaped filter medium 10. When the filter fixing plate 21 in the filter fixing jig 20 of this embodiment is made of wood, placing the metal member 30 under the bellows-shaped filter material 10 prevents vibrations and energy from the head 53 (welding The metal member 30 absorbs the hardening energy), contributing to successful crimping and welding.

Next, the air filter manufacturing method of this embodiment will be described with reference to FIGS. 4 to 6. FIG. 4 is a flowchart for explaining the air filter manufacturing method of this embodiment. Moreover, FIGS. 5 and 6 are process diagrams (partially enlarged top views) for explaining the air filter manufacturing method, and schematically show the structure of the bellows-shaped filter material 10 in order to express the process in an easy-to-understand manner. There is.

First, a bellows-shaped filter material (pleated filter material) 10 as shown in FIG. 3 is prepared (step S100). Next, the bellows-shaped filter material 10 is set in the filter fixing jig 20 (step S200). Specifically, the bellows-shaped filter material 10 is set so that the recesses of the bellows-shaped filter material 10 are fitted into the plurality of projections 22 of the filter fixing jig 20 as shown in FIG. In other words, the filter convex portion 12 of the bellows-shaped filter material 10 is fitted into the groove portion 29 of the filter fixing jig 20 . In this way, the bellows-shaped filter material 10 is fixed onto the filter fixing jig 20.

Next, with the bellows-shaped filter material 10 placed on the filter fixing jig 20, the ultrasonic head 53 is used to move along the outer edges (23, 24) of the filter fixing area 25 made up of the filter protrusions 12. Then, the bellows-shaped filter material 10 is ultrasonically welded (step S220). Specifically, as shown in FIG. 5, a region (curved end) corresponding to the outer edge (curved end) 23 of the filter fixing region 25 of the bellows-shaped filter material 10 placed on the filter fixing jig 20 Ultrasonic welding is performed along 33 to form a crimped region 35. Similarly, ultrasonic welding is performed along a region (straight edge) 34 corresponding to the outer edge (straight edge) 24 of the filter fixing region 25 to form a crimp region 35. The outside of this crimp area 35 becomes an unnecessary portion 37. In addition, FIG. 5 shows how the area (straight edge) 34 corresponding to the outer edge (straight edge) 24 of the filter fixing area 25 is crimped up to the middle of the area (straight edge) 34 by ultrasonic welding, and then the straight edge 34 is crimped. The remaining parts will also be ultrasonically welded.

The conditions for ultrasonic welding in this embodiment are, for example, a pressure of 0.35 MPa, an output of 600 W, an amplitude time (ultrasonic generation time) of 0.7 seconds, and a HOLD (cooling time) of 1 second, but are not limited to these. Rather, a suitable one can be adopted as appropriate depending on the characteristics and structure of the finished pleated filter. Welding strength does not increase or decrease due to a synergistic effect by increasing pressure, output, and amplitude time, but increases or decreases depending on the material type and thickness and the balance between pressure, output, and amplitude time. As a result, if the strength is weak, the shape cannot be maintained, and if it is too strong, the bellows-shaped filter material (pleated filter material) 10 will melt, but in the case of ultrasonic welding, the default conditions and method of the ultrasonic welding machine are used. By making adjustments according to the following, it is possible to obtain appropriate conditions. In addition, in the configuration of this embodiment, the ultrasonic head 53 whose contact surface (crimping) is approximately rectangular (or approximately square) is used to form the crimping area 35 by dividing the ultrasonic welding into multiple times to make it easier to understand the process. However, within the capabilities of the ultrasonic welding machine, an ultrasonic head 53 having a shape (structure) corresponding to the outer edges (23, 24) of the pleated filter fixing area 25 was manufactured, and the ultrasonic head 53 was used to The crimp area 35 can be formed (at one time). As the head 53 (collective head) of this embodiment, for example, in the case of a curved line, a head with a maximum width of 120 mm x 240 m can be constructed, and in the case of a straight line, a head with a width of 10 mm and a width of 350 mm or less can be constructed. Yes, but the range will vary depending on the equipment used.

Next, after performing ultrasonic welding along the regions (33, 34) corresponding to the outer edges (23, 24) of the filter fixing region 25 to form the crimping region 35, unnecessary portions 37 are cut away (step S240). ). The unnecessary portion 37 can be cut out along a part of the crimp region 35 (for example, the central portion or the outer edge of the crimp region 35) using a cutting tool (cutter, scissors, etc.). Alternatively, the unnecessary portion 37 can be removed by cutting (or cutting) in one (batch) process using a filter cutting jig that corresponds to the shape of the outer edges (23, 24) of the filter fixing region 25. It is possible to do this. In this way, the pleated air filter of this embodiment can be obtained.

Note that, subsequently, after removing the unnecessary portion 37, as shown in FIG. 6, the protective material 18 (18a, 18b) can be attached to the crimping region 35 (step S300). In the illustrated example, a protective material 18a having a similar curved shape is attached to the crimping area 35 (upper side) having a curved shape (13), and a similar linear protective material 18a is attached to the crimping area 35 (lower side) having a linear shape (14). A protective material 18b is attached. When the protective material 18 is made of a flexible material (for example, urethane foam, expanded foam, or other flexible material), the shape flexibility of the pleated air filter 101 can be maintained. In the pleated air filter 101 of this embodiment, since the pleated filter end plate 119 of the pleated air filter 1000 shown in FIG. Can be flexibly deformed. If the protective material 18 shown in FIG. 6 is flexible, the pleated air filter 101 can be easily changed in the thickness direction.

The air filter manufacturing apparatus 100 of this embodiment includes a filter fixing jig 20 having a plurality of convex portions 22 corresponding to the pitch of the pleated air filter, and a head that compresses and welds a part of the bellows-shaped filter material 10. 53. The outer edges (23, 24) of the filter fixing region 25 constructed by the plurality of convex portions 22 can have various shapes such as curved lines and diagonal lines. Therefore, by welding the bellows-shaped filter material 10 with the head 53 along the outer edge of the pleated filter fixing region 25, pleated air filters 101 having end faces with various shapes such as curved lines and diagonal lines can be produced relatively easily. can do.

FIG. 7 shows another configuration of the pleated air filter manufacturing apparatus 50 according to this embodiment. The head 53A (53) in the air filter manufacturing apparatus 50 shown in FIG. 7 includes a batch welding part 59 that welds the outer edge of the filter fixing area (25) all at once. The collective welded portion 59 has a shape corresponding to the outer edge of the pleated air filter 101 (the outer edge of the welded portion 35 and the filter fixing region (25)) as shown in FIGS. 5 and 6. When the shape of the outer edge of the pleated air filter 101 changes, the shape of the collective welded portion 59 changes accordingly. Further, the head 53 has a replaceable structure.

FIG. 8 shows another configuration of the pleated air filter manufacturing apparatus 50 according to this embodiment, in which the crimping part (welding part) of the head 53B is linear. Using this head 53B, the diagonally shaded end (the welded part 35, the outer edge of the filter fixing region (25)) can be manufactured. In addition, the air filter manufacturing apparatus 50 shown in FIG. ), it is also possible to produce the outer edge (welded part 35, outer edge of the filter fixing region (25)) of the pleated air filter 101 as shown in FIGS. 5 and 6. The combination can be determined according to the outer edge of the pleated air filter 101 (the outer edge of the welded portion 35 and the filter fixing region (25)).

FIG. 9 schematically shows the configuration of a filter cutting jig 60 that cuts the unnecessary portion (37) all at once. The filter cutting jig 60 includes a cutting blade (cutter) 62 corresponding to the outer edge of the pleated air filter 101 (the outer edge of the crimping region (welding portion) 35 and the filter fixing region (25)). The cutting blade 62 of this embodiment is arranged on the cutting blade support 61. The illustrated cutting blade 62 is composed of a combination of a curved part 62a and a straight part 62b. It is also possible to use a structure in which the curved part 62a and the straight part 62b are connected (integrated).

When cutting the unnecessary part (37) all at once, the bellows-shaped filter material 10 having the unnecessary part (37) and the crimped area (welded part) 35 is placed on the filter cutting jig 60, and in this state, the press machine By pressing with a , unnecessary parts can be removed all at once. Alternatively, a method may be used in which the cutting blade 62 is moved to cut the unnecessary portion (37). By using such a filter cutting jig 60 that can be removed all at once, the unnecessary portion (37) of the bellows-shaped filter material 10 can be efficiently removed, and throughput can be improved.

Next, the air filter manufacturing method and air filter of this embodiment will be described with reference to FIGS. 10 and 11. FIG. 10 is a diagram (plan view) showing the configuration of the air filter 101 according to this embodiment. Moreover, FIG. 11 is a diagram (perspective view) showing the configuration of the cylindrical air filter 200 of this embodiment.

The air filter 101 shown in FIG. 10 includes a crimping region 38 in which the outer periphery of the bellows-shaped filter material 10 (pleated filter material) shown in FIG. 3 is welded (ultrasonic welding). Specifically, after preparing the filter fixing jig 20 shown in FIG. The material 10 is placed and then crimped by the head 53 along areas (16, 17) corresponding to the outer edge of the filter fixing area 25. Then, the air filter 101 shown in FIG. 10 is manufactured.

The pleated air filter 200 shown in FIG. 11 is obtained by rolling the pleated air filter 101 shown in FIG. 10 into a cylindrical shape and fixing it (by bonding, crimping, etc.). The reason why such a cylindrical shape can be manufactured is that the air filter 101 shown in FIG. 10 has flexibility, and the air filter 1000 shown in FIG. 18 can be manufactured into a cylindrical shape. I can't.

FIG. 12 is a perspective view of the air filter 101 shown in FIG. 10. The air filter 101 of this embodiment can be curved along the thickness direction 91 (see arrow 90). Thereby, a cylindrical air filter 200 as shown in FIG. 11 can be easily constructed. Here, the thickness direction 91 is the vertical direction (vertical direction) when the air filter 101 is arranged horizontally. Further, the direction of curving (arrow 90) is the thickness direction 91 along the direction (93) perpendicular to the direction 92 in which the convex portion 12 (ridge line 12t) extends. In the direction 92 in which the convex portion 12 (edge line 12t) extends, the convex portion 12 acts as a structural resistance and cannot be curved or is difficult to curve.

Further, in the air filter 101 of the present embodiment, it is sufficient that a crimped part (welded part) 38a extending at least along the long side 16 (in the direction of arrow 93) is formed; It is preferable that an extending crimped portion (welded portion) 38b is also formed. When the crimped parts (welded parts) 38 (38a, 38b) are present so as to surround the entire periphery (16, 17), the shape of the region (filter region) 15 where the plurality of convex parts 12 are present is made more stable. be able to. Note that depending on the structure of the filter storage section (not shown) that stores the air filter 101, the crimp portion 38a may be located along the long side 16 (arrow 93), and the crimp portion 38a may be located along the short side 17 (arrow 92). In some cases, the air filter 101 may be provided without the crimp portion 38b.

Furthermore, in the air filter 101 of this embodiment, the inclined portion 19 is formed at the end of the convex portion 12 of the bellows-shaped filter material 10. This inclined portion 19 is provided to prevent force (tension) from being applied to the end portion of the convex portion 12 when forming the crimp portion 38 (38a), thereby preventing the portion from tearing or becoming thin. The inclined portion 19 will be further explained with reference to FIGS. 13 and 14.

13 and 14 are a top view and a perspective view, respectively, of the filter fixing jig 20 for manufacturing the air filter 101 shown in FIG. 12. In the filter fixing jig 20 shown in FIGS. 13 and 14, the end of the convex portion 22 has a tapered structure, and an inclined surface 27 is formed. Further, a metal member (metal plate) 30 (30A) is arranged on the filter fixing plate 21 at a position corresponding to the crimped part (welded part) 38 (38a) of the bellows-shaped filter material 10. The metal member 30 may be fixed or movable.

When the thickness (upper surface height) of the metal member 30 is set to the middle of the height of the convex portion 22, the position of the crimping portion 38 is equal to the thickness of the air filter 101 (distance between the front ridge line 12t and the back ridge line 12t). Located in the middle. In other words, the crimp portion 38 can be positioned at the center of the thickness of the air filter 101 with respect to the thickness direction 91. The position of the crimp part 38 is set within a range of ±15% from the center of the thickness of the air filter 101 (for example, within a distance of ±15% from the center line between the front ridge line 12t and the back ridge line 12t). (within a distance of ±10% from the line), it is possible to keep the force (tension, etc.) applied to the convex portion 22 after crimping constant, which is preferable in terms of shape stability and lifespan. Furthermore, by adjusting the thickness (upper surface height) of the metal member 30, it is possible to form the reference crimp portion 38 at a desired position in the thickness direction 91.

When the bellows-shaped filter material 10 is placed on the filter fixing jig 20 shown in FIG. 14 and is crimped (welded) with the head 53, the filter material 10 including the unnecessary part 37 (see FIG. 5) is formed as shown in FIG. 12. A convex portion 12 is obtained. Here, since an inclined part (tapered part, chamfered part) 27 is formed in the convex part 22 of the filter fixing jig 20 shown in FIG. An inclined portion (tapered portion, chamfered portion) 19 is also formed at the end portion of 12 . The angle θt of the inclined portion (tapered portion) 27 of the convex portion 22 (here, the angle between the upper surface and the inclined surface) is, for example, 5° to 25° (10° in one example), but is not limited thereto. It's not something you can do. An inclined surface 19 having a corresponding angle θt is formed at the end of the convex portion 12 of the bellows-shaped filter material 10. Depending on how the head 35 is crimped (welded), the angle (slanted shape) may not be completely the same, but the sloped surface 19 of the convex portion 12 roughly corresponds to the sloped portion (tapered portion) 27 of the convex portion 22. is obtained. Furthermore, in the illustrated example, the inclined surfaces 27 (inclination angle θt) at both ends of the convex portion 22 of the fixing jig 20 are the same, but they may be different. Unless there is a special reason, it is preferable to use the same one because it will be symmetrical.

Here, in the case where the end of the convex part 12 of the bellows-shaped filter material 10 shown in FIG. (or approximately right angle). In other words, the angle between the top surface and the side surface (wall surface) of the convex portion 22 of the filter fixing jig 20 is 90 degrees (or approximately a right angle). In that case, when crimping is performed, the bellows-shaped filter material 10 located at the 90° corner will be pulled excessively by the crimping compared to other parts, and may be damaged or thinned. , there is a possibility that it will be torn. On the other hand, in the configuration of this embodiment, since there is an inclined surface (tapered surface) 27 at the corner between the upper surface and the side surface (wall surface) of the convex part 22 of the filter fixing jig 20, when crimping is performed, the 90° Compared to the case of a corner of 100°, it is possible to reduce excessive force (tension). As a result, damage, thinning, and tearing can be prevented. Therefore, the strength of the air filter 101 of this embodiment (especially the strength of the end portion (19) of the convex portion 12) can be improved, and the life of the air filter 101 can be extended.

FIG. 15 is a perspective view of a filter fixing jig 20 corresponding to the configuration shown in FIG. Also in the filter fixing jig 20 shown in FIG. 15, an inclined surface (tapered surface) 27 is formed at each end (corner) of the convex portion 22. In the illustrated filter fixing jig 20, a metal member 30 may be arranged.

Although FIG. 15 shows the filter fixing jig 20 corresponding to the configuration shown in FIG. area) can be changed. When it is desired to make the outer edge shape of the air filter 101 circular, it is preferable to make the filter fixing region 25 of the filter fixing jig 20 circular. When the outer edge shape of the air filter 101 is desired to be triangular, trapezoidal, hexagonal, etc., the filter fixing area 25 of the filter fixing jig 20 is correspondingly shaped into a triangular, trapezoidal, hexagonal, etc. shape. In the case of triangles, trapezoids, hexagons, etc., there are parts whose outer edges are diagonally lined (see diagonal line 13 in FIG. 10), so there is a great advantage in manufacturing by the method of this embodiment. That is, by using the method of this embodiment, even the air filter 101 having diagonal lines can be easily manufactured.

In addition, in the pleated air filter manufacturing method of this embodiment, after the bellows-shaped filter material 10 is placed on the filter fixing jig 20 having the convex portions 22, a part of the bellows-shaped filter material 10 is welded. The filter fixing jig 20 has a filter fixing region 25, and in the welding process, the bellows-shaped filter material 10 is crimped (welded) along the outer edge of the filter fixing region 25, as shown in FIG. A flexible air filter 101 as shown can be manufactured relatively easily. Therefore, the air filter 101 shown in FIG. 12 can be deformed (curved) to form a wavy air filter 102 as shown in FIG. 16. Alternatively, a semicircular (approximately semicircular) air filter 103 as shown in FIG. 17 may be used. In addition, in FIG. 17, the convex portion 12 (ridge line 12t) located on the back surface side is omitted. According to the method of this embodiment, it is possible to handle even if the filter housing part (not shown) of the product is not flat but has a complicated shape. By using (102, 103), it is possible to respond flexibly. Furthermore, even if the filter storage part (not shown) of the product is not rectangular (rectangle, square) but has a complicated shape (even if it has curved lines and/or diagonal lines), the air filter of this embodiment 101 etc. can be handled flexibly.

Furthermore, by using a welding device 50 as shown in FIG. 7, it is convenient to perform the welding process all at once. In addition, by using a filter removal jig 60 as shown in FIG. 9, unnecessary portions 37 can be conveniently removed all at once.

Furthermore, as described above, according to the air filter manufacturing method of this embodiment, in addition to flat and curved filters, the cylindrical air filter 200 can also be manufactured by further performing curving. The technical advantage of easily manufacturing the cylindrical air filter 200 is also very large.

The non-flexible pleated filter 1000 shown in FIG. 18 has many restrictions on equipment for removing various types of dust contained in the air, and is further restricted to a rectangular shape. According to the method of this embodiment, it is possible to easily (and inexpensively) manufacture a pleated filter that is free from such restrictions and has a large degree of freedom in design. Further, in the pleated filter 1000 shown in FIG. 18, it was necessary to attach the pleated filter end plate 119 with adhesive, which was time-consuming. According to the method of this embodiment, such materials (filter end plate 119, adhesive) are not used, so material costs and manufacturing costs can be reduced. Furthermore, when combining or further processing non-flexible pleated filters 1000 to create a complex three-dimensional structure, a material other than the filter material may be used to fix such a complex shape. This requires a lot of effort and effort, and furthermore, the use of a material other than the filter material is unfavorable from the viewpoint of pressure loss performance. That is, the use of a material other than the filter material makes it difficult for the filter to come through, which adversely affects the filter characteristics. On the other hand, according to the method of this embodiment, materials not related to the filter performance are not used, so compared to that, the filter does not become difficult to pass through, and the cost performance and ecological performance are also improved. can be improved.

Although the present invention has been described above using preferred embodiments, such description is not a limitation, and of course, various modifications are possible. Furthermore, the features of the embodiments described above can be mutually applied. For example, an inclined surface 27 can be provided at the end of the convex part 22 of the filter fixing jig 20 shown in FIG. It is also possible to use a configuration without surface 27.

According to the present invention, it is possible to provide a manufacturing apparatus and a manufacturing method that can relatively easily manufacture a pleated air filter having curved or diagonal end portions and/or a pleated air filter having flexibility.

10 Bellows-shaped filter material (pleated filter material)
12 Filter convex portion 15 Filter material 18 Protective material 19 Inclined portion (tapered portion)
20 Filter fixing jig 21 Filter fixing plate 22 Convex portion (multiple convex portions)
23 Outer edge (curved edge)
24 Outer edge (straight edge)
25 Filter fixing area 27 Inclined surface (tapered surface)
29 Groove 30 Paperweight 33 Curved end 34 Straight end 35 Crimping area 37 Unwanted part 38 Crimping area 50 Welding device 51 Filter workbench 52 Switch 53 Head 55 Welding main body 57 Handle 59 Bulk welding part 60 Filter removal jig 61 Cutting blade support part 62 Cutting blade 100 Air filter manufacturing device 101 Pleated air filters 102, 103 Pleated air filter 200 Cylindrical air filter

Claims (14)

An air filter manufacturing device for manufacturing pleated air filters,
A filter fixing jig equipped with a plurality of convex portions corresponding to the pitch of a pleated air filter having a structure in which a filter material is folded into a bellows shape;
a head for compressing and welding a part of the bellows-shaped filter material set in the filter fixing jig;
The plurality of convex portions include a groove portion located between the plurality of convex portions,
The head is a head corresponding to an outer edge of a filter fixing area constructed by the plurality of convex parts of the filter fixing jig,
Each end of the plurality of convex portions has a tapered shape ,
The head has a collective welding part that welds the outer edge of the filter fixing area all at once,
The collective welding portion is the outer edge located on the outside of each end of the plurality of convex portions, and extends in a direction perpendicular to the direction in which the ridge lines of the plurality of convex portions extend. Air filter manufacturing equipment that has a shape that corresponds to the part . The air filter manufacturing apparatus according to claim 1, wherein the plurality of convex portions of the filter fixing jig are arranged at regular intervals on the filter fixing plate. The filter fixing plate is made of wood;
The air filter manufacturing apparatus according to claim 2, wherein a metal plate member is arranged on the filter fixing plate. The head is connected to a mechanism that can be raised and lowered,
The air filter manufacturing apparatus according to any one of claims 1 to 3 , wherein the head has a replaceable configuration. The air filter production according to any one of claims 1 to 3 , further comprising a filter cutting jig that cuts unnecessary parts of the bellows-shaped filter material all at once along the outer edge of the filter fixing area. Device. An air filter manufacturing method for manufacturing a pleated air filter, the method comprising:
arranging a bellows-shaped filter material on a filter fixing jig having a plurality of convex portions corresponding to the pitch of a pleated air filter having a structure in which the filter material is folded into a bellows shape;
Welding a part of the bellows-shaped filter material placed on the filter fixing jig,
The filter fixing jig has a filter fixing area constructed by the plurality of convex parts,
In the welding step, at least a portion of the bellows-shaped filter material is welded all at once along the outer edge of the filter fixing region,
Each end of the plurality of convex portions has a tapered shape,
In the step of welding, an inclined portion is formed in a portion of the bellows-shaped filter material corresponding to the end portion having the tapered shape ,
In the welding step, a portion along the outer edge of the filter fixing area is welded all at once;
A portion along the outer edge of the filter fixing region is located outside each end of the plurality of convex portions and extends along a direction perpendicular to the direction in which the ridge lines of the plurality of convex portions extend. The air filter manufacturing method corresponds to the above . 7. The air filter manufacturing method according to claim 6 , further comprising cutting off an unnecessary portion of the bellows-shaped filter material after the welding step. 8. The air filter manufacturing method according to claim 7 , wherein in the step of cutting off the unnecessary portion, the unnecessary portion is cut off all at once using a filter cutting jig corresponding to the shape of the outer edge of the filter fixing region. 9. The air filter manufacturing method according to claim 7, further comprising: attaching a flexible protective material to the welded portion of the bellows-shaped filter material after the cutting step. 7. The air filter manufacturing method according to claim 6, further comprising bending the bellows-shaped filter material after the welding step. 7. The air filter manufacturing method according to claim 6, further comprising forming the bellows-shaped filter material into a cylindrical shape after the welding step. A pleated air filter having a structure in which a filter material is folded into a bellows shape,
a bellows-shaped filter material having a convex portion;
A welded part formed around the bellows-shaped filter material,
The pleated air filter is bendable in a thickness direction along a direction perpendicular to the direction in which the convex portion extends,
An inclined portion is formed at the end of the convex portion of the bellows-shaped filtering material, and is formed by compressing a part of the bellows-shaped filtering material.
The pleated air filter is characterized in that the welded portion is located outside the end of the convex portion and is formed along a direction perpendicular to the direction in which the convex portion extends. The pleated air filter according to claim 12 , wherein the welded portion is formed all around the circumference of the bellows-shaped filter material. The pleated air filter according to claim 12 or 13 , wherein the pleated air filter has a cylindrical shape.

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