JPH0427888B2 - - Google Patents

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention is applicable to air temperature control equipment, air purification equipment,
The present invention relates to a method for manufacturing an air cleaning net, that is, a dust net for an air cleaner in equipment that moves air such as a ventilation fan, and a mold used for manufacturing the same.

<Prior art> Conventionally, dust nets for this type of air cleaner are generally flat plate-shaped, and are used by being installed inside equipment with the flat plate surface perpendicular to the air passage, obstructing air circulation. ing. On the other hand, as typified by automobile oil purifiers, there are also known oil purifiers in which the purifying surface is not flat but has a chrysanthemum-shaped cylindrical zigzag wave shape.

The present invention relates to an air dust net, such as the latter, in which the net forming the air purifying surface is formed in a one-dimensional zigzag wave shape.

<Problems to be Solved by the Invention> The latter conventional flat-shaped net has a small air filtration area, and while it is clean, air passes through easily, resulting in poor filtration efficiency and a predetermined amount of dust adhering to the net surface. Then, there was a problem in that dust accumulated rapidly, blocking the passage of air and making it difficult.
In order to avoid this drawback, as in the latter method, a method in which the net is bent in one dimension so that the cross-sectional shape has a zigzag wave shape has already been conceived with the aim of increasing the cleaning surface of the net. It has been implemented. However, when the net has a zigzag wave shape like this, it cannot be attached to the frame unless a core wire such as wire is inserted and sewn into the entire outer periphery of the net material itself. There were problems in that it took time and effort to attach the wire by suturing it, and it was difficult to mass-produce it, resulting in an expensive product.

For example, Japanese Patent Application Laid-open No. 50-149748 and
In order to solve this problem, Japanese Patent Publication No. 60-41517 discloses that a frame made of a synthetic resin material is integrally injection molded around the peripheral edge of a sheet-like filter medium folded into a corrugated shape, thereby creating a frame made of a net material. Improvement plans for simplifying the installation work have been described, but all of them are aimed at pleated filter media in which the flat filter media has been preprocessed to form a large number of zigzag wave-shaped folds. However, since the work of preparing the formwork and applying the corrugations still remains, there was a limit to the improvement of work efficiency.

Furthermore, Japanese Patent Application Laid-open No. 63-16021 discloses that, at the same time, wave-shaped folds are formed in a flat filter medium by a group of wedge-shaped blades that face each other and are movable relative to each other.
A method is described in which the peripheral edge of the filter medium is attached to the frame by sandwiching and fitting the pleated filter medium between a female half and a male half that are constituent elements of the frame. To do this, the female half and the male half must be prepared separately in advance, which requires mold production and molding work, and the male and female halves must be assembled to form a frame. This posed the problem of requiring complex and expensive equipment for drive and control, which naturally limits improvements in work efficiency and reductions in manufacturing costs.

In order to solve these conventional problems, the present invention aims to prevent the fraying of the net by casting the entire outer periphery of the net into a synthetic resin material, and at the same time to reduce the casting work. Simultaneously with the manufacture of the frame, the flat net material itself is formed into a zigzag wave shape and shaped all at once. By having a structure in which the entire outer peripheral edge portion is embedded within the frame, the purpose is to improve beauty and work efficiency in the manufacturing process.

<Means for Solving the Problems> The structure of the present invention for achieving the object will be explained using FIGS. 1 to 11 corresponding to the embodiments. This is an invention of a method, which comprises a cleaner net 2 formed of natural fiber or a synthetic resin material with a high melting point and having an uneven wave shape in cross section, and a frame body 1 made of a synthetic resin material with approximately the same melting point or a low melting point. , regarding the manufacture of a dust net for an air cleaner in which the entire outer periphery of the cleaner net 2 is cast and embedded in the frame 1, the flat material 2 of the cleaner net 2 is
a is slightly wider than the width of the cleaner action, and the cleaner net material 2a is formed with a large number of uneven corrugations a, b, which are divided into upper and lower parts and fit into each other.
c...n, and at least one of the upper and lower molds 11 and 21 has an uneven waveform a,
It is placed between the upper and lower molds B which are divided into parts b, c...n so that they can be moved relatively freely, and each uneven waveform a, b, c is placed between the upper and lower molds B.
A desired unit mold of n is moved to fit with the other opposing mold 21 or 11, and then a unit mold adjacent to the fitted unit mold is moved to fit the other mold. 21 or 11, and by sequentially fitting all the unit molds to the other mold 21 or 11 in this way, the cleaner net material 2a is bent into a concave and convex wave shape, and at the same time it is shaped. The inner part adjacent to the entire outer periphery and the entire periphery of the cleaner net 2 bent and formed in this manner are firmly clamped between the upper and lower molds 11 and 21, and the cleaner net 2 and the entire outer periphery are strongly clamped. The peripheral edge portion is not clamped in the frame body forming cavities 13, 14 formed by the upper and lower molds 11, 21, or in the protruding cavities 13a, 14a formed continuously on the inner surfaces of the cavities 13, 14. After the cleaner net 2 is positioned, a synthetic resin material having a lower melting point than that of the material forming the cleaner net 2 is injected into these cavities, cured, and then taken out to obtain a product. Moreover, the second invention is
This is an invention of a mold used for carrying out the above method, which is a composite of a cleaner net 2 formed of natural fiber or a synthetic resin material with a high melting point and having an uneven wave shape in cross section, and a cleaner net 2 having approximately the same melting point or a low melting point as the cleaner net 2. Regarding a mold for producing a dust net for an air cleaner, which consists of a frame body 1 made of a resin material, and in which the entire outer periphery of the cleaner net 2 is cast and embedded in the frame body 1, the mold is divided into upper and lower parts. A large number of concave and convex waveforms a, b, c...n that fit into each other are formed on opposing surfaces, and the concave and convex waveforms a, b of at least one of the upper and lower molds 11 and 21 are , c...n are formed separately for each waveform so as to be relatively movable, and the structure is such that a desired unit mold of each of these uneven waveforms a, b, c...n can be individually moved during use. It is equipped with a split mold B for bending and shaping a flat cleaner net material 2a into a cleaner net 2 having an uneven wave shape in cross section, and at least one of these uneven wave shapes a, b, c...n. Both end portions in the longitudinal direction and the outermost corrugated portion are formed by molds 11,
Cleaner net material 2 in mating position 21
The gap is slightly smaller than the thickness opposite to the thickness of a, and is formed in the gap that tightly clamps the net material 2a, and the longitudinal outer end side position and outermost side of each of these uneven waveforms a, b, c...n A frame body forming cavity 13 is provided at the entire outer circumferential portion including the outer position of the corrugated portion.
14 is formed.

<Function> Since the present invention is configured using such a method and mold, the net material may be flat, and the finished product has a beautiful appearance as a whole. Since the outer peripheral edge portion of the net 2 is embedded in the inner peripheral surface of the frame 1, the net does not fray or become distorted, and the zigzag shape is not disturbed. In addition, the process from zigzag processing of flat net material to commercialization can be performed in a single process, resulting in a homogeneous product, which can be expected to have the advantage of being suitable for mass production. It is.

<Examples> Examples of the present invention will be described below based on the drawings. First, the manufacturing method of the first invention will be explained.

1 to 11 are diagrams showing a first embodiment of the present invention, and FIGS. 1 to 6 and 7 to 10 respectively show molds separated in the order of manufacturing steps. A sectional view of the zigzag unevenness direction of the part corresponding to the -section shown in FIG. 7 and the linear direction of the part corresponding to the -section shown in FIG. FIG.

First, to explain mold B, mold (B)
It consists of a two-split mold consisting of an upper mold 11 and a lower mold 21, and as shown in FIGS. 1 and 7, it is formed into a zigzag uneven triangular wave shape in the direction shown in FIG. 1 (hereinafter referred to as the uneven direction). , are formed linearly in the direction shown in FIG. 7 (hereinafter referred to as the linear direction). In this embodiment, the upper mold 11 is placed inside the outer frame 11'.
Thirteen convex waveforms a, b, c...m are formed, and each of the convex waveforms is separately formed so as to be able to move up and down relatively. Waveform (a', b', c'...l') and external waveform 21
', 21'', and are similarly divided into parts so that they can be moved relative to each other.Thus, in the longitudinal direction of these two molds 11, 21, the intermediate parts 12, 22 excluding only both end portions are In the fitted posture of both (the posture shown in FIGS. 4 and 8), the gap is slightly smaller than the gap corresponding to the thickness of the cleaner net material 2a, and the net material 2a is held under strong pressure. As shown in FIGS. 1 and 7, voids 14a and 24a for forming the net end holding protrusions 4a with large gaps are provided along these uneven shapes at both end portions in the direction, respectively, and the upper mold 11 is provided with gaps 14a and 24a for forming the net end holding projections 4a. A void section 14, 14 for forming one opposing side frame 4, 4 in series with the void section 14a is formed on the outside thereof, and a horizontally elongated void section 15, 15 for forming the fitting plate section 5, 5 is formed below it. It has been formed.
Both outer parts of the lower mold 21 are formed in the horizontally elongated gaps 15, 15.
A flat wall 25 is formed in a state that closes the.

Further, at both end portions in the uneven direction, as shown in FIG.
1 has a vertical wall 23 and a flat wall 26 forming the inner wall surface and lower surface of the side frames 3, 3.

The cleaner net material 2a is a net fabric made of vinylidene chloride resin monofilament with a softening temperature of 185 to 200°C, which is usually called Saran (trademark), and is braided into a net shape.As shown in FIG. The upper and lower molds 11 and 2 having the above-described structure are pulled out by the clamping and drawing tool 6 through the guide 7.
1 and lowering the unit waveform mold g located in the middle part of the upper mold 11,
The unit waveform mold at the intermediate position of the lower mold 21 facing this
f' and g' are raised, the middle part of the net material 2a is strongly clamped and shaped into a V shape as shown in FIG. After lowering h, both adjacent unit waveform molds e' and h' of the lower formwork 21 are raised, and all the unit waveform molds are successively lowered and raised, as shown in Fig. 3. Outer waveform mold 2 at half of both end positions of mold 21
1' and 21'' are raised, the winding drum 2b side of the cleaner net material 2a is cut with a cutter (K), the outer frame 11' of the upper mold 11 is lowered, and the cleaner net material 2a is placed in the upper and lower molds. 11 and 21 into an uneven wave shape, and both ends in the uneven direction are located in the cavity 13 as shown in FIG. 4, and both ends in the width direction of the cleaner net material 2a are As shown in FIG.
Then, as shown in Figures 5 and 9, hard vinyl chloride resin with a melting temperature of 100 to 120°C is injected into the entire cavity formed by these upper and lower molds 11 and 21. , take it out after curing.

The molded product molded as described above becomes a finished product A without requiring any post-processing.

In the air cleaner dust net A thus formed, as shown in FIGS. 6, 10, and 11, both longitudinal end portions of the net portion 2 formed in an uneven shape are connected to the frame body 1. The protrusions 4a, 4a are molded into triangular wave-shaped protrusions 4a, 4a having inclined surfaces 41, 42 that are continuous and protrude from one opposing side wall 4, 4 of the frame 1, and both end portions in the concave and convex direction are connected to the other side of the frame 1. It has a structure in which it is embedded and held in the interior of the opposing side walls 3, 3 in a cast-like manner.

FIG. 12 to FIG. 13 show another embodiment (second embodiment) of the mold B. In the first embodiment, both the upper and lower molds 11, 21 are formed with each uneven waveform ( a, b, c...m, a', b', c'...l') are divided into waveforms and made relatively movable. In this embodiment, the upper and lower molds 11 and 21 are change direction,
Only the upper mold 11 is made movable by being divided into concave and convex waveforms, and the entire lower mold 21 is formed into a series of molds. In this way, both the upper and lower molds 11,
After placing the cleaner net material 2a cut to a predetermined length between the parts 21 and 21, it is lowered from the unit mold g in the center of the upper mold 11, and the cleaner net material 2a is placed in the middle in the length direction of the cleaner net material 2a as shown in FIG. Place the part into the bottom mold 2
In this order, the unit molds f and h are bent and held in a V-shape between the molds 1 and 1, and then both adjacent unit molds f and h are lowered.
The cleaner net material 2a is sequentially formed into a concave and convex wave shape, and the resin for forming the frame is injection molded into the cavity formed by the upper and lower molds 11 and 21, as in the first embodiment. This is what I did.

The third embodiment shown in FIGS. 14 to 16 is
Mold B formed in the same manner as in the second embodiment
This shows an example in which a different implementation method is carried out using the drive roller 8.
After the cleaner net material 2a is wound and fed out between the upper and lower molds 11 and 21 from the drum 2b as shown in FIG. 14 as shown in FIG. As shown, the cleaner net material 2a is lowered from the outer mold 11'' on one end side (right side in the figure) of the upper mold 11, and then successively lowered from the adjacent unit molds m, l, k, . . . It is sequentially bent into a concave and convex wave shape, held and shaped, and during this time the feed rollers 8, 8
The vertically moving roller 8' has moved upward so that the cleaner net material 2a can be freely fed out in the required amount from the winding drum 2b. Therefore, the cleaner net material 2a is cut, and finally, the left outer mold 11' is lowered, and as shown in FIG. It will be done. The subsequent steps are the same as in the first embodiment.

Even with these methods, the manufacturing method according to the present invention can be carried out, and the dust net according to the present invention can also be manufactured.

17 to 18 respectively show other embodiments of the waveform shape of the wave cleaner net 2, the one in FIG. 17 has an uneven waveform with a curved cross-sectional shape, and the one in FIG. 18 has a trapezoidal wave shape. Further, FIGS. 19 to 21 respectively show other embodiments of the embedding structure between the frame body 1 and the outer peripheral edge portion of the corrugated cleaner net 2, and the one in FIG. The outer edge portion of is shaped to protrude laterally outward, and is cast into a protrusion 3a formed to protrude toward the inner surface of the side wall 3 of the frame 1, as shown in Fig. 20. 21 has a structure in which the outer end portion of the corrugated cleaner net 2 in the flat direction is directly buried within the thickness of the side wall 4 of the frame 1, and the structure shown in FIG. 21 has a structure in which it is buried over the entire width of the side wall 4 That is. The present invention can be implemented with such a structure, and when compared with the embodiments shown in FIGS. 1 to 18 and 20 to 21, the structure in FIG. Although the edge portion of the net 2 embedded in the body side wall protrusion 3a is somewhat easy to pull out, there is an advantage that the mold structure and manufacturing process can be simplified.

The shape of the frame 1 according to the present invention is shown as being rectangular in plan view in the first embodiment, but it may be square, circular, elliptical, etc. In the case of a rectangular shape, the net 2 may have a structure in which the concave and convex directions are provided along the longitudinal direction. Further, the cleaner net material 2a is not limited to being made of monofilament, but may be made of twisted monofilament, or may be made of nonwoven fabric.
Furthermore, the material is not limited to vinylidene chloride, but may also be polypropylene, polyester, or natural fiber.
In short, any material with a high melting point that does not melt during frame molding may be used. In addition to the above-mentioned vinyl chloride resin, ABS, polystyrene resin, and other synthetic resin materials with relatively low melting points are selected as the molding material for the frame 1.

Although the embodiments considered to be representative of the present invention have been described above, the present invention is not necessarily limited to the methods or structures of these embodiments, and the present invention is not necessarily limited to the methods or structures of these embodiments. This invention can be implemented with appropriate modifications within the scope of achieving the objectives mentioned above and having the effects mentioned below.

<Effects of the Invention> As is already clear from the above description, the dust net formed by the method of the present invention has a zigzag uneven wave shape in cross section, but the dust net has a zigzag uneven wave shape in cross section. Since the peripheral part is directly embedded in the wall of the frame in a cast-like manner, the cleaner net can be left as a flat material, and there is no need to process the net itself, making it easy to incorporate into the frame. Even though no machining is required, the net is reliably shaped into the required waveform, and its entire circumference is firmly held by the frame.
It is possible to obtain a dust net that is strong and has a large cleaner area, which does not fray or distort its shape, and which does not come out of the frame even when subjected to external impact, and in addition, it is possible to obtain such a dust net by using the mold of the present invention. In particular, by the method of the present invention, a homogeneous product can be obtained extremely easily and in a single process using a flat net material that has not been processed into a corrugated shape, and is suitable for mass production and can be provided to the market at a low price. As a result, we can now expect remarkable results.

[Brief explanation of drawings]

1 to 11 show a first embodiment of the present invention, and FIGS. 1 to 6 are a mold separation posture and a mold movement start posture of a portion corresponding to the − cross section in FIG. 7. , cross-sectional views of the posture immediately before the final mold movement, the mold assembly completion posture, the resin injection posture, and the taken-out product posture, respectively. FIGS. 7 to 10 are the mold separation posture of the − cross-section corresponding portion in FIG. FIG. 11 is a partially cutaway perspective view of the molded dust net, and FIGS.
3 is a sectional view of the mold separation posture in the uneven direction and the upper mold movement start posture showing the second embodiment, and FIGS. 14 to 16 are sectional views of the mold separation posture in the uneven direction and the top 17 to 21 are longitudinal sectional views showing different embodiments of the molded product, and FIGS.
18 and 18 are respectively central vertical sectional views in the uneven direction, FIG. 19 is a partially cutaway vertical sectional view of the same, and FIGS. 20 and 21 are partially cutaway vertical sectional views in the longitudinal direction. In the figure, numeral 1 is a frame body, 2 is a cleaner net,
2a is the cleaner net material, 11 is the upper mold, 21
is the lower mold, 13, 14, 13a, 14a are cavities, A is the dust net, B is the mold, a, b, c...
n is an uneven waveform.

Claims (1)

[Scope of Claims] 1. A flat cleaner net material 2a made of natural fiber or high-melting point synthetic resin is formed into upper and lower molds 11, 21 each having a large number of corrugated corrugations a, b, c...n that fit into each other. At least one of 11 and 21 is disposed between upper and lower molds B which are formed separately for each uneven waveform a, b, c...n so as to be relatively movable, and the mold B
In the method of embedding the entire outer periphery of a cleaner net 2 having an uneven wave shape in cross section and shaped into an uneven wave shape in a frame 1 made of a synthetic resin material having approximately the same melting point or a low melting point as the cleaner net, The entire periphery of the inner part adjacent to the entire outer periphery of No. 2 is firmly clamped by the mold B, and the entire outer periphery is formed into a frame body forming cavity 13 formed by the mold B. , 14 or in the protruding cavities 13a, 14a formed in series on the inner surfaces of the cavities 13, 14 in a non-sandwiched position, the synthetic resin material having a lower melting point than the material forming the cleaner net 2 is placed. A method for manufacturing a dust net for an air cleaner, which comprises injecting a dust net into these cavities, curing it, and then taking it out. 2. The method for producing a dust net for an air cleaner according to claim 1, wherein the low melting point synthetic resin material is a resin selected from the group consisting of vinyl chloride resin and ABS resin. 3. The method for producing a dust net for an air cleaner according to claim 1, wherein the cleaner net material 2a is made of a material selected from the group consisting of monofilament, twisted monofilament, and nonwoven fabric. 4. The method for producing a dust net for an air cleaner according to claim 1, wherein the cleaner net material 2a is made of resin fiber selected from the group consisting of vinylidene chloride and polypropylene. 5. The method of manufacturing a dust net for an air cleaner according to claim 1, wherein the portion where the cleaner net material 2a is strongly clamped by the upper and lower molds 11, 21 is the entire inner surface of the net material 2a excluding the outer peripheral edge portion. 6. The device according to claim 1, wherein the portion where the cleaner net material 2a is strongly clamped by the upper and lower molds 11, 21 is only a predetermined width portion of the entire inner circumferential surface of the net material 2a adjacent to the outer peripheral edge portion. A method for manufacturing dust nets for air cleaners. 7 A large number of concave and convex waveforms a, b, c... that fit into each other
Molds 11 and 21 divided into upper and lower parts consisting of n
At least one of the molds 11 or 21 is formed into sections such that they can move relatively freely for each of the uneven waveforms a, b, c...n, and when used, each of the uneven waveforms a, b, c...n The cleaner net 2 has a structure in which desired unit molds can be moved individually, and is made of a flat cleaner net material 2a made of natural fibers or a synthetic resin material with a high melting point and has an uneven wave shape when viewed in cross section.
In a split mold for bending and shaping, at least the longitudinally opposite end portions and the outermost waveform portion of each of these uneven waveforms a, b, c...n are formed by the fitting of the upper and lower molds 11 and 21. The entire outer periphery is formed in a gap that strongly holds the cleaner net material 2a in the posture, and includes the longitudinal outer end position of each of these uneven waveforms a, b, c...n and the outer position of the outermost waveform part. Cleaner net material 2 on the part
A mold for producing a dust net for an air cleaner, characterized in that cavities 13 and 14 for forming a frame are formed of a synthetic resin material having approximately the same melting point or a low melting point as that of a. 8 Cavity 1 for embedding the cleaner net material 2a on the inner side of the frame body forming cavities 13 and 14
8. The mold for producing a dust net for an air cleaner according to claim 7, wherein 3a and 14a are formed in a continuous manner. 9. Molding for manufacturing a dust net for an air cleaner according to claim 7, wherein the frame body forming cavities 13 and 14 have a shape selected from the group consisting of a square, a rectangle, and a circle in plan view. Mold.