JPH06106013A - Air filter - Google Patents

Abstract

PURPOSE:To improve the dust collection performance of the air filter and to reduce the size of the air filter. CONSTITUTION:The raw fabrics 2, 3 of the air filter 4 constituted by alternately laminating the flat planar raw fabrics 2 and the corrugated raw fabrics 3 and forming the spacings between these raw fabrics as vent paths are subjected to raising in the vent path positions and, therefore, the dust of the air passing these vent paths is removed by the napped parts, by which the dust collecting performance is greatly improved. In addition, the dust collecting performance is greatly improved and, therefore, the size of the air filter 4 is reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air filter incorporated in an air conditioner, an air cleaner or the like.

[0002]

2. Description of the Related Art An example of the structure of an air filter incorporated in an air conditioner or the like is disclosed in Japanese Patent Application Laid-Open No. 4-60320. This air filter heat-bonds a charged fiber to a synthetic resin net to form a non-woven fabric, and from this non-woven fabric, a flat plate-shaped web and a corrugated plate-shaped web are formed. Is configured.

[0003]

In the above-described air filter, if the pitch and the peak height of the corrugated sheet material are made too small, the pressure loss and the noise increase. There was a limit. If the dust collection performance is not improved, the dust collection performance cannot be maintained even if the size is reduced.

The present invention provides an air filter capable of improving dust collecting performance and downsizing.

[0005]

SUMMARY OF THE INVENTION According to the present invention, a flat plate-shaped raw material in which fibers are heat-sealed and a corrugated sheet-shaped raw material in which fibers are heat-sealed are alternately laminated, and In the air filter having the gap as an air passage, the flat plate-shaped original fabric and / or the corrugated plate-shaped original fabric is napped so as to be located in the air passage.

[0006]

In this air filter, since fluffing is provided in the ventilation passage, dust in the air passing through the ventilation passage can be removed at the fluffed portion due to the fluffing.

[0007]

Embodiments of the present invention will be described with reference to the drawings.

In FIGS. 1 and 2, reference numeral 1 denotes a non-woven fabric formed by heat-sealing [heat embossing] polypropylene charging fibers, for example, the basis weight of the charging fibers is 40 to 60.
It is set to g / m ² . And, as this non-woven fabric, those without a dust collecting function such as a reinforcing net are not used,
It is made of only charged fibers. A flat plate-shaped raw fabric 2 and a corrugated plate-shaped raw fabric 3 are formed from a non-woven fabric, and these raw fabrics 2 and 3 are alternately laminated to form an air filter 4. Then, air is caused to flow through the gap between the original fabrics 2 and 3.

The pitch P of the corrugated sheet 3 is 5.0 m.
m, and the mountain height H is set to about 4.0 to 5.0 mm.

Further, the surface of the original fabric, that is, the ventilation passages through which air flows is fluffed, and both sides of the original fabrics 2 and 3 are fluffed by the raised fabric.

In FIG. 3, reference numeral 5 is an air conditioner to be hung on an indoor wall or the like, and 6 is a prefilter detachably attached to the inside of a suction grill, in which a frame and a net are integrally formed. Reference numeral 7 denotes a frame body for holding the air filter, and the air filter is attached together with this frame so as to be detachable. Reference numeral 8 is a heat exchanger, 9 is a drain pan for receiving drainage from the heat exchanger, 10 is a blower fan, and 11 is an outlet.

Next, a method of manufacturing the air filter 4 will be described.

In FIG. 5, reference numerals 20 and 21 are rolls of non-woven fabric that have been electrically charged, 22 and 23 are fluffing machines for raising the rolls, and 24 is corrugated. By changing the size of the blade of the gear, the peak height H and the pitch P [see FIG. 1] can be freely set. Reference numeral 25 is a roller for applying an adhesive to the corrugated sheet material 26, 27 is an adhesive layer, and 40 is a roller for combining the corrugated sheet material 26 and the flat sheet material 28. Numeral 29 is a single-stage body 3 to which the original fabrics 26 and 28 are bonded
It is a winding machine of 0. In this way, the raw fabric raised by the fluffing machine 22 is corrugated by the gear 24, and is bonded to the raw fabric 28 raised by the fluffing machine 23.

In FIG. 6, reference numeral 31 is a one-step body cut into a predetermined size by a cutter.

In FIG. 7, reference numeral 32 is a block of a honeycomb structure in which one-stage bodies 31 are laminated.

In FIG. 8, reference numeral 33 is a holding jig for compressing and adhering the block 32.

In FIG. 9, reference numeral 34 designates a predetermined thickness Z from the block 32 [usually 5 to 15 mm in a domestic air conditioner].
It is a honeycomb structure air filter cut to a degree.

In FIG. 10, 36 is an air filter 34.
It is a cutting jig that cuts to align the ends of the product and to finish it to a specified size.It may be a mechanical cutting jig, a thermal cutting jig, or a jig that uses both of them. Is also good.

In FIG. 11, reference numeral 4 denotes a completed air filter, which is placed on the table 25 or the like and visually inspected to determine whether it is a good product or a defective product.

The air filter 4 of the present invention is produced through the working steps shown in FIGS.

When the air filter 4 is manufactured by such a method, a large number of air filters 4 can be manufactured at once by cutting the block 33, so that the air filter 4 can be manufactured at low cost. Further, the thickness Z and the width L of the air filter 4 can be freely adjusted, and the dust collecting function and the pressure loss can be adjusted depending on the size of the thickness Z.

In the air conditioner 5 in which the air filter 4 as described above is incorporated, the air sucked by the rotation of the blower fan 10 first has a relatively large dust removed by the prefilter 6 on the windward side. Then, finer dust is removed by the air filter 4 on the leeward side of the prefilter, and the cleaned air is cooled or heated by the heat exchanger 8 and blown out from the air outlet 11.

In this case, the air filter 4 is formed in a honeycomb shape and has a large air passage side wall area. The air passage side wall is almost evenly brushed, and fine air particles passing through the air passage are finely woven. Dust is removed at the fluffed portion on the side wall of the ventilation passage. For this reason, the air filter 4 according to the present invention is provided as compared with the conventional air filter which is not brushed.
Then, the dust collection performance can be significantly improved. Moreover, since the dust collection performance is greatly improved, the air filter can be made extremely small as long as it maintains a dust collection function similar to that of the conventional one.

FIG. 4 shows the results of a comparative experiment conducted by incorporating a conventional air filter which is not raised and an air filter 4 of the present invention which is raised in an air conditioner 5. In this experiment, cigarettes were allowed to spontaneously burn in a room of the same size, and the remaining rate of cigarette smoke was measured over time. When the air filter 4 of the present invention is used, the time required for the concentration of cigarette smoke to become half the initial concentration is reduced by about 25% compared to the case where the conventional air filter is used.
It was confirmed that the dust collection performance was significantly improved.

The conventional air filter, which is produced by cutting a large block as shown in FIGS. 9 and 10, without raising hair on the side wall of the ventilation passage, may have some fluff at the cut end. It has also been confirmed that even if the cut ends are greatly fluffed, the air filter has no great difference in dust collection performance from the conventional air filter shown in FIG.

When incorporated in the air conditioner 5, the air purifier, etc., the thickness Z may have to be reduced especially. When the thickness Z is reduced, air is hardly turbulently flown in the honeycomb type air filter and passes through the ventilation passage immediately, so that the dust collecting performance is not large. However, in the air filter 4, the ventilation path is raised, and the fluffed portion disturbs the air and removes fine dust. Therefore, when the thickness Z is small, the dust collection is particularly difficult. It can exhibit high performance.

Further, the improvement of the dust collecting performance can be adjusted by the degree of raising the hair. For example, raising the fluff to increase the fluff greatly improves the dust collection performance, and raising the fluff to decrease the fluff slightly improves the dust collection performance. Furthermore, the pressure loss can be adjusted depending on the degree of raising the hair.

In the air filter 4 of the present invention, the method of mechanically raising the fibers by the fluffing machines 22 and 23 has been described, but the fluffing is caused by changing the temperature at the time of heat-bonding [heat embossing] the charged fibers. You can also Then, by adjusting the temperature at the time of heat fusion, it is possible to adjust the fluffing condition of the charged fibers, so that it is possible to adjust the dust collection performance and the pressure loss.

In this air filter 4, since a member having no dust collecting function such as a reinforcing net is not used, the weight per unit area of the charged fiber can be increased, and the dust collecting performance can be improved by the increased amount per unit weight. You can Thus, the air filter 4 in which the original fabric is composed of only the charged fibers and the original fabric is raised, the dust collecting performance can be greatly improved.

As shown in FIGS. 12 and 13, an air filter 51 may be constructed by using as one of the raw fabrics 50 one side of which is raised.

Further, on the leeward side of the air filters 4, 51 of the present invention, activated carbon which is made of reticulated urethane foam as a base material and whose main particle size distribution range of granular activated carbon is 60 to 100 mesh is described above in a state where its micropores are not damaged. An air filter for deodorization, which is a structure that is fixed and carried on urethane foam, may be arranged. Such an air filter can remove not only fine dust but also indoor odor.

[0032]

Industrial Applicability According to the present invention, a flat plate-like raw material in which fibers are heat-sealed and a corrugated sheet-like original material in which fibers are heat-sealed are alternately laminated, and the air passages between these raw cloths are provided. In the air filter described above, the flat sheet-shaped fabric and / or the corrugated sheet-shaped raw fabric is napped so as to be located in the ventilation passage, so dust in the air passing through the ventilation passage is collected at the fluffed portion. Since it can be removed, the dust collection performance can be greatly improved. Moreover, since the dust collection performance can be significantly improved, the air filter can be downsized.

[Brief description of drawings]

FIG. 1 is an enlarged side view of an air filter showing an embodiment of the present invention.

FIG. 2 is a side view of a main part of the air filter.

FIG. 3 is an explanatory view showing a state where the air filter is incorporated in an air conditioner.

FIG. 4 is a diagram showing a relationship between elapsed time and smoke remaining rate.

FIG. 5 is an explanatory diagram showing step processing.

FIG. 6 is an explanatory view showing a cutting step.

FIG. 7 is an explanatory diagram showing a laminating step.

FIG. 8 is an explanatory diagram showing a press drying step.

FIG. 9 is an explanatory diagram showing a cutting step.

FIG. 10 is an explanatory diagram showing an end cutting step.

FIG. 11 is an explanatory diagram showing an inspection process.

FIG. 12 is an enlarged side view of an air filter showing another embodiment of the present invention.

FIG. 13 is a side view of a main part of the air filter.

[Explanation of symbols]

 2 Flat plate-shaped roll 3 Corrugated plate-shaped roll 4 Air filter 50 Roll 51 Air filter

Claims (1)

[Claims] 1. An air filter in which a flat plate-shaped raw material in which fibers are heat-sealed and a corrugated plate-shaped raw material in which fibers are heat-sealed are alternately laminated, and an air passage is formed as a gap between these raw material sheets. At
An air filter, wherein the flat plate-shaped raw material and / or the corrugated plate-shaped raw material is provided with naps located in the ventilation passage.