JPH0838834A - Manufacture of filter - Google Patents
Manufacture of filterInfo
- Publication number
- JPH0838834A JPH0838834A JP19759494A JP19759494A JPH0838834A JP H0838834 A JPH0838834 A JP H0838834A JP 19759494 A JP19759494 A JP 19759494A JP 19759494 A JP19759494 A JP 19759494A JP H0838834 A JPH0838834 A JP H0838834A
- Authority
- JP
- Japan
- Prior art keywords
- filter
- fiber
- filter medium
- bonding
- corrugated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Filtering Materials (AREA)
- Filtering Of Dispersed Particles In Gases (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は，不織布よりなるフィル
タの製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a filter made of non-woven fabric.
【０００２】[0002]
【従来技術】自動車用エンジン等の内燃機関の吸気系に
は，吸気した空気に含まれるゴミ，埃等を取り除くため
のエアフィルタが設けてある。上記エアフィルタは，ケ
ースとキャップとよりなりなるハウジングと，該ハウジ
ング内に装着したフィルタとよりなる。2. Description of the Related Art An intake air system of an internal combustion engine such as an automobile engine is provided with an air filter for removing dust and dirt contained in the intake air. The air filter includes a housing including a case and a cap, and a filter mounted inside the housing.
【０００３】そして，上記フィルタは，不織布よりなる
濾材をひだ状，波状，プリーツ状と呼ばれる形状に折り
曲げた濾過エレメントと，該濾過エレメントの外周を保
持し，ハウジングへの装着を補助するための樹脂枠とよ
りなる。また，上記樹脂枠の更に外周には，樹脂枠とハ
ウジングとの間のシール性を確保するために，ゴムより
なるシール部材が設けられている。即ち，上記樹脂枠と
シール部材とによって，上記フィルタはハウジングに対
して装着可能になる。The filter is formed by bending a filter material made of a non-woven fabric into a shape called a pleated shape, a wavy shape, or a pleated shape, and a resin for holding the outer periphery of the filter element and assisting mounting to the housing. It consists of a frame. Further, a seal member made of rubber is provided on the further outer periphery of the resin frame in order to secure a sealing property between the resin frame and the housing. That is, the filter can be attached to the housing by the resin frame and the seal member.
【０００４】以下に，上記濾過エレメントの，従来の製
造方法について説明する。まず，後述するスパンボンド
法等により製造されたシート状の基布の上に，ポリエス
テル，レーヨン等からなる濾材繊維を積層する。上記濾
材繊維が積層された基布に対し，ニードルパンチによる
繊維結合処理を加え，基布と濾材繊維，及び濾材繊維同
士の間で繊維をからみあわせてこれらを結合させる。次
に，基布と濾材繊維にバインダを含浸させ，乾燥する。
これによりシート状の濾材を得る。次に，上記濾材をひ
だ折り加工し，所望の長さに切断する。そして，上記濾
過エレメントに，別工程において成形した樹脂枠，シー
ル部材を組みつけて，フィルタとする。A conventional method for manufacturing the above-mentioned filtration element will be described below. First, a filter medium fiber made of polyester, rayon or the like is laminated on a sheet-shaped base fabric manufactured by a spunbond method or the like described later. The base fabric on which the filter medium fibers are laminated is subjected to a fiber-bonding treatment with a needle punch, and the base fabric, the filter medium fibers, and the filter medium fibers are entangled with each other to bond them. Next, the base cloth and the filter medium fibers are impregnated with a binder and dried.
As a result, a sheet-shaped filter medium is obtained. Next, the filter medium is pleated and cut to a desired length. Then, the filter element is assembled with the resin frame and the seal member molded in another step to form a filter.
【０００５】[0005]
【解決しようとする課題】しかしながら，上記フィルタ
においては，濾過エレメントと樹脂枠とシール部材と
を，異なる材料からなる別部品として製造しなくてはな
らない。また，上記濾過エレメントは材料となる濾材の
製造工程と，該濾材より濾過エレメントを成形する工程
とがまったくの別工程となっている。このため，従来の
濾過エレメントの製造は繁雑で，手間がかかる。以上の
理由から製造コストが高くなる。However, in the above filter, the filter element, the resin frame, and the seal member must be manufactured as separate parts made of different materials. Further, in the above-mentioned filter element, the manufacturing process of the filter medium as a material and the process of molding the filter element from the filter medium are completely different processes. Therefore, the manufacturing of the conventional filter element is complicated and time-consuming. For the above reasons, the manufacturing cost becomes high.
【０００６】また，濾材より濾過エレメントを成形する
際に，折り曲げ部は内側で繊維が圧縮され，空気が通ら
なくなり，濾過性能を低下させていた。Further, when the filter element is molded from the filter material, the fibers are compressed inside the bent portion, and air is not passed therethrough, which deteriorates the filtering performance.
【０００７】本発明は，かかる問題点に鑑み，安価に製
造可能であって，同一材料で構成され，かつ濾過性能に
優れた，フィルタの製造方法を提供しようとするもので
ある。In view of the above problems, the present invention aims to provide a method of manufacturing a filter which can be manufactured at low cost, is made of the same material, and has excellent filtering performance.
【０００８】[0008]
【課題の解決手段】本発明は，得ようとするフィルタの
片側面の形状に沿った型面を有する成形型を用い，該成
形型の表面に濾材繊維を供給すると共に付着させて第一
中間体を形成する濾材繊維供給工程と，上記第一中間体
における濾材繊維を互いに結合させて第二中間体を形成
する繊維結合工程と，上記第二中間体を上下方向よりプ
レスして，所望するフィルタ形状に成形する成形工程と
よりなることを特徴とするフィルタの製造方法にある
（第１方法）。The present invention uses a molding die having a molding surface which conforms to the shape of one side surface of a filter to be obtained, and supplies and attaches filter medium fibers to the surface of the molding die to form a first intermediate A step of supplying a filter medium fiber for forming a body, a step of connecting a filter medium fiber in the first intermediate body to each other to form a second intermediate body, and a step of pressing the second intermediate body in the vertical direction to obtain a desired shape A method of manufacturing a filter is characterized by comprising a molding step of molding into a filter shape (first method).
【０００９】上記成形型における型面は，濾材繊維を積
層し，第一中間体を形成する部分である。その形状は，
得ようとするフィルタの片側面の形状に沿った凸部，ま
たは凹部である。例えば，後述する濾材繊維の供給方法
が湿式法である場合には上記型面が凹部となり，乾式法
である場合には凸部となる。The mold surface of the above-mentioned molding die is a portion where the filter medium fibers are laminated to form the first intermediate body. Its shape is
It is a convex portion or a concave portion along the shape of one side surface of the filter to be obtained. For example, when the method of supplying the filter medium fibers described later is a wet method, the mold surface becomes a concave portion, and when it is a dry method, it becomes a convex portion.
【００１０】次に，上記濾材繊維を供給する方法は，湿
式法及び乾式法とに大別される。上記湿式法は，製紙方
法とほぼ同様である。即ち，濾材繊維を水中に均一に懸
濁し，これを上記成形型ですくい，成形型型面に第一中
間体を形成するものである。Next, the method of supplying the filter medium fibers is roughly classified into a wet method and a dry method. The wet method is almost the same as the paper manufacturing method. That is, the filter medium fibers are uniformly suspended in water, and this is scooped with the above molding die to form the first intermediate on the molding die surface.
【００１１】上記乾式法としては，例えばエアーレイド
法及びカード法がある。上記エアーレイド法は，原料と
なる繊維塊を解繊し，繊維を生成する。上記繊維を空気
中に飛散させた後，気流によって成形型上に繊維を集
め，成形する方法である。また，カード法は，カード機
を用い，繊維塊より解繊した繊維を成形型上に集め，成
形する方法である。Examples of the dry method include an air raid method and a card method. The air-laid method disintegrates a fiber mass as a raw material to generate fibers. This is a method in which the above fibers are scattered in the air, and then the fibers are collected on a molding die by an air flow to be molded. The card method is a method in which a card machine is used to collect the fibers disentangled from the fiber mass on a molding die and mold the fibers.
【００１２】また，上記濾材繊維供給工程において，成
形型に予め基布をスパンボンド法，メルトブロー法によ
り形成し，上記基布の上に濾材繊維を積層することもで
きる。この場合には，基布によって第一中間体の強度が
向上するため，これを成形型から取り外したりする際の
取扱いが容易になる。このため，上記第一中間体の，後
述する金型への移動が容易になり，作業性が向上する。Further, in the filter medium fiber supplying step, it is also possible to previously form a base cloth on a molding die by a spun bond method or a melt blow method and laminate the filter cloth fibers on the base cloth. In this case, since the strength of the first intermediate body is improved by the base cloth, it is easy to handle when removing it from the molding die. Therefore, the above-mentioned first intermediate can be easily moved to the mold described later, and the workability is improved.
【００１３】上記スパンボンド法とは，紡糸機から直
接，高温の濾材繊維を集積し，成形型に供給する方法で
ある。この時，濾材繊維は半溶融状態であり，よって濾
材繊維は互いの接触点で融着し，不織布を形成する。ま
た，上記メルトブロー法とは，紡糸機から生じた濾材繊
維を気流により吹き飛ばし，成形型に集める方法であ
る。上記と同様に濾材繊維は半溶融状態であるため，互
いが接触することにより，不織布となる。The spunbond method is a method in which high-temperature filter medium fibers are directly collected from a spinning machine and supplied to a molding die. At this time, the filter medium fibers are in a semi-molten state, and thus the filter medium fibers are fused at the points of contact with each other to form a nonwoven fabric. The melt-blowing method is a method in which the filter medium fibers generated from the spinning machine are blown off by an air stream and collected in a molding die. Similar to the above, since the filter medium fibers are in a semi-molten state, they come into contact with each other to become a nonwoven fabric.
【００１４】また，上記濾材繊維供給工程においては，
複数の種類の異なる濾材繊維を順次供給することによ
り，密度勾配型の不織布が成形できる。これにより，フ
ィルタの濾過性能が向上する。なお，上記濾材繊維とし
ては，例えば，ポリエステル，ポリプロピレン，レーヨ
ン，ガラス，アセテート等を使用する。Further, in the above-mentioned filter medium fiber supplying step,
A density gradient type nonwoven fabric can be formed by sequentially supplying a plurality of different types of filter medium fibers. This improves the filtering performance of the filter. As the filter medium fiber, for example, polyester, polypropylene, rayon, glass, acetate or the like is used.
【００１５】上記繊維結合工程とは，第一中間体におい
て，単に積層されているだけの濾材繊維を互いに絡み合
わせる等により，繊維間を一体的に結合する工程であ
る。そして，上記工程における繊維結合の方法は，機械
的結合，接着剤結合，熱接着結合のいずれかにより行
う。なお，上記繊維結合方法は複数の異なる方法を併用
してもよい。The fiber-bonding step is a step of integrally bonding the fibers in the first intermediate body by, for example, intertwining the filter medium fibers that are simply laminated together. The fiber bonding method in the above step is any of mechanical bonding, adhesive bonding, and thermal bonding. It should be noted that a plurality of different methods may be used in combination as the above fiber bonding method.
【００１６】上記機械的結合とは，第一中間体における
繊維を，機械的な作用により絡み合わせ，互いを交絡さ
せるものである。繊維の交絡に当たって，ニードルを使
用する場合にはニードルパンチ法，ジェット水流を使用
するスパンレース法，ウォータージェットパンチ法，更
に，繊維をフィラメント糸で縫うステッチボンド法があ
る。上述する各種の結合方法の中では，スパンレース法
及びウォータージェット法が最も好ましい。これは，凹
凸のあるフィルターの各部の繊維間を満遍なく一体的に
結合させるために，多方向からジェット水流の噴射を行
うことができるからである。The above-mentioned mechanical coupling means that the fibers in the first intermediate are entangled with each other by a mechanical action to entangle each other. In the case of using a needle for entanglement of fibers, there are a needle punch method, a spunlace method using a jet stream, a water jet punch method, and a stitch bond method in which fibers are sewn with filament yarn. Among the various joining methods described above, the spunlace method and the water jet method are most preferable. This is because the jet water flow can be jetted from multiple directions in order to uniformly connect the fibers of each part of the filter having irregularities uniformly.
【００１７】また，上記接着剤結合とは，接着バインダ
ーを繊維間に含浸させて，繊維間を接着する方法であ
る。接着バインダーを賦与する方法によって浸漬接着
法，スプレー法，泡沫法に分類される。上記浸漬接着法
とは，接着バインダを満たした容器内に，上記第一中間
体を投入する方法である。また，スプレー法は上記第一
中間体に対し，液状のバインダを吹き付ける方法であ
る。また，泡沫法は，粉体である接着バインダーを上記
第一中間体に対して振り掛ける方法である。上記方法の
中ではスプレー法と泡沫法とがウォータージェット法と
組合せる場合に適している。The adhesive bonding is a method of impregnating fibers with an adhesive binder to bond the fibers. Depending on the method of applying the adhesive binder, it is classified into the dip adhesion method, spray method and foam method. The dip adhesion method is a method in which the first intermediate is put into a container filled with an adhesive binder. The spray method is a method in which a liquid binder is sprayed on the first intermediate. The foam method is a method in which an adhesive binder which is a powder is sprinkled on the first intermediate. Among the above methods, the spray method and the foam method are suitable when combined with the water jet method.
【００１８】更に，熱接着結合は，低融点の繊維あるい
は溶融用添加剤を第一中間体に予め混合し，加熱により
これを溶融させ，繊維同士を接着させる方法である。加
熱方法としては，高温空気を利用するスルーエアーヒー
ティング，またカレンダー機を用いるカレンダー法があ
る。Further, the thermoadhesive bonding is a method in which fibers having a low melting point or a melting additive are mixed in advance with the first intermediate, and this is melted by heating to bond the fibers together. As a heating method, there are through air heating using high temperature air and a calendar method using a calendar machine.
【００１９】上記成形工程とは，上記濾材繊維間を完全
に結合させると共に，第一中間体をフィルタの形状に成
形する工程である。上記成形工程においては，得ようと
するフィルタと同形状のキャビティを有するプレス金型
を準備し，上記キャビティ内に第二中間体を配置する。
そして，上記第二中間体に対し，熱プレス処理を施す。
これにより，上記中間体内の濾材繊維は，繊維間が互い
に結合し，不織布状態となる。よって，完成したフィル
タを得ることができる。The forming step is a step of completely bonding the filter medium fibers and forming the first intermediate body into a filter shape. In the molding step, a press die having a cavity having the same shape as the filter to be obtained is prepared, and the second intermediate body is placed in the cavity.
Then, a hot press treatment is applied to the second intermediate body.
As a result, the filter medium fibers in the intermediate body are bonded to each other and become a non-woven fabric. Therefore, a completed filter can be obtained.
【００２０】また，上記成形型は多孔体であることが好
ましい。この場合には，濾材繊維を供給する際に用いる
空気，水等の各種流体が成形型を自由に通過でき，効率
的に濾材繊維のみを成形型に積層することができる。上
記多孔体としては，金網等の網状体，多数の細孔を穿設
した多孔板，目の粗い濾布などがある。Further, the molding die is preferably a porous body. In this case, various fluids such as air and water used for supplying the filter medium fibers can freely pass through the mold, and only the filter medium fibers can be efficiently laminated on the mold. Examples of the porous body include a mesh-like body such as a wire mesh, a porous plate having a large number of pores formed therein, and a coarse filter cloth.
【００２１】なお，上記製造工程によって製造されたフ
ィルタの一例としては，複数の波状袋部よりなる濾過部
と，該濾過部の外周縁に配設したツバ部とを有し，上記
波状袋部及びツバ部の基材は同一の不織布により構成さ
れているフィルタがある。As an example of the filter manufactured by the above manufacturing process, the filter having a plurality of corrugated bag portions and the brim portion arranged on the outer peripheral edge of the filter portion are provided. There is a filter in which the base material of the brim portion is made of the same non-woven fabric.
【００２２】次に，上述の第一方法とは異なるフィルタ
の製造方法を以下に説明する。即ち，この製造方法は，
濾材繊維のシートを波状体に成形する波状加工工程と，
上記波状体の両側部を押圧して多数の波状袋部を形成す
る側部閉塞工程と，上記波状体の濾材繊維を結合させる
繊維結合工程と，上記波状体を上下方向にプレスして所
望するフィルタの形状に成形する成形工程とよりなるこ
とを特徴とする（第２方法）。Next, a method of manufacturing a filter different from the above-mentioned first method will be described below. That is, this manufacturing method
A corrugating process for molding a sheet of filter medium fiber into a corrugated body,
A side closing step of pressing both side portions of the corrugated body to form a large number of corrugated bag portions, a fiber bonding step of coupling the filter medium fibers of the corrugated body, and pressing the corrugated body in the vertical direction to obtain a desired shape. It is characterized by comprising a molding step of molding into a filter shape (second method).
【００２３】上記濾材繊維のシートとは，例えば，エア
ーレイド法及びカード法等によって，濾材繊維を平板状
に集積したもので，上述した各種繊維結合工程を行って
いないシートである。上記波状加工工程は，例えば，上
記シートを折り曲げることにより加工する。上記側部閉
塞工程においては，上記波板状の側部を例えば，ローラ
ー等により押圧して，波状体の両側部をその濾材繊維に
より閉止する。The above-mentioned sheet of the filter medium fiber is a sheet obtained by accumulating the filter medium fibers in a flat plate shape by, for example, the air laid method or the card method, and is a sheet in which the above-mentioned various fiber bonding steps are not performed. The corrugation process is performed by, for example, bending the sheet. In the side part closing step, the side parts of the corrugated plate are pressed by, for example, a roller or the like, and both side parts of the corrugated body are closed by the filter medium fibers.
【００２４】以下，繊維結合工程，成形工程は上述の第
１方法と同様である。また，本製造方法においても，繊
維結合工程における濾材繊維の結合は，上述の第１方法
と同様に，機械的結合，接着剤結合，熱接着結合のいず
れかにより行うことが好ましい。本製造方法によれば，
多数の波状袋部を有し，濾過性能に優れたフィルタを，
同一材料により，容易かつ安価に製造することができ
る。Hereinafter, the fiber bonding step and the molding step are the same as those in the above-mentioned first method. Also in the present manufacturing method, it is preferable to bond the filter medium fibers in the fiber bonding step by any one of mechanical bonding, adhesive bonding, and thermal adhesive bonding, as in the first method described above. According to this manufacturing method,
A filter with a large number of corrugated bags and excellent in filtering performance
The same material can be easily and inexpensively manufactured.
【００２５】更に，上述の製造方法とは異なるフィルタ
の製造方法を以下に説明する。即ち，この製造方法は，
濾材繊維のシートを濾過部とツバ部とに切断する切断工
程と，上記濾過部を波状体に加工する波状加工工程と，
上記波状体の周縁部に上記ツバ部を一体的に接着するツ
バ部接着工程と，上記波状体の濾材繊維を結合させる繊
維結合工程と，上記波状体を上下方向にプレスして所望
するフィルタの形状に成形する成形工程よりなることを
特徴とする（第３方法）。Further, a method of manufacturing a filter different from the above manufacturing method will be described below. That is, this manufacturing method
A cutting step of cutting a sheet of filter medium fiber into a filtering portion and a brim portion, and a corrugating processing step of processing the filtering portion into a corrugated body,
A brim bonding step of integrally bonding the brim to the peripheral edge of the corrugated body, a fiber bonding step of bonding the filter medium fibers of the corrugated body, and a vertical pressing of the corrugated body to form a desired filter. It is characterized by comprising a forming step of forming into a shape (third method).
【００２６】即ち，本製造方法はフィルタの各部を濾材
繊維のシートより別々に成形し，これらを接合し第一中
間体とするものである。なお，本製造方法において，得
ようとするフィルタの波状袋部が，波状体と側面板を有
している場合には，上記ツバ部接着工程において，上記
波状体の側面に側面板を接着する操作を行う。That is, according to the present manufacturing method, each part of the filter is separately molded from the sheet of the filter medium fiber, and these are joined to form the first intermediate. In this manufacturing method, when the corrugated bag portion of the filter to be obtained has the corrugated body and the side plate, the side plate is bonded to the side surface of the corrugated body in the brim bonding step. Do the operation.
【００２７】上記切断工程はカッター等の切断工具によ
り行う。また，ツバ部の接着工程は，接着剤，ホットメ
ルト，繊維を熱溶着させる接着方法を利用する。以下，
繊維結合工程，成形工程は上述の第１及び第２方法と同
様である。また，本製造方法においても，繊維結合工程
における濾材繊維の結合は，上述の第１及び第２方法と
同様に，機械的結合，接着剤結合，熱接着結合のいずれ
かにより行うことが好ましい。本製造方法によれば，多
数の波状袋部を有し，濾過性能に優れたフィルタを，同
一材料により，容易かつ安価に製造することができる。The above cutting step is performed by a cutting tool such as a cutter. Further, in the bonding process of the brim portion, an adhesive, a hot melt, or a bonding method of thermally welding fibers is used. Less than,
The fiber bonding step and the molding step are the same as those of the above-mentioned first and second methods. Also in the present manufacturing method, it is preferable to bond the filter medium fibers in the fiber bonding step by any one of mechanical bonding, adhesive bonding, and thermal adhesive bonding, as in the first and second methods described above. According to this manufacturing method, it is possible to easily and inexpensively manufacture a filter having a large number of corrugated bags and excellent in filtering performance, using the same material.
【００２８】[0028]
【作用及び効果】本発明の，上記第１方法のフィルタの
製造方法は，濾材繊維供給工程と，繊維結合工程と，成
形工程からなり，濾材繊維供給工程においては，所望の
フィルタの片側面に沿った型面を有する成形型を用い，
該成形型に濾材繊維を供給することによって，濾材繊維
からなるフィルタの第一中間体を形成するものである。The operation and effect of the filter manufacturing method of the first method of the present invention comprises a filter medium fiber supplying step, a fiber bonding step, and a molding step. In the filter medium fiber supplying step, one side surface of a desired filter is provided. Using a mold with a mold surface along
By supplying the filter medium fibers to the molding die, the first intermediate body of the filter made of the filter medium fibers is formed.
【００２９】即ち，本方法は，従来例のごとく，異なる
基材からなるフィルタの各部品を別部品として作成し，
その後これらを組み立ててフィルタとするという方法で
はない。本方法は，濾材繊維によって，得ようとするフ
ィルタの形状に集積した第一中間体を形成することによ
って，濾材繊維のみからなるフィルタを製造することが
できる。よって，フィルタの製造工程が極めて簡素とな
り，製造コストが安価となる。That is, in this method, as in the conventional example, each part of the filter made of different base materials is prepared as a separate part,
After that, they are not assembled into a filter. This method can produce a filter consisting of filter medium fibers only, by forming the first intermediate body that is formed by the filter medium fibers in the shape of the filter to be obtained. Therefore, the manufacturing process of the filter is extremely simple and the manufacturing cost is low.
【００３０】また，本方法は濾材繊維を所望のフィルタ
の概略形状に成形した後に，濾材繊維に対して繊維結合
工程を施すものである。このため，得られたフィルタ
は，折り曲げ部の繊維構造が均一になると共に，袋状側
面部も濾過に有効に使うことができ濾過性能が向上でき
る。また，上記第２方法，第３方法においても，同様の
効果を得ることができる。In this method, the filter medium fibers are molded into a desired filter shape, and then the filter medium fibers are subjected to a fiber bonding step. Therefore, in the obtained filter, the fiber structure of the bent portion becomes uniform, and the bag-shaped side surface portion can be effectively used for filtration, and the filtration performance can be improved. Also, the same effect can be obtained by the second method and the third method.
【００３１】上記のごとく，本発明によれば，安価に製
造可能であって，同一材料で構成され，かつ濾過性能に
優れた，フィルタの製造方法を提供することができる。As described above, according to the present invention, it is possible to provide a method of manufacturing a filter which can be manufactured at low cost, is made of the same material, and has excellent filtering performance.
【００３２】[0032]
実施例１ 本発明の実施例にかかるフィルタの製造方法につき，図
１〜図５を用いて説明する。即ち，図１に示すごとく，
得ようとするフィルタ１（図５参照）の片側面の形状に
沿った型面を有する成形型２を用い，該成形型２の表面
に３種類の異なる濾材繊維１１，１２，１３を供給する
と共に付着させて第一中間体１０１を形成する濾材繊維
供給工程を行う。Example 1 A method of manufacturing a filter according to an example of the present invention will be described with reference to FIGS. That is, as shown in FIG.
A mold 2 having a mold surface conforming to the shape of one side surface of the filter 1 (see FIG. 5) to be obtained is used, and three kinds of different filter medium fibers 11, 12, 13 are supplied to the surface of the mold 2. A filter medium fiber supplying step of forming the first intermediate body 101 by adhering together is performed.
【００３３】次に，図１及び図２に示すごとく，上記第
一中間体１０１における濾材繊維１１，１２，１３を互
いに結合させて，第二中間体１０２を形成する繊維結合
工程を行う。なお，この繊維結合工程は，後述するごと
く二つの結合方法を用いている。そして，図２に示すご
とく，最後に上記第二中間体１０２を上下方向よりプレ
スして，所望するフィルタ１の形状に成形する成形工程
を行う。以下，これらにつき詳しく説明する。Next, as shown in FIGS. 1 and 2, a fiber bonding step is performed in which the filter medium fibers 11, 12, and 13 in the first intermediate body 101 are bonded to each other to form the second intermediate body 102. In this fiber bonding step, two bonding methods are used as described later. Then, as shown in FIG. 2, finally, a molding step is performed in which the second intermediate body 102 is pressed in the vertical direction to form the filter 1 into a desired shape. These will be described in detail below.
【００３４】まず，上記濾材繊維供給工程について説明
する。図１（Ａ）に示すごとく，後述するフィルタ１
（図５参照）の下面側（内側）と同形状であって，金属
ネットからなる成形型２を準備する。次に，図１（Ｂ）
に示すごとく，３種類の異なる濾材繊維１１，１２，１
３を上記成形型２に，エアーレイド法を利用し，順次積
層する。なお，上記エアーレイド法とは，原料となる繊
維塊を解繊し，繊維を生成する。上記繊維を空気中に飛
散させた後，気流によって成形型２上に繊維を集め，成
形する方法である。First, the filter medium fiber supplying step will be described. As shown in FIG. 1A, a filter 1 described later
A molding die 2 having the same shape as the lower surface side (inside) of the metal net (see FIG. 5) and made of a metal net is prepared. Next, FIG. 1 (B)
As shown in Figure 3, three different types of filter media fibers 11, 12, 1
3 is sequentially laminated on the mold 2 by using the air laid method. The air-laid method is to defibrate a fiber mass as a raw material to generate fibers. This is a method in which the fibers are scattered in the air, and then the fibers are collected on the molding die 2 by an air flow to mold the fibers.
【００３５】この時，最も細い濾材繊維１１を下層に，
次に太い濾材繊維１２を中層に，最も太い濾材繊維１３
を上層に積層する。濾材繊維１１は，太さ１．５デニー
ルのレーヨン３０％（重量％，以下同じ），２デニール
のレーヨン７０％からなり，成形型２への単位面積あた
りの供給量は８０〜１００ｇ／ｍ2である。At this time, the thinnest filter medium fiber 11 is used as the lower layer,
Next, the thickest filter medium fiber 12 is used as the middle layer, and the thickest filter medium fiber 13 is formed.
Is laminated on the upper layer. The filter medium fiber 11 is composed of 30% rayon having a thickness of 1.5 denier (weight%, the same applies hereinafter) and 70% rayon having a thickness of 2 denier, and the supply amount per unit area to the molding die 2 is 80 to 100 g / m 2. Is.
【００３６】濾材繊維１２は，太さ１．５デニールのポ
リエステル７０％，２．５デニールのポリエステル３０
％からなリ，成形型２への供給量は４０〜６０ｇ／ｍ2
である。濾材繊維１３は，太さ２デニールのポリエステ
ル６０％，６デニールのポリエステル４０％からなリ，
成形型２への供給量は２５〜４５ｇ／ｍ2である。The filter medium fiber 12 is composed of 70% polyester having a thickness of 1.5 denier and 30% polyester having a thickness of 2.5 denier.
%, Supply amount to the molding die 2 is 40 to 60 g / m 2
Is. The filter medium fiber 13 is made of 60% polyester having a thickness of 2 denier and 40% polyester having a thickness of 6 denier,
The amount supplied to the molding die 2 is 25 to 45 g / m 2 .
【００３７】これにより，第一中間体１０１が形成され
る。第一中間体１０１は，図３にその拡大図を示すごと
く，濾材繊維１１，１２，および１３を順次積層させた
もので，柔らかな状態にあり，次の繊維結合工程まで，
このまま成形型２の上に置かれている。As a result, the first intermediate body 101 is formed. As shown in the enlarged view of FIG. 3, the first intermediate body 101 is one in which filter medium fibers 11, 12, and 13 are sequentially laminated, and is in a soft state until the next fiber bonding step.
It is placed on the mold 2 as it is.
【００３８】次に，上記繊維結合工程及び成形工程につ
いて説明する。なお，本例における上記繊維結合工程は
機械的結合と接着剤結合を組み合わせたものである。ま
ず，図１（Ｃ）に示すごとく，第一中間体１０１に対し
て，第１回目の結合方法としてウォータージェットパン
チ法による機械的結合を施す。即ち，第一中間体１０１
に対して，噴射密度３５〜４５本／ｃｍ2となるよう
に，ジェット水流１９を与える。これにより，各濾材繊
維１１，１２，１３が互いに絡まり合い，第二中間体１
０２となる。なお，図４に，成形型２上に形成された，
上記第二中間体１０２の拡大断面図を示す。Next, the fiber bonding step and the molding step will be described. The fiber bonding step in this example is a combination of mechanical bonding and adhesive bonding. First, as shown in FIG. 1C, the first intermediate body 101 is mechanically bonded by a water jet punch method as a first bonding method. That is, the first intermediate 101
On the other hand, the jet water flow 19 is applied so that the injection density is 35 to 45 lines / cm 2 . As a result, the filter medium fibers 11, 12, and 13 are entangled with each other, and the second intermediate 1
It becomes 02. In addition, in FIG. 4, formed on the molding die 2,
The enlarged sectional view of the said 2nd intermediate body 102 is shown.
【００３９】次に，上記第二中間体１０２に対して，２
回目の結合方法として，接着剤結合を行う。即ち，図２
（Ａ）に示すごとく，接着剤１８である水溶性アクリル
樹脂を上記第二中間体１０２に対して散布する。その
後，上記第二中間体１０２を乾燥させ，成形型２からは
ずす。Next, with respect to the second intermediate body 102, 2
Adhesive bonding is performed as the second bonding method. That is, FIG.
As shown in (A), a water-soluble acrylic resin that is the adhesive 18 is sprayed on the second intermediate body 102. Then, the second intermediate body 102 is dried and removed from the mold 2.
【００４０】最後に，上記アクリル樹脂を含んだ第二中
間体１０２を，図２（Ｂ）に示すごとく，金型２１，２
２を用いて，上下方向より第二中間体に対して，熱プレ
スを行う。なお，金型のキャビティ２０は得ようとする
フィルタ１と同形状である。上記熱プレスにより，多数
の波状袋部１５（図５）を有するフィルタ１が得られ
る。熱プレス終了後，図２（Ｃ）に示すごとく，金型２
１，２２よりフィルタ１を取り外す。Finally, as shown in FIG. 2B, the second intermediate body 102 containing the above acrylic resin is molded into molds 21 and 2.
2 is used to heat-press the second intermediate body from above and below. The cavity 20 of the mold has the same shape as the filter 1 to be obtained. By the above hot press, the filter 1 having a large number of corrugated bag portions 15 (FIG. 5) is obtained. After the hot press is completed, as shown in FIG.
Remove the filter 1 from the Nos. 1 and 22.
【００４１】次に，図５に本例の製造方法により製造さ
れたフィルタ１を示す。本例のフィルタ１は，いわゆる
濾過エレメント自体に，その形状を保持する外周の枠部
を同一材料で一体に成形したものであって，濾過エレメ
ントと枠とを含めてフィルタと総称している。上記フィ
ルタ１は，複数の波状袋部１５よりなる濾過部１５０
と，該濾過部１５０の外周縁に配設した枠としてのツバ
部１５３とを有してなる。上記波状袋部１５及びツバ部
１５３の基材は同一のポリエステル繊維等よりなる不織
布により構成されている。Next, FIG. 5 shows the filter 1 manufactured by the manufacturing method of this embodiment. The filter 1 of this example is a so-called filter element itself in which an outer peripheral frame portion that retains its shape is integrally formed of the same material, and is collectively referred to as a filter including the filter element and the frame. The filter 1 includes a filter section 150 including a plurality of corrugated bag sections 15.
And a brim portion 153 as a frame arranged on the outer peripheral edge of the filtering portion 150. The base materials of the corrugated bag portion 15 and the brim portion 153 are composed of the same non-woven fabric made of polyester fiber or the like.
【００４２】また，上記濾過部１５０における波状袋部
１５は波状板１５１と側面板１５２とよりなり，上記波
状袋部１５及びツバ部１５３は一体成形されている。な
お，上記フィルタ１においては，上記波状袋部１５の下
方からその上方に向けて流体が流通し，濾過を行う。The corrugated bag portion 15 of the filter section 150 is composed of a corrugated plate 151 and a side plate 152, and the corrugated bag portion 15 and the brim portion 153 are integrally formed. In the filter 1, the fluid flows from the lower side of the corrugated bag portion 15 to the upper side thereof to perform filtration.
【００４３】次に，本例における作用効果につき説明す
る。本例のフィルタの製造方法は，濾材繊維供給工程
と，繊維結合工程と，成形工程からなり，濾材繊維供給
工程においては，所望のフィルタの片側面に沿った型面
を有する成形型を用い，該成形型に濾材繊維を供給する
ことによって，濾材繊維からなるフィルタの第一中間体
を形成するものである。Next, the function and effect of this example will be described. The filter manufacturing method of this example comprises a filter medium fiber supplying step, a fiber bonding step, and a molding step. In the filter medium fiber supplying step, a mold having a mold surface along one side surface of a desired filter is used, By supplying the filter medium fibers to the molding die, the first intermediate body of the filter made of the filter medium fibers is formed.
【００４４】即ち，本例は，従来例のごとく，異なる基
材からなるフィルタの各部品を別部品として作成し，そ
の後これらを組み立ててフィルタとするという方法では
ない。本例は，濾材繊維によって，得ようとするフィル
タの形状に集積した第一中間体を形成することによっ
て，濾材繊維のみからなるフィルタを製造することがで
きる。よって，フィルタの製造工程が極めて簡素とな
り，製造コストが安価となる。That is, this example is different from the conventional example in that each part of the filter made of different base materials is prepared as a separate part, and then these parts are assembled into a filter. In this example, by forming the first intermediate body in which the filter medium fibers are integrated in the shape of the filter to be obtained, it is possible to manufacture a filter consisting of the filter medium fibers only. Therefore, the manufacturing process of the filter is extremely simple and the manufacturing cost is low.
【００４５】また，本例は濾材繊維を所望のフィルタの
概略形状に成形した後に，濾材繊維に対して繊維結合工
程を施すものである。このため，得られたフィルタは，
内部の繊維構造が均一になると共に，袋状側面部も濾過
に有効に使うことができ濾過性能が向上できる。In this embodiment, the filter medium fibers are molded into a desired filter shape, and then the filter medium fibers are subjected to a fiber bonding step. Therefore, the obtained filter is
The inner fiber structure becomes uniform, and the bag-shaped side surface can be effectively used for filtration, and the filtration performance can be improved.
【００４６】従って，本例によれば，安価に製造可能で
あって，同一材料で構成され，かつ濾過性能に優れた，
フィルタの製造方法を提供することができる。Therefore, according to this example, it can be manufactured at low cost, is composed of the same material, and has excellent filtering performance.
A method for manufacturing a filter can be provided.
【００４７】また，本例のフィルタを製造する際に使用
した成形型２は，金属ネットより構成されている。この
ため，ウォータージェットパンチ及び水溶性アクリル樹
脂散布の際に，余分な液体が第一中間体及び第二中間体
内に残留することがない。このため，第二中間体の乾燥
時間が短くなる。また，本例のフィルタ１は，太さの異
なる濾材繊維よりなるため，密度勾配を有する。従っ
て，濾過の際には，濾過流体が最初は粗く，最後は細か
くという濾過作用を受ける。よって，本例の製造方法に
より製造されたフィルタは，濾過性能に優れている。The mold 2 used when manufacturing the filter of this example is made of a metal net. Therefore, during water jet punching and water-soluble acrylic resin spraying, excess liquid does not remain in the first intermediate body and the second intermediate body. Therefore, the drying time of the second intermediate is shortened. Further, the filter 1 of this example has a density gradient because it is made of filter medium fibers having different thicknesses. Therefore, during filtration, the filtered fluid is initially coarse and finally fine. Therefore, the filter manufactured by the manufacturing method of this example has excellent filtering performance.
【００４８】実施例２ 本例は，図６に示すごとく，濾材繊維供給工程におい
て，成形型に予め基布を形成し，該基布の上に濾材繊維
を供給し，その後は実施例１と同様の製造工程を経て，
実施例１と同形状のフィルタを製造するものである。Example 2 In this example, as shown in FIG. 6, in a filter medium fiber supplying step, a base cloth was previously formed in a molding die, the filter medium fibers were supplied on the base cloth, and thereafter, as in Example 1. After going through the same manufacturing process,
A filter having the same shape as in Example 1 is manufactured.
【００４９】即ち，本例の製造工程は，濾材繊維のシー
トを波状体に成形する波状加工工程と，上記波状体の両
側部を押圧して多数の波状袋部を形成する側部閉塞工程
と，上記波状体の濾材繊維を結合させる繊維結合工程
と，上記波状体を上下方向にプレスして所望するフィル
タの形状に成形する成形工程とよりなる。以下，これら
につき詳しく説明する。That is, the manufacturing process of this example includes a corrugating process for molding a sheet of filter medium fiber into a corrugated body, and a side blocking process for pressing both side portions of the corrugated body to form a large number of corrugated bag portions. A fiber bonding step of bonding the corrugated filter media fibers and a molding step of pressing the corrugated material in the vertical direction to mold it into a desired filter shape. These will be described in detail below.
【００５０】本例の濾材繊維供給工程においては，ま
ず，図６（Ａ）に示すごとく，実施例１と同様の成形型
２を準備する。そして，上記成形型２の上に，メルトブ
ロー法により，ポリエステル１００％からなる濾材繊維
を，供給量を５０〜１５０ｇ／ｍ2として供給する。In the filter medium fiber supplying step of this example, first, as shown in FIG. 6A, a molding die 2 similar to that of Example 1 is prepared. Then, a filter material fiber made of 100% polyester is supplied onto the molding die 2 by a melt blow method at a supply amount of 50 to 150 g / m 2 .
【００５１】なお，上記メルトブロー法とは，紡糸機か
ら生じた濾材繊維を気流により吹き飛ばし，成形型に集
積する方法である。この時，濾材繊維は半溶融状態であ
り，従って，濾材繊維同士は互いの接触点で融着し，一
体化する。よって，図６（Ｂ）に示すごとく，成形型２
の上に基布１４が形成される。その後，図６（Ｃ）に示
すごとく，実施例１と同様に，濾材繊維１２及び１３を
基布１４の上に供給して，第一中間体１０４を得る。そ
の他は，実施例１と同様である。The melt-blowing method is a method in which the filter medium fibers generated from the spinning machine are blown off by an air stream and accumulated in a molding die. At this time, the filter medium fibers are in a semi-molten state, so that the filter medium fibers are fused and integrated at the contact points. Therefore, as shown in FIG.
The base cloth 14 is formed on the base. Thereafter, as shown in FIG. 6C, the filter medium fibers 12 and 13 are supplied onto the base cloth 14 in the same manner as in Example 1 to obtain the first intermediate body 104. Others are the same as in the first embodiment.
【００５２】本例の場合には，基布１４によって第一中
間体１０４の強度が向上する。このため，第一中間体１
０４を成形型２から取り外すことが容易になる。このた
め，上記第一中間体１４の，金型への移動が容易にな
り，作業性が向上する。その他は，実施例１と同様の作
用効果を有する。In the case of this example, the strength of the first intermediate body 104 is improved by the base cloth 14. Therefore, the first intermediate 1
It becomes easy to remove 04 from the mold 2. Therefore, the first intermediate body 14 can be easily moved to the mold, and the workability is improved. Others have the same effects as those of the first embodiment.
【００５３】実施例３ 本例は，図７に示すごとく，成形型を使用せず第一中間
体を成形し，その後は，実施例１と同様の工程を経て，
実施例１と同形状のフィルタ（図５参照）を製造するも
のである。即ち，本例の製造工程は，濾材繊維のシート
を波状体に成形する波状加工工程と，上記波状体の両側
部を押圧して多数の波状袋部を形成する側部閉塞工程
と，上記波状体の濾材繊維を結合させる繊維結合工程
と，上記波状体を上下方向にプレスして所望するフィル
タの形状に成形する成形工程とよりなる。Example 3 In this example, as shown in FIG. 7, a first intermediate was formed without using a forming die, and thereafter, the same steps as in Example 1 were carried out,
A filter having the same shape as that of Example 1 (see FIG. 5) is manufactured. That is, the manufacturing process of this example includes a corrugating process for molding a sheet of filter medium fiber into a corrugated body, a side closing process for pressing both side portions of the corrugated body to form a large number of corrugated bags, and the corrugated corrugation. It comprises a fiber bonding step of bonding the filter medium fibers of the body, and a molding step of pressing the corrugated body in the vertical direction to mold it into a desired filter shape.
【００５４】上記シートは実施例１と同様の濾材繊維を
用い，これらを図７（Ａ）に示すごとく，平板状に集積
したものである。即ち，三種類の異なる濾材繊維を，移
動するシート作成コンベア４９上に，最も細い濾材繊維
１１を下層に，次に太い濾材繊維１２を中層に，最も太
い濾材繊維１３を上層に，実施例１と同様にエアーレイ
ド法を利用し順次積層する。これにより，三層構造のシ
ート４００を得る。なお，同図における符号４１，４
２，４３は各濾材繊維１１，１２，１３の原料となる繊
維塊，４９０は供給用コンベア，４８は繊維供給器であ
る。The above-mentioned sheet uses the same filter medium fibers as in Example 1, and these are stacked in a flat plate shape as shown in FIG. 7 (A). That is, three kinds of different filter medium fibers are moved on the moving sheet forming conveyor 49, the thinnest filter medium fiber 11 is the lower layer, the thickest filter medium fiber 12 is the middle layer, and the thickest filter medium fiber 13 is the upper layer. Similarly to the above, the layers are sequentially laminated using the air raid method. As a result, the sheet 400 having a three-layer structure is obtained. Incidentally, reference numerals 41 and 4 in FIG.
Reference numerals 2 and 43 are fiber lumps which are raw materials of the filter medium fibers 11, 12 and 13, 490 is a supply conveyor, and 48 is a fiber feeder.
【００５５】下層の濾材繊維１１は，太さ１．５デニー
ルのレーヨン３０％，２デニールのレーヨン７０％から
なり，単位面積あたりの供給量は８０〜１００ｇ／ｍ2
である。中層の濾材繊維１２は，太さ１．５デニールの
ポリエステル７０％，２．５デニールのポリエステル３
０％からなリ，供給量は４０〜６０ｇ／ｍ2である。上
層の濾材繊維１３は，太さ２デニールのポリエステル６
０％，６デニールのポリエステル４０％からなリ，供給
量は２５〜４５ｇ／ｍ2である。The lower filter medium fiber 11 comprises 30% rayon having a thickness of 1.5 denier and 70% rayon having a thickness of 2 denier, and the supply amount per unit area is 80 to 100 g / m 2.
Is. The medium filter medium fiber 12 is made of 70% polyester having a thickness of 1.5 denier and 3% polyester having a thickness of 2.5 denier.
The amount supplied from 0% is 40 to 60 g / m 2 . The upper filter medium fiber 13 is made of polyester 6 having a thickness of 2 denier.
It is made of 0%, 40% polyester of 6 denier, and the supply amount is 25 to 45 g / m 2 .
【００５６】次に，上記波状加工工程においては，ま
ず，図７（Ｂ）に示すごとく，上記シート４００を波状
加工機３１に投入する。これにより，上記シート４０１
は全体がひだ折りされ，波状体４０１となる。その後，
上記波状体４０１を所望の長さに切断する。上記波状加
工機３１は，ベルト３１５に適宜の間隔を置いて立設し
た成形板３１３を有する一対の回転機３１０により構成
されている。Next, in the corrugating process, first, as shown in FIG. 7B, the sheet 400 is put into the corrugating machine 31. As a result, the sheet 401
Is fold-folded into a corrugated body 401. afterwards,
The corrugated body 401 is cut into a desired length. The corrugating machine 31 is composed of a pair of rotating machines 310 each having a molding plate 313 standing upright on a belt 315 with an appropriate interval.
【００５７】上記側部閉塞工程は，図７（Ｃ）に示すご
とく，所望の長さに切断された波状体４０１の両側部４
０３をローラー３２にて押圧し，平らにする。これによ
り，波状体４１の側部４０３が閉塞される。また，上記
閉塞された側部の下面には，図５において示す，フィル
タ１のツバ部１５３となる。As shown in FIG. 7C, the side portion closing step is performed on both side portions 4 of the corrugated body 401 cut into a desired length.
03 is pressed by the roller 32 to make it flat. As a result, the side portion 403 of the corrugated body 41 is closed. Further, on the lower surface of the closed side portion, a collar portion 153 of the filter 1 shown in FIG. 5 is formed.
【００５８】従って，上記工程より，所望するフィルタ
の概略形状を有する第一中間体を形成することができ
る。なお，上記の側部４０３の閉塞の際には，波状体４
０１は，未だ柔らかい状態にあるので，容易に変形し，
波状袋体１５（図５）とツバ部１５３とが形成される。
その他は実施例１と同様である。また，作用効果も実施
例１と同様である。Therefore, the first intermediate having the desired shape of the filter can be formed by the above steps. When the side portion 403 is closed, the corrugated body 4 is
01 is still in a soft state, so it easily deforms,
The corrugated bag body 15 (FIG. 5) and the brim portion 153 are formed.
Others are the same as in the first embodiment. Further, the function and effect are similar to those of the first embodiment.
【００５９】実施例４ 本例は，図８に示すごとく，成形型を使用せず，第一中
間体を成形し，その後は，実施例１と同様の工程を経
て，実施例１と同形状のフィルタ（図５参照）を製造す
るものである。即ち，本例のフィルタの製造工程は，濾
材繊維のシートを濾過部とツバ部とに切断する切断工程
と，上記濾過部を波状体に加工する波状加工工程と，上
記波状板の周縁部に上記ツバ部を一体的に接着するツバ
部接着工程と，上記波状体の濾材繊維を結合させる繊維
結合工程と，上記波状体を上下方向にプレスして所望す
るフィルタの形状に成形する成形工程よりなる。Example 4 In this example, as shown in FIG. 8, the first intermediate was molded without using a molding die, and thereafter, the same steps as those in Example 1 were performed to obtain the same shape as that of Example 1. The filter (see FIG. 5) is manufactured. That is, the manufacturing process of the filter of this example includes a cutting process of cutting a sheet of filter medium fiber into a filtering part and a brim part, a corrugating process of processing the filtering part into a corrugated body, and a peripheral part of the corrugated plate. From the brim bonding step of integrally bonding the brim, the fiber bonding step of bonding the filter medium fibers of the corrugated body, and the molding step of pressing the corrugated body in the vertical direction to mold it into a desired filter shape. Become.
【００６０】上記シートは実施例３と同様に，濾材繊維
を平板状に集積したものである。即ち，三種類の異なる
濾材繊維を，最も細い繊維を下層に，次に太い繊維を中
層に，最も太い繊維を上層に，エアーレイド法を利用し
順次積層する。Similar to the third embodiment, the above-mentioned sheet is obtained by accumulating filter medium fibers in a flat plate shape. That is, three kinds of different filter media fibers are sequentially laminated by using the air laid method, with the thinnest fiber being the lower layer, the thickest fiber being the middle layer, and the thickest fiber being the upper layer.
【００６１】上記切断工程において，図８（Ａ）に示す
ごとく，上記シート４００の両側をカッターで切断す
る。これより，上記シート４００は中央シート４０５と
二枚の側面シート４０６に分離する。In the cutting step, as shown in FIG. 8A, both sides of the sheet 400 are cut by a cutter. As a result, the sheet 400 is separated into the central sheet 405 and the two side sheets 406.
【００６２】上記波状加工工程において，図７（Ｂ）に
示すごとく，上記中央シート４０５を実施例３と同様の
波状加工機３１に投入する。これにより，上記中央シー
ト４０５は全体がひだ折りされ，波状体４０７となる。
その後，上記波状体４０７を所望の長さに切断する。ま
た，二枚の側面シート４０６も同様の長さに切断してお
く。In the corrugating step, as shown in FIG. 7B, the central sheet 405 is put into the corrugating machine 31 similar to that of the third embodiment. As a result, the central sheet 405 is entirely folded and becomes a corrugated body 407.
Then, the corrugated body 407 is cut into a desired length. In addition, the two side sheets 406 are also cut into the same length.
【００６３】上記ツバ部接着工程において，図７（Ｃ）
に示すごとく，上記切断された波状体４０７の両側面に
上記二枚の側面シート４０６を接着剤により接着する。
なお，現時点では，波状体４０７の側面より，側面シー
ト４０６が一部はみ出している。この部分は，この後に
行われる，繊維結合工程，成形工程等の間に自然に波状
体側に織り込まれて行く。よって，上記工程より，所望
するフィルタの概略形状を有する第一中間体を形成する
ことができる。その他は実施例１と同様である。また，
作用効果も実施例１と同様である。In the process of bonding the brim portion, as shown in FIG.
As shown in FIG. 7, the two side sheets 406 are adhered to both side surfaces of the cut corrugated body 407 with an adhesive.
At this point, the side surface sheet 406 is partially protruding from the side surface of the corrugated body 407. This portion is naturally woven into the corrugated body side during the fiber bonding step, the molding step, and the like, which are performed thereafter. Therefore, the 1st intermediate body which has a desired schematic shape of a filter can be formed from the above process. Others are the same as in the first embodiment. Also,
The function and effect are similar to those of the first embodiment.
【００６４】実施例５ 本例のフィルタの製造方法は，成形型に濾材繊維を供給
するに当たって，製紙方法と同様の湿式法を利用するも
のである。即ち，本例の製造方法に当たっては，まず，
得ようとするフィルタの片側面に沿った凹状の型面を有
する成形型を準備する。なお，上記成形型は実施例２と
同様金属ネットより構成されている。また，濾材繊維を
分散させた水溶液を準備する。Example 5 In the method of manufacturing the filter of this example, when supplying the filter medium fibers to the molding die, a wet method similar to the paper manufacturing method is used. That is, in the manufacturing method of this example, first,
A mold having a concave mold surface along one side surface of the filter to be obtained is prepared. The molding die is composed of a metal net as in the second embodiment. In addition, an aqueous solution in which the filter medium fibers are dispersed is prepared.
【００６５】そして，上記成形型を上記水溶液中に投入
する。その後，成形型を引き上げ，脱水することによっ
て，成形型の型面に抄造された第一中間体を得る。Then, the molding die is put into the aqueous solution. Then, the molding die is pulled up and dehydrated to obtain a first intermediate body formed on the molding surface of the molding die.
【００６６】その後は，実施例１と同様に，上記第一中
間体における濾材繊維を互いに結合させて第二中間体を
形成する繊維結合工程，そして上記第二中間体を上下方
向よりプレスして，所望するフィルタ形状に成形する成
形工程を行う。本例も実施例１と同様の作用効果を有す
る。Thereafter, as in Example 1, a fiber bonding step of bonding the filter medium fibers in the first intermediate body to each other to form a second intermediate body, and pressing the second intermediate body in the vertical direction. The molding process of molding into a desired filter shape is performed. This example also has the same effects as the first example.
【００６７】なお，以上に述べた実施例は，いわゆる濾
過エレメントの成形と同時にその外周に枠を形成したフ
ィルタである。上記実施例の各製造方法により，樹脂製
の枠内に収容可能なフィルタを製造してもよい。また，
フィルタ外周の枠としてのつば部はフィルタの固定用あ
るいは流体のもれ防止用として有効であるが，つば部に
スポンジ等のシール部材を設けてもよい。The embodiment described above is a filter in which a frame is formed on the outer periphery of a so-called filtering element at the same time when the so-called filtering element is molded. A filter that can be housed in a resin frame may be manufactured by each of the manufacturing methods of the above embodiments. Also,
The brim as a frame on the outer periphery of the filter is effective for fixing the filter or preventing leakage of fluid, but a sponge or other sealing member may be provided at the brim.
【図１】実施例１におけるフィルタの製造方法の説明
図。FIG. 1 is an explanatory diagram of a filter manufacturing method according to a first embodiment.
【図２】図１に続く，フィルタの製造方法の説明図。FIG. 2 is an explanatory view of the filter manufacturing method following FIG.
【図３】実施例１における第一中間体の拡大説明図。FIG. 3 is an enlarged explanatory view of a first intermediate body in Example 1.
【図４】実施例１における第二中間体の拡大説明図。4 is an enlarged explanatory view of a second intermediate body in Example 1. FIG.
【図５】実施例１において得られたフィルタの斜視図。FIG. 5 is a perspective view of the filter obtained in Example 1.
【図６】実施例２におけるフィルタの製造方法の説明
図。FIG. 6 is an explanatory diagram of a filter manufacturing method according to the second embodiment.
【図７】実施例３におけるフィルタの製造方法の説明
図。FIG. 7 is an explanatory diagram of a filter manufacturing method according to the third embodiment.
【図８】実施例４におけるフィルタの製造方法の説明
図。FIG. 8 is an explanatory view of a filter manufacturing method according to the fourth embodiment.
１．．．フィルタ， １０１．．．第一中間体， １０２．．．第二中間体， １１，１２，１３．．．濾材繊維， １５．．．波状袋部， １５１．．．波状板， １５２．．．側面板， １５３．．．ツバ部， ２．．．成形型， ３１．．．波状加工機， 1. ． ． Filter, 101. ． ． First intermediate, 102. ． ． Second intermediate, 11, 12, 13. ． ． Filter media fibers, 15. ． ． Wavy bag portion, 151. ． ． Corrugated plate, 152. ． ． Side plate, 153. ． ． Collar part, 2. ． ． Mold, 31. ． ． Corrugating machine,
───────────────────────────────────────────────────── フロントページの続き (72)発明者 岡薗 哲郎 愛知県刈谷市昭和町１丁目１番地 日本電 装株式会社内 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tetsuro Okazono 1-1, Showa-cho, Kariya city, Aichi Nihon Denso Co., Ltd.
Claims (9)
沿った型面を有する成形型を用い，該成形型の表面に濾
材繊維を供給すると共に付着させて第一中間体を形成す
る濾材繊維供給工程と，上記第一中間体における濾材繊
維を互いに結合させて第二中間体を形成する繊維結合工
程と，上記第二中間体を上下方向よりプレスして，所望
するフィルタ形状に成形する成形工程とよりなることを
特徴とするフィルタの製造方法。1. A filter medium comprising a mold having a mold surface conforming to the shape of one side surface of a filter to be obtained, and supplying and adhering filter medium fibers to the surface of the mold to form a first intermediate. A fiber feeding step, a fiber binding step of binding the filter medium fibers in the first intermediate body to each other to form a second intermediate body, and pressing the second intermediate body from above and below to form a desired filter shape. A method of manufacturing a filter, which comprises a molding step.
おいては，複数種類の濾材繊維を順次供給して，複数種
類の濾材繊維層からなる第一中間体を成形することを特
徴とするフィルタの製造方法。2. The filter according to claim 1, wherein in the filter medium supplying step, a plurality of types of filter medium fibers are sequentially supplied to form a first intermediate body composed of a plurality of types of filter medium fiber layers. Production method.
て，上記繊維結合工程における濾材繊維の結合は，機械
的結合，接着剤結合，熱接着結合のいずれかにより行う
ことを特徴とするフィルタの製造方法。3. The filter according to claim 1, wherein the filter medium fibers are bonded in the fiber bonding step by any one of mechanical bonding, adhesive bonding, and thermal adhesive bonding. Manufacturing method.
上記成形型は，多孔体であることを特徴とするフィルタ
の製造方法。4. The method according to claim 1, wherein
The method for manufacturing a filter, wherein the molding die is a porous body.
状加工工程と，上記波状体の両側部を押圧して多数の波
状袋部を形成する側部閉塞工程と，上記波状体の濾材繊
維を結合させる繊維結合工程と，上記波状体を上下方向
にプレスして所望するフィルタの形状に成形する成形工
程とよりなることを特徴とするフィルタの製造方法。5. A corrugated processing step of forming a sheet of filter medium fiber into a corrugated body, a side closing step of pressing both side portions of the corrugated body to form a plurality of corrugated bag portions, and a filter medium fiber of the corrugated body. A method of manufacturing a filter, comprising: a fiber bonding step of bonding the corrugated fibers and a molding step of pressing the corrugated body in the vertical direction to mold the corrugated material into a desired filter shape.
おける濾材繊維の結合は，機械的結合，接着剤結合，熱
接着結合のいずれかにより行うことを特徴とするフィル
タの製造方法。6. The method for manufacturing a filter according to claim 5, wherein the binding of the filter medium fibers in the fiber binding step is performed by any one of mechanical binding, adhesive binding, and thermal adhesive binding.
切断する切断工程と，上記濾過部を波状体に加工する波
状加工工程と，上記波状体の周縁部に上記ツバ部を一体
的に接着するツバ部接着工程と，上記波状体の濾材繊維
を結合させる繊維結合工程と，上記波状体を上下方向に
プレスして所望するフィルタの形状に成形する成形工程
よりなることを特徴とするフィルタの製造方法。7. A cutting step of cutting a sheet of filter media fiber into a filtering portion and a brim portion, a corrugating step of processing the filtering portion into a corrugated body, and the brim portion integrally formed on a peripheral portion of the corrugated body. It is characterized in that it comprises a brim bonding step for adhering to the substrate, a fiber bonding step for bonding the filter medium fibers of the corrugated body, and a molding step for pressing the corrugated body in the vertical direction to mold it into a desired filter shape. Filter manufacturing method.
において，上記波状体の側面に側面板を接着することを
特徴とするフィルタの製造方法。8. The method for manufacturing a filter according to claim 7, wherein a side plate is bonded to a side surface of the corrugated body in the brim portion bonding step.
て，上記繊維結合工程における濾材繊維の結合は，機械
的結合，接着剤結合，熱接着結合のいずれかにより行う
ことを特徴とするフィルタの製造方法。9. The filter according to claim 7, wherein the filter medium fibers are bonded in the fiber bonding step by any one of mechanical bonding, adhesive bonding, and thermal adhesive bonding. Manufacturing method.
Priority Applications (9)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19759494A JP3301227B2 (en) | 1994-07-28 | 1994-07-28 | Filter manufacturing method |
| TW84106584A TW290472B (en) | 1994-07-12 | 1995-06-27 | |
| US08/498,230 US5674302A (en) | 1994-07-12 | 1995-07-05 | Automobile filter element |
| DE69505062T DE69505062T2 (en) | 1994-07-12 | 1995-07-07 | Filter element and the process for its production |
| EP95110655A EP0692294B1 (en) | 1994-07-12 | 1995-07-07 | Filter element and process for manufacturing the same |
| AT95110655T ATE171643T1 (en) | 1994-07-12 | 1995-07-07 | FILTER ELEMENT AND PROCESS FOR PRODUCING IT |
| KR1019950020126A KR100299496B1 (en) | 1994-07-12 | 1995-07-08 | Filter element and its manufacturing method |
| CN95108389A CN1065149C (en) | 1994-07-12 | 1995-07-12 | filter element |
| US08/863,890 US5993580A (en) | 1994-07-12 | 1997-05-28 | Process for manufacturing a filter element |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19759494A JP3301227B2 (en) | 1994-07-28 | 1994-07-28 | Filter manufacturing method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0838834A true JPH0838834A (en) | 1996-02-13 |
| JP3301227B2 JP3301227B2 (en) | 2002-07-15 |
Family
ID=16377089
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP19759494A Expired - Lifetime JP3301227B2 (en) | 1994-07-12 | 1994-07-28 | Filter manufacturing method |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3301227B2 (en) |
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1149620A2 (en) * | 2000-04-28 | 2001-10-31 | Toyoda Boshoku Corporation | Filter medium and production method thereof |
| JP2002115158A (en) * | 2000-10-06 | 2002-04-19 | Toyoda Spinning & Weaving Co Ltd | Method for forming nonwoven fabric |
| JP2002219315A (en) * | 2001-01-24 | 2002-08-06 | Toyoda Spinning & Weaving Co Ltd | Filter and method for manufacture the same |
| JP2002263426A (en) * | 2001-03-13 | 2002-09-17 | Toyoda Spinning & Weaving Co Ltd | Filter and its manufacturing method |
| EP1240933A2 (en) * | 2001-03-13 | 2002-09-18 | Toyoda Boshoku Corporation | Production method and apparatus for filter, forming die for filter, forming assembly for forming filter, and filter |
| JP2002273121A (en) * | 2001-03-21 | 2002-09-24 | Toyoda Spinning & Weaving Co Ltd | Filter manufacturing method and filter |
| US6743270B2 (en) | 2000-12-20 | 2004-06-01 | Toyoda Boshoku Corporation | Filter and manufacturing method thereof |
| JP2004301121A (en) * | 2003-03-20 | 2004-10-28 | Ambic Co Ltd | Nonwoven fabric air filter for internal combustion engine |
| US6932923B2 (en) * | 2003-03-03 | 2005-08-23 | Arvin Technologies, Inc. | Method of making a melt-blown filter medium for use in air filters in internal combustion engines and product |
| EP1911868A1 (en) * | 2006-10-11 | 2008-04-16 | FARE' S.p.A. | A device and a process of producing a shaped non-woven matting |
| WO2008084816A1 (en) * | 2007-01-10 | 2008-07-17 | Nifco Inc. | Filter apparatus for fuel |
| JP2013504409A (en) * | 2009-09-12 | 2013-02-07 | ハイダック フィルターテヒニク ゲゼルシャフト ミット ベシュレンクテル ハフツング | Method for forming a filter element having a filter medium |
| JP2015035406A (en) * | 2013-08-09 | 2015-02-19 | 日東電工株式会社 | Ventilation member |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| IT1393983B1 (en) * | 2009-04-27 | 2012-05-17 | Ufi Filters Spa | AIR FILTER UNIT FOR MOTOR VEHICLES AND FILTER ELEMENT |
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1994
- 1994-07-28 JP JP19759494A patent/JP3301227B2/en not_active Expired - Lifetime
Cited By (25)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1149620A3 (en) * | 2000-04-28 | 2003-02-05 | Toyoda Boshoku Corporation | Filter medium and production method thereof |
| EP1149620A2 (en) * | 2000-04-28 | 2001-10-31 | Toyoda Boshoku Corporation | Filter medium and production method thereof |
| US6454827B2 (en) * | 2000-04-28 | 2002-09-24 | Toyoda Boshoku Corporation | Filter medium and production method thereof |
| JP2002115158A (en) * | 2000-10-06 | 2002-04-19 | Toyoda Spinning & Weaving Co Ltd | Method for forming nonwoven fabric |
| US6743270B2 (en) | 2000-12-20 | 2004-06-01 | Toyoda Boshoku Corporation | Filter and manufacturing method thereof |
| JP2002219315A (en) * | 2001-01-24 | 2002-08-06 | Toyoda Spinning & Weaving Co Ltd | Filter and method for manufacture the same |
| JP4595206B2 (en) * | 2001-01-24 | 2010-12-08 | トヨタ紡織株式会社 | Filter and manufacturing method thereof |
| US6743274B2 (en) * | 2001-01-24 | 2004-06-01 | Toyoda Boshoku Corporation | Filter and production method thereof |
| US6758877B2 (en) * | 2001-03-13 | 2004-07-06 | Toyoda Boshoku Corporation | Filter and method for manufacturing the filter |
| JP2002263426A (en) * | 2001-03-13 | 2002-09-17 | Toyoda Spinning & Weaving Co Ltd | Filter and its manufacturing method |
| EP1240933A3 (en) * | 2001-03-13 | 2003-01-29 | Toyoda Boshoku Corporation | Production method and apparatus for filter, forming die for filter, forming assembly for forming filter, and filter |
| EP1240933A2 (en) * | 2001-03-13 | 2002-09-18 | Toyoda Boshoku Corporation | Production method and apparatus for filter, forming die for filter, forming assembly for forming filter, and filter |
| JP4631185B2 (en) * | 2001-03-13 | 2011-02-16 | トヨタ紡織株式会社 | Filter and manufacturing method thereof |
| JP2002273121A (en) * | 2001-03-21 | 2002-09-24 | Toyoda Spinning & Weaving Co Ltd | Filter manufacturing method and filter |
| US6732868B2 (en) | 2001-03-21 | 2004-05-11 | Toyoda Boshoku Corporation | Production method and apparatus for filter, forming die for filter, forming assembly for forming filter, and filter |
| JP4670166B2 (en) * | 2001-03-21 | 2011-04-13 | トヨタ紡織株式会社 | Filter manufacturing method |
| US6932923B2 (en) * | 2003-03-03 | 2005-08-23 | Arvin Technologies, Inc. | Method of making a melt-blown filter medium for use in air filters in internal combustion engines and product |
| CN100368618C (en) * | 2003-03-03 | 2008-02-13 | 普瑞雷特飞尔特北美有限责任公司 | Method for manufacturing melt-blown filter medium used for air filter of internal combustion engine and product |
| JP2004301121A (en) * | 2003-03-20 | 2004-10-28 | Ambic Co Ltd | Nonwoven fabric air filter for internal combustion engine |
| EP1911868A1 (en) * | 2006-10-11 | 2008-04-16 | FARE' S.p.A. | A device and a process of producing a shaped non-woven matting |
| JP2008168194A (en) * | 2007-01-10 | 2008-07-24 | Nifco Inc | Filter device for fuel |
| WO2008084816A1 (en) * | 2007-01-10 | 2008-07-17 | Nifco Inc. | Filter apparatus for fuel |
| US8137546B2 (en) | 2007-01-10 | 2012-03-20 | Nifco, Inc. | Fuel filter device |
| JP2013504409A (en) * | 2009-09-12 | 2013-02-07 | ハイダック フィルターテヒニク ゲゼルシャフト ミット ベシュレンクテル ハフツング | Method for forming a filter element having a filter medium |
| JP2015035406A (en) * | 2013-08-09 | 2015-02-19 | 日東電工株式会社 | Ventilation member |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3301227B2 (en) | 2002-07-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EXPY | Cancellation because of completion of term |