JPH0847614A - Air filter and production thereof - Google Patents

Abstract

PURPOSE:To provide a production method of an air filter capable of collecting dust having various particle sizes, facilitating the production thereof and being at a low production cost, and an air filter therefore. CONSTITUTION:A belt-like filter medium 10 is folded with pleats in an oblique direction against the longitudinal direction to alternately form a peak part 11 and a valley part 12, and the belt-like filter medium 10 is folded back at every specified length to be successively laminated and a flow path of each laminated layer is formed so that flow paths of each laminated layer mutually cross with the flow paths of the adjacent layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air filter manufacturing method and an air filter used in various air conditioners.

[0002]

2. Description of the Related Art As an air filter for an air conditioner, an air cleaner, etc., as shown in FIG. 12, a filter having a honeycomb cross section has been proposed (Japanese Patent Laid-Open No. Hei 4).
-176310). That is, the first sheet 91 made of a non-woven fabric is continuously folded to form pleats having peaks and valleys on the entire surface of the first sheet 91. As a result, a large number of flow paths 90 are formed in the first sheet 91.

The first sheet 91 is cut to a predetermined length, and on the other hand, it is superposed on a flat second sheet 92 having the same length and made of the same non-woven fabric as described above, and the ridge line 910 of the mountain portion of the first sheet 91 and The bottom line 919 of the valley is adhered to the surface of the second sheet 92. Finally, a plurality of unit layers composed of the first sheet 91 and the second sheet 92 are laminated to form a filter 9 having a honeycomb section (FIG. 12).

The air filter 9 is assembled into a frame 99 made of resin or the like to form a filter device.
Therefore, the first sheet 91 and the second sheet 92 are previously cut into a predetermined length according to the size of the frame body as described above. In the air filter 9, the air to be filtered is circulated through the linear flow passage 90 having a triangular cross section to filter the air. That is, the flow path 90
When the air to be filtered passes through the air, dust in the air is collected by the air filter 9.

Next, as shown in FIG. 13, a description will be given of an air filter 95 having a honeycomb-shaped cross section, which is different from the air filter 9 (DE3923094-C2).
(German patent)). That is, as shown in FIG.
Also in the above honeycomb-shaped air filter 95, the first sheet 91 having pleats formed on the entire surface is replaced by the flat second sheet 9
It is composed by stacking two. However, Figure 1
As shown in FIG. 3 (B), the first sheet 93 installed directly above or below the certain first sheet 91 and one second sheet 92 has the ridge line 9 of the mountain portion in the first sheet 93.
30 and the bottom line 919 of the valley portion of the first sheet 91 are overlapped so as to intersect each other.

A triangular linear flow path is formed between the ridgeline 930 and the bottom line 919. This flow path is shown in FIG.
As shown in (B), they intersect with each other in an oblique direction.
Therefore, the inflow air 900 flowing through the flow path does not intersect the upper flow path and the lower flow path of the second sheet 92, and the directions thereof are different from each other. Incidentally, in the air filter 95, as in the air filter 9 shown in FIG. 12, the air to be filtered is circulated through the flow passage 90 to filter the air.

[0007]

However, the air filters 9 and 95 have some problems. That is, in manufacturing the air filters 9 and 95, it is necessary to cut the first sheet 91 and the second sheet 92 according to the size of the frame body 99. Since the size of the frame body 99 depends on the air conditioner or the like to which it is assembled, it is necessary to manufacture the air filters 9 and 95 separately for each device. Therefore, the manufacturing cost becomes high.

Further, in the method for manufacturing the air filters 9 and 95, the filter medium is folded to form a first sheet, and the first sheet and the flat second sheet are cut to a predetermined length and then joined. The process of forming a unit layer and further stacking a plurality of unit layers and assembling it to the frame is performed. Therefore, there are many manufacturing processes,
It also takes time and effort in manufacturing. Also, the manufacturing cost is high.

Next, in the air filters 9 and 95, the air to be filtered is made to flow through the flow path 9 of the air filters 9 and 95 by the filter material.
When passing 0, dust is collected. However, the dust having a coarse particle size has a large inertial force, and since the void 90 is linear and parallel to the flow of the inflowing air 900, a part of the dust remains with the flow of the inflowing air 900 as it is.
Will pass straight through.

Further, in the air filter 95,
In order to collect dust with a large particle size, the flow paths are set in different directions, but it is necessary to confirm the front and back of the first sheets 91, 93 and adhere them to the second sheet 92. Therefore, the manufacturing of the air filter 95 is more troublesome.

In view of the above problems, the present invention is excellent in the collection efficiency of dusts having various particle sizes, and is easy to manufacture,
It is an object of the present invention to provide an air filter manufacturing method and an air filter that are inexpensive to manufacture.

[0012]

According to the present invention, a band-shaped filter medium is folded in a direction oblique to the longitudinal direction to alternately form peaks and valleys, and the band-shaped filter medium is folded back at a predetermined length. The method for manufacturing an air filter is characterized in that the flow paths of the layers are sequentially laminated, and the flow paths of the stacked layers intersect with the flow paths of the adjacent layers adjacent to each other.

The most notable point in the present invention is that the flow paths of the laminated layers are configured so as to intersect with the flow paths of the adjacent layers adjacent to each other, and the flow paths of the respective layers are intertwined with each other.

The band-shaped filter medium is a sheet whose one side is significantly longer than the other side. Then, the band-shaped filter medium is fold-folded obliquely with respect to its longitudinal direction to form a corrugated body having alternating peaks and valleys (FIG. 1). The peaks and valleys of the corrugated body may have sharp tips or may be rounded. When the band-shaped filter medium is folded, the folding line is folded such that the folding line is inclined at a constant angle other than 0 degree with respect to each side of the filter medium, that is, in the longitudinal direction.

As the band-shaped filter medium, in addition to a general filter medium, for example, a non-woven fabric made of electret fibers can be used. The material is, for example, polypropylene or polyester. In addition, it is also preferable to use activated carbon fiber paper or the like for the band-shaped filter medium. In this case, the air filter can be provided with a deodorizing function in addition to the normal air filtering function.

It is preferable that the air filter is mounted on a frame made of resin or the like and used as a filter device. In this case, the strength is greatly improved compared to the case where the air filter is used alone. Further, when the air filter is assembled to the frame body and used, the predetermined length of the folding back at the time of stacking is almost equal to the inner diameter of the frame body. The predetermined length of the folding back is constant if the shape of the frame body is, for example, a rectangle, but the folding length changes if the shape of the frame body is, for example, a trapezoid.

Next, in laminating the above band-shaped filter medium,
The ridgeline of the mountain portion in one layer, that is, the upper edge of the mountain portion and the bottom line of the valley portion in the adjacent layer adjacent above the one layer,
That is, it is preferable to stack so that the lower end of the valley portion partially abuts. Further, it is preferable that both of them are adhered and fixed at the time of contact. As a result, the air filter does not have to lose its shape due to the pressure of air or the like, and is excellent in strength. In the adhesive fixing, for example, an adhesive, hot melt or the like is used to join the contact points of the peaks and valleys.

Next, it is preferable that a plurality of the fold-folded band-shaped filter media are laminated in advance to form channels intersecting with each other. That is, for example, two fold-folded band-shaped filter media are previously laminated and abutted as described above to form a laminate in which mutually intersecting flow paths are formed. After that, the above-mentioned laminated body can be folded back and laminated in sequence for each predetermined length (Example 2). According to this method,
The number of times the band-shaped filter medium is folded back is reduced. Therefore, the number of processing steps can be reduced and the manufacturing cost can be reduced.

Next, the flow path in the air filter is a void formed between the crests and crests, the troughs and the troughs of the strip-shaped filter medium. Then, the above-mentioned flow path is a complicatedly branched and complicated flow path (Fig. 3). And
Dust in the filtered air is collected by the air filter as the filtered air passes through the flow path.

Next, it is preferable that the band-shaped filter medium has an uneven surface. The uneven surface can be formed by pressing or the like. By having the uneven surface, the collecting area of the band-shaped filter medium is increased and the collecting efficiency of the air filter is improved. In addition, it becomes easy to perform pleating.

Next, manufactured by the above manufacturing method,
The air filter will be described. That is, in the air filter, the band-shaped filter medium is folded in a diagonal direction with respect to the longitudinal direction to alternately form peaks and valleys, and the band-shaped filter medium is folded back at a predetermined length. It is characterized in that the layers are sequentially laminated, and the channels of the laminated layers intersect with the channels of the adjacent layers adjacent to each other. In addition, it is preferable that the band-shaped filter medium has an uneven surface. Further, it is preferable that a plurality of the fold-folded band-shaped filter media are laminated in advance, and flow paths intersecting with each other are formed between the respective layers. The air filter also has the same effects as the above-described manufacturing method.

[0022]

In the method of manufacturing an air filter according to the present invention, the band-shaped filter medium is pleated in a diagonal direction with respect to the longitudinal direction thereof, and further folded back at a predetermined length to be laminated successively.

Therefore, this manufacturing method has many complicated and many steps such as cutting each layer, joining these into a unit layer, and assembling a plurality of unit layers like the above-mentioned conventional manufacturing method. Does not need Therefore, the manufacturing is easy and the manufacturing cost is low. Further, in general, the air filter is often used by being attached to a frame or the like. In the case of the air filter based on the above manufacturing method, the band-shaped filter medium may be folded back and mounted inside various frame bodies as described above, and the assembly is easy.

The air filter is also capable of collecting dust such as cigarette smoke in the air having a small particle size. In addition, coarse dust particles such as pollen in the air are collected by the air filter as follows. That is, in the air filter obtained by the above-described manufacturing method, when the strip-shaped filter medium is laminated, the channels of each layer are configured to intersect with the channels of the adjacent layers adjacent to each other (FIG. 3). for that reason,
The flow paths will be intricate with each other (Figs. 2 and 3).

Therefore, when the air to be filtered passes through the flow path, a turbulent flow occurs. Therefore, the coarse particles are
By being caught in the turbulent flow, it is collected by the air filter around the turbulent flow. As a result, the air filter can collect dust of small particle size to coarse dust equally, and exhibits excellent collection efficiency. Further, the air filter according to the present invention also has the same effect as the above.

As described above, according to the present invention, the collection efficiency of dust having various particle sizes is excellent, and the production is easy,
It is possible to provide an air filter manufacturing method and an air filter that are inexpensive to manufacture.

[0027]

【Example】

Example 1 An air filter according to an example of the present invention, a method for manufacturing the same, and a filter device using the air filter will be described with reference to FIG.
~ It demonstrates using FIG. The above filter device is
As will be described later, the filter device is installed in the front panel of the room air conditioner (Fig. 7). As shown in FIG. 1 (A), in manufacturing the air filter 1 of this example, a band-shaped filter medium 10 using electret fibers made of polypropylene is pleated in an oblique direction with respect to a longitudinal direction thereof, and a mountain portion is formed. 11 and valleys 12 are formed alternately.

Next, as shown in FIG. 1 (B), the band-shaped filter medium 10 is folded back in a direction of an arrow shown in the figure at predetermined lengths and sequentially laminated. The predetermined length is a length corresponding to the frame 20 to which the air filter 1 is assembled, as will be described later (FIG. 3).

It should be noted that, as shown in FIGS. 1 and 2, the ridge lines 110 of the crests 11 and the bottom lines 120 of the troughs 12 which are adjacent to each other partially abut each other between the laminated layers. It is that. This is a strip filter medium 10
Is a sheet of filter material that is folded back and laminated.
Since the ridges 11 and the valleys 12 of 0 are formed obliquely in the longitudinal direction of the strip-shaped filter medium 10, by the above-mentioned folded lamination,
This is because the valley portion 12 of the upper layer and the mountain portion 11 of the lower layer intersect with each other and make point contact. Also, due to this intersection, the channels intersect as described later (Fig. 3). In addition, the ridge line 11
The abutting portion 15 between 0 and the bottom line 120 is bonded by a bonding means such as an adhesive.

Next, the flow passages 13 of the respective layers intersect with the flow passages 14 of the adjacent adjacent layers. The above-mentioned flow path is a path through which the air to be filtered flows, and is a void formed by the crests and crests and the troughs and troughs of the air filter 1. The arrow in FIG. 3 represents a flow state in which the air 6 to be filtered is intricate.

Next, the filter device 2 including the air filter 1 will be described. As shown in FIG. 4, the filter device 2 is constructed by assembling the air filter 1 into a frame body 20 made of resin. In assembling, the inner side surface 201 of the frame body 20 and the folded-back end portion 19 of the air filter 1 are bonded with an adhesive.

Further, FIG. 5 shows a perspective view of the filter device 2. In the filter device 2, the air 6 to be filtered flows in from the front side in FIG. 5, and the air filter 1 inside is filtered. Note that FIG. 6 shows a partially enlarged view of the filter device 2. On the front surface of the filter device 2, the ends of the voids forming the flow paths 13 and 14 of the air filter 1 are lined up.

Then, as shown in FIG. 7, the air conditioner 29
Two sets of the filter device 2 are inserted in parallel in the front panel 290 of the above. In the figure, reference numeral 291 is an air outlet, reference numeral 292 is an air intake, and reference numeral 293 is an operation panel.

Next, the function and effect of the air filter 1 of this embodiment will be described. In manufacturing the air filter 1, the band-shaped filter medium 10 is pleated in a diagonal direction with respect to the longitudinal direction, folded back at a predetermined length, and sequentially laminated.

Therefore, unlike the conventional method for manufacturing an air filter, it is not necessary to perform complicated and many steps of cutting each layer, joining these to form a unit layer, and assembling a plurality of unit layers. . Therefore, it is easy to manufacture,
In addition, the manufacturing cost becomes low.

Next, in the air filter 1, the air is filtered by introducing the air to be filtered into the flow paths 13 and 14 formed by the voids formed by the ridges 11 and the valleys 12 on the opposite side. This is done by sending out from the void. The air filter 1 is made of electret fibers. Therefore, dust particles having a small particle size such as cigarette smoke in the air are collected by the air filter 1 by the static electricity of the electret fibers.

Further, the dust having a coarse particle size such as pollen in the air is collected by the air filter 1 as follows. That is, the air filter 1 has
The ridgeline 110 of the adjacent mountain part 11 and the bottom line 120 of the valley part 12
Are partially brought into contact with each other, and the flow channels of each layer are configured to intersect with and cross the flow channels of the adjacent layers.
Therefore, when the filtered air 6 passes through the flow path, a turbulent flow is generated in the contact portion 15. Therefore, the coarse particles are caught in the turbulent flow and the surrounding air filter 1
To be collected by.

Therefore, according to this example, it is possible to provide an air filter which is excellent in the collection efficiency of dust having various particle diameters, is easy to manufacture, and is inexpensive to manufacture.

Further, in this example, the air filter 1 is assembled to the frame body 20 and used as the filter device 2. Therefore, the strength is higher than that when the air filter 1 is used alone. Further, the air filter 1 is attached to the frame 2
In assembling to 0, as described above, the folded end 19 of the air filter 1 is bonded to the frame body 20. In this case, since the folds of the air filter 1 are in the oblique direction, a slight triangular dead flow region is formed in the region where the frame 20 is bonded to the frame 20.

However, even in this region, the pressure loss is relatively small because the filter medium itself has some breathability. In addition, this dead stream is due to the flow of air,
Since it hits the downstream side, it is less likely to cause clogging, and thus a rapid pressure loss due to clogging can be avoided.

Embodiment 2 This embodiment describes a method of manufacturing an air filter, which is different from the embodiment 1, as shown in FIGS. In this example, two fold-folded band-shaped filter media are laminated in advance, and after the flow paths intersecting with each other are formed between the layers,
This is folded back every predetermined length to form an air filter.

That is, as shown in FIG. 8, first, two flat band-shaped filter media 30 are respectively introduced into the surface shape processing section 41. As a result, the concavo-convex surface 302 is formed on the band-shaped filter medium 30 as shown in FIG. The surface shape processing unit 41 is a press machine.

Next, the two band-shaped filter media 301 having the uneven surface are fold-folded in the filter-folder 42 in an oblique direction with respect to the longitudinal direction. Therefore, the ridge portions 11 and the valley portions 12 are alternately formed on the band-shaped filter medium 301. The filter media fold machine 42 is a device that utilizes meshing of gears and the like.

Next, the strip-shaped filter medium 302 is sent together into one joining device 43. And in the joining device 43,
The two band-shaped filter media 302 are stacked in a pair of upper and lower states. That is, as shown in FIG. 10 (A), the ridge line 110 and the valley part 12 of the mountain part 11 which are adjacent to each other in each laminated layer
Bottom lines 120 of the two parts partially abut each other,
At 5, the ridge line 110 and the bottom line 120 are bonded. An adhesive is used for the above adhesion. As a result, the two strip-shaped filter media 3
A laminated body 303 in which 021 and 3022 are laminated is obtained.

This laminated body 303 is composed of a pair of upper and lower strip-shaped filter media 3021 and 3022. Since the directions of the peaks and valleys of the stacks are different depending on the upper and lower strip-shaped filter media, a flow path intersecting them is formed. It Then, as shown in FIG. 10 (B), the laminated body 303 is folded back at a predetermined length,
Obtain the air filter 3. By this folding back, further intersecting channels are formed in the laminated body 303. Others are the same as in the first embodiment.

In the method of manufacturing the air filter 31 of this example, a layer and its adjacent layer are preliminarily joined by the joining device 43 to form the laminated body 303, which is then bent at a predetermined length to form the air filter 3. . For this reason, the flow path and the like in the air filter 3 are strong and hard to lose their shape. Others have the same effects as those of the first embodiment.

Embodiment 3 As shown in FIG. 11, this embodiment is an air filter 5 having a different shape from the air filters manufactured by the manufacturing methods of Embodiments 1 and 2. That is, as shown in FIG.
The band-shaped filter medium 50 is pleated in an oblique direction with respect to the longitudinal direction, and the peaks 11 and the valleys 12 are alternately formed. After that, the strip-shaped filter medium 50 is folded back into a predetermined length and laminated in order.

At the time of stacking, a flat sheet 51 is provided between each layer and its adjacent layer. The sheet 51 is made of the same electret fiber as the band-shaped filter medium. The sheet 51 and each layer are adhered to each other at the ridge line 110 of the mountain portion 11 and the bottom line 120 of the valley portion 12 of each layer. Others are the same as in the first embodiment.

Further, in the air filter 5 of this embodiment, the intersection of the flow paths between the layers is somewhat hindered by the sheet 51. However, the ridge line 110 and the valley part 1 of the mountain part 11 of each layer
The bottom line 120 and the second bottom line 120 are in line contact with the seat 51. Therefore, the air filter 5 of this example is structurally stronger than the air filters of the other examples. It is also possible to make the flow of air in the flow paths between the layers intersect with each other through the sheet 51 by using a mesh sheet having a higher air permeability as the filter medium constituting the sheet 51.

[Brief description of drawings]

FIG. 1 is an explanatory view of (A) a band-shaped filter medium and (B) an air filter according to a first embodiment.

FIG. 2 is a partially enlarged view of the air filter according to the first embodiment.

FIG. 3 is an explanatory view showing the flow path of the air filter in the first embodiment.

FIG. 4 is an explanatory diagram of a filter device according to the first embodiment.

FIG. 5 is a perspective view of the filter device according to the first embodiment.

FIG. 6 is a partially enlarged view of the filter device according to the first embodiment.

FIG. 7 is a development explanatory diagram when the filter device according to the first embodiment is attached to an air conditioner.

FIG. 8 is an explanatory diagram of an air filter manufacturing process according to the second embodiment.

FIG. 9 is an explanatory view of a strip-shaped filter medium in Example 2.

FIG. 10 is an explanatory diagram of (A) a band-shaped filter medium and (B) an air filter of an air filter according to a second embodiment.

FIG. 11 is a perspective view of an air filter according to a third embodiment.

FIG. 12 is a cross-sectional view of a conventional air filter.

FIG. 13 is a cross-sectional view of a conventional (A) air filter,
(B) Perspective view.

[Explanation of symbols]

 1. ． ． Air filter, 10. ． ． Band-shaped filter medium, 11. ． ． Yamabe, 110. ． ． Ridge, 12. ． ． Tanibe, 120. ． ． Bottom line, 2. ． ． Filter device, 20. ． ． Frame, 29. ． ． Air conditioner,

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tomohide Nishino 1-1, Showa-cho, Kariya city, Aichi Prefecture Nihondenso Co., Ltd.

Claims (6)

[Claims] 1. A band-shaped filter medium is pleated in an oblique direction with respect to a longitudinal direction of the band-shaped filter medium so that peaks and valleys are alternately formed, and the band-shaped filter medium is folded back at a predetermined length and sequentially laminated. A method for manufacturing an air filter, wherein the flow paths of the stacked layers are configured to intersect with the flow paths of the adjacent layers adjacent to each other. 2. The method for manufacturing an air filter according to claim 1, wherein the band-shaped filter medium has an uneven surface. 3. The method for manufacturing an air filter according to claim 1, wherein a plurality of the band-shaped filter media folded and folded are laminated in advance, and channels intersecting with each other are formed between the layers. 4. A band-shaped filter medium is pleated in an oblique direction with respect to a longitudinal direction of the band-shaped filter medium so that peaks and troughs are alternately formed, and the band-shaped filter medium is folded back at predetermined lengths one after another. An air filter, which is formed by stacking layers, and the flow paths of the stacked layers intersect with the flow paths of adjacent layers adjacent to each other. 5. The air filter according to claim 4, wherein the band-shaped filter medium has an uneven surface. 6. The air filter according to claim 4 or 5, wherein a plurality of the band-shaped filter media folded and folded are laminated in advance, and intersecting channels are formed between the respective layers.